- 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 3
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 3: New Developments in Thermal Spray Processes and Materials
Shockwave Induced Cold Spraying: Evaluation of a New Solid-State Spraying Process
1:00 PM – 1:20 PM
Julio Villafuerte, Centerline Windsor Ltd
Shockwave Induced Spraying (SISP) is a new solid-state spraying process that enables the deposition of dense metals, alloys, cermets and polymers on substrates at lower temperatures than what is typically used in traditional thermal spray processes and with high deposition efficiencies and rates. The properties of both the feedstock and the substrate remain unaffected throughout spraying. In thermal spray processes, such as high velocity oxygen fuel (HVOF) and plasma spraying, bonding is obtained by the combination of thermal and kinetic energy of the sprayed particles. In numerous applications the thermal component, which typically melts the spray material, is sufficient to produce undesirable oxidation, porosity, metallurgical transformations and residual stresses. Similar to cold gas dynamic spraying (or cold spray), SISP can produce thick coatings onto a diversity of surfaces at reduced temperature, minimizing thermal effects such as oxidation, tensile residual stresses, and metallurgical transformations. It is understood that this novel process can be used to enhance surfaces for corrosion protection, thermal insulation, thermal dissipation, wear resistance, electrical conductivity, restoration, and other applications without the detrimental effects of elevated process temperatures. In this presentation, the working principles, as well as potential benefits of the novel SISP technology for a number of applications are reviewed.
Carbide Based Thermal Spray Powders with Alternative Matrix Alloys - The Only Choice to Protect Your Health and Environment
1:20 PM – 1:40 PM
Stefan Zimmerman, Benno Gries, Jürgen Fischer, H.C. Starck GmbH
Cobalt-containing carbide powders such as WC-Co and WC-Co-Cr for thermal spraying exist in numerous modifications varying in chemistry, carbide size, and production method. They are widely used for wear, erosion and corrosion protection in many industrial fields. However, for decades it has been well known from the hard metal industry that WC and Co-containing hard metals in breathable dust form can provoke severe lung diseases if inhaled. Recent examinations have proven that this toxicity can be significantly reduced if the Co is pre-alloyed by Fe. In thermal spraying, employees are also dealing with Co containing carbides; for example, in powder and coating production.
Therefore, in order to reduce the hazards for health and environment, new agglomerated and sintered carbide powders using alternative matrix materials — such as Fe-Cr-Al and other Fe based alloys — have been developed and investigated. In the present study, the powders were HVOF sprayed in order to examine the influence of their different composition and morphology on the microstructure and the properties of the coatings in comparison to standard materials. The experiments comprise microstructural examinations, wear and corrosion tests.
Optimization of Cold Sprayed Titanium Coatings on Adhesion Strength
1:40 PM – 2:00 PM
W. Wong and S. Yue, McGill University; E. Irissou and J. G. Legoux, National Research Council Canada
Cold gas dynamic spray, a ground-breaking technology in the past decades for the field of thermal spray, is a solid state high kinetic energy coating and free-form technique. This technique has triggered major interest in the aerospace industry due to its potential to fabricate aerospace engine components with minimal material waste. Owing to the severe requirements in producing these components, cold sprayed coatings must prove themselves reliable to earn recognition and to sustain their place in the industry. Thus, in this study, the adhesion strength of cold sprayed titanium coatings using nitrogen as propelling gas was evaluated according to the ASTM C-633-01 standard. A number of feedstock titanium powder size distributions were used. Different particle impact velocities were achieved by varying process conditions such as temperature and pressure. In addition, an assortment of substrates of different surface roughness and hardness were investigated, including aluminum alloy, pure titanium, and steel. Furthermore, the coating properties were studied via scanning electron microscopy and microhardness testing.
Advanced Deposition Characteristics of Atmospheric Plasma Sprayed Bronze/Diamond Composite by Thermal Barrier Effect of Nickel Protective Thin Film
2:00 PM – 2:20 PM
Hyunteak Na, Sanghoon Yoon, Kicheol Kang, and Changhee Lee, Hanyang University; Hyungjun Kim, Research Instittute of Industrial Science & Technology
Atmospheric plasma spraying (APS) is one of the simple and economic processes. It can simplify and replace the conventional processes to obtain bronze/diamond composite coating in a single step. However, graphitization and oxidation of diamond in the high temperature plasma gas flow are the main drawbacks of the APS process. Hence, the diamond particle size was sharply decreased during flight in the APS gas flow field. Also, a high diamond fraction along with uniform diamond distribution could not be obtained without considering process parameters in relation with thermal properties. In this study, to reduce the graphitization and oxidation of diamond during flight in plasma gas flow field, nickel-coated (3 μm thickness) diamond particles were used. For comparison with the nickel-coated diamonds case, bare diamonds were also deposited with bronze on an aluminum substrate. The microstructure of the coating and the diamond size were observed and analyzed using a scanning electron microscope (SEM) and image analyzer. The results show that diamond size was retained with uniform distribution in the composite coating and the diamond fraction was also increased.
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