How to Choose the Right Thermal Spray Method?
Using the thermal spray coating on the parts, components and various surfaces is a smart decision. However, it is important to choose the thermal spray process carefully. The selection of spray process helps ensure the coating meets the application’s requirements. Let us take a look the factors that need to be considered to choose the appropriate thermal spray process.
Know the Different Thermal Spray methods
Arc Spray: Arc spray is considered the most economical coating technique for most applications. It creates a semi-porous coating of 0.002” to 0.125” thickness. Also, the deposition rate and overall throughput is higher than other thermal spraying processes. In this coating technique, a DC power source is used to establish an electric arc. This electric arc melts a wire feed to form a semi-molten plume. However, it can be used to deposit only conductive materials.
Plasma Spray: This coating method uses a plasma touch for applying thin layers. The coatings applied can be measured in thousandths of an inch or micrometers. This is a reliable method that can be adapted for different materials. Plasma spray is ideal choice when ceramics, carbides and high temperature applications require a robust coating for wear, temperature and/or corrosion resistance.
Cold Spray: Cold spraying or supersonic particle deposition is a solid-state coating technique. This technique is ideal for metal alloys and blends. In this method, an electrically heated high-pressure carrier gas is utilized. Since the coating is applied at low temperatures, it is ideal for heat-sensitive parts. It is also a preferred choice for dense coatings that do not damage the surface.
Consider your Project’s Needs
Each method of thermal spay has certain limitations and advantages. This is why the specific needs of an application should be analyzed before selecting the process for thermal spraying.
Temperature Conditions: Consider the condition of your project to choose a coating method. For substrates that can withstand a high temperatures, plasma spraying can be great option. If you are dealing with heat-sensitive parts, cold spraying is a better choice.
Exposure to Moisture: For surfaces exposed to moisture, arc spraying is a good option. Arc Spraying metals with galvanizing properties can help a product survive harsh environments.
Surface: Not all coatings are suited for all types of surfaces. This means the surface material is also important factor to choose a thermal spray method. For instance: If you want to enhance the aesthetics and durability of plastic surfaces, Class A painting in the Bay Area is the best choice.
Cost: Each thermal spray coating methods comes with its own cost. Wire arc spraying is a more affordable option than plasma spraying. Consider the initial cost as well as maintenance needs over time.
Coating Thickness: The thickness of coating is another crucial factor to consider during selection of thermal spray method. If you need a thin and smooth coating, plasma spraying is the best choice. For wear protection on large surfaces, arc spraying is a useful option.
Conclusion:
Choosing a thermal spray method is an important decision that requires careful consideration of various factors. By understanding the different coating methods and your project’s needs you can choose the right option. Consulting an expert who can assess your specific needs can also help make an informed decision.