- Each nonmember attendee will receive a two-year complimentary membership in AWS.
- The registration fee does not include hotel accommodations. Hotel accommodations are subject to hotel regulations and are the responsibility of the attendee.
- As an added benefit, AWS Conference attendees are awarded 1 PDH (Professional Development Hour) for each hour of conference attendance. These PDH’s can be applied toward AWS recertifications and renewals.
Thermal Spray Conference - New Developments in Thermal Spray Coatings, Processes and Applications
Home > Educational Programs > Thermal Spray Session 2
Monday, November 16, 2009 • 9:00 AM – 4:30 PM
Chairs: Dan Hayden, Hayden Corporation; Bob Unger, Polymet Corporation
Member of AWS, FMA, SME, NAM, or PMA: $345
Nonmembers: $480 • Registration Code: W22
Room N230a
The American Welding Society and The International Thermal Spray Association are organizing the first Thermal Spray and Coatings Conference, to be held in conjunction with the 2009 FABTECH INTERNATIONAL & AWS WELDING SHOW Including METALFORM. The program is intended to introduce the process and its uses to new potential users with morning and afternoon sessions focusing on actual applications and new developments in thermal spray technology.
Session 2: Successful Applications
Wire Arc Sprayed Anti-Corrosion and Wear-Resistant Coatings for Waste Incineration Plants
10:40 AM – 11:00 AM
J. Wilden, Berlin Institute of Technology, Berlin, Germany
In waste incineration plants the metallic components are subjected to conditions, which can induce to high temperature corrosion. This kind of deterioration is especially related to the presence of chlorides, generated during the incineration of the waste. To protect metal parts inside the plant thermal spray coatings are in use. These coatings must be able to avoid the reaction of chlorine compounds and the metal surface. Typically for atmospheres containing chlorine at high temperature are Ni-based alloys. However, because of the high costs of these alloys, there is an aim to develop coatings with good corrosion resistance, but less expensive. There are indications that Fe-Cr-Si alloys are rather resistant in environments containing chlorine compounds at high temperatures.
Therefore, in this study, different compositions of Fe-Cr-Si alloys are evaluated as coating materials. The layers were applied using the arc spraying process, which is generally the most economic method to apply metal coatings. Nevertheless, also this method has to be adapted to obtain coatings with required corrosion resistance. In this work, the first results in terms of characterization of the arc sprayed coatings and their performance in corrosion tests are presented.
Tungsten-Based Coatings to Enhance the Performance of Casting Molds
11:00 AM – 11:20 AM
J. Wilden, S. Jahn, V.E. Drescher, Berlin Institute of Technology, Berlin, Germany
Casting molds, especially in the aluminum industry, show a short lifespan due to the high corrosiveness of molten metals and alternating thermal and mechanical loads. By using new materials, for example tungsten-based pseudoalloys, the lifetime of casting molds can be elongated up to a thousandfold. In spite of the advantages of these materials, high manufacturing cost and the increasing commodity price of tungsten prohibit the use of molds consisting of these progressive materials. By coating the standard steel molds with a layer of these materials the excellent thermal and corrosive resistance of the pseudoalloy surface can be combined with minimal manufacturing costs. In the present work, steel substrates and real components of casting molds were coated with tungsten-based pseudoalloys. Different compositions and coatings processes were compared to produce the best performance of the coatings.
A Review on Cold Gas Dynamic Sprayed Coatings
11:20 AM – 11:40 AM
Tarun Goyal, SVIET, Ram Nagar (Banur), Punjab; Dr. T. S. Sidhu, SBSCET, Ferozpur Punjab; Dr. R. S. Walia, PEC (Deemed University), Chandigarh
Cold gas dynamic spray process is a high-rate material deposition process in which fine, solid powder particles are accelerated in a supersonic jet of compressed gas to impact the target substrate surface at velocities ranging from 1640-3280 ft/s (500-1000 m/sec). In this paper, a review of literature is made in respect to the coating deposition by cold spray process. The successful bonding of the powder particles on the impinging surface depends on the number of parameters — gas parameter, powder properties, substrate properties, nozzle geometry, process parameters and spray conditions. The deposition of particles on the substrate takes place due to plastic deformation at the onset of adiabatic shear instability. The cold-sprayed coatings are uniform, dense, and hard and have good electrical and thermal conductivity, which provides cost-effective and environmental friendly technological applications.
Practical Applications of Cold Gas-Dynamic Spray (Low Pressure Cold Spray)
11:40 AM – 12:00 PM
David W. Wright, Accuwright Industries
Accuwright Industries, Inc. is a leader in research and development and in production applications of LP Cold Spray. By applying soft materials such as aluminum, copper, zinc and alloys of these materials, Accuwright has developed and pioneered repairs for aluminum and magnesium housings and worn components with aerospace and industrial applications. We propose to describe a brief history of our developments, specific application success and to share practical potential in Cold Spray process capabilities.
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