Thermal Spray Coatings: APS
Properties of thermally sprayed coatings by spray process and coating material. Processes: HVOF (high velocity oxy-fuel), APS (atmospheric plasma spray), wire arc spray, detonation gun, and cold spray. Materials: WC-Co and Cr3C2-NiCr carbide cermets, Al2O3/Al2O3-TiO2/Cr2O3/ZrO2-YSZ oxide ceramics, MCrAlY bond coats, NiCr, Stellite 6, 316L stainless, copper, zinc, aluminum, and specialty alloys. Properties: hardness (HV), bond strength (MPa), porosity (%), oxide content (%), surface roughness Ra (um), deposition efficiency (%), thickness range, max service temperature, wear rate, and application guidance. Per ASM Handbook Vol 5A and Oerlikon Metco/Praxair/Höganäs product data.
| spray process | coating material | application | bond strength mpa max (MPa) | bond strength mpa min (MPa) | bond strength mpa typical (MPa) | deposition efficiency pct max | deposition efficiency pct min | deposition efficiency pct typical (%) | hardness hv max (HV) | hardness hv min (HV) | hardness hv typical (HV) | material category | max service temp c (degC) | porosity pct max (%) | porosity pct min (%) | porosity pct typical (%) | surface roughness ra um max | surface roughness ra um min | surface roughness ra um typical (um) | thickness range um max (um) | thickness range um min (um) | wear rate relative |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| APS | Al2O3_99 | Electrical insulation; wear; dielectric coatings; piston crowns; electronic components; textile guides | 40 | 20 | 30 | 40 | 20 | 30 | 1,200 | 950 | 1,050 | ceramic_oxide | 1,500 | 10 | 3 | 6 | 20 | 10 | 14 | 600 | 100 | medium |
| APS | Al2O3_TiO2_60_40 | Higher titania for toughness; impact resistance; pump housings; slurry abrasion; grey color coating | 35 | 18 | 25 | 40 | 20 | 30 | 950 | 700 | 800 | ceramic_oxide | 1,100 | 13 | 5 | 8 | 20 | 10 | 14 | 600 | 100 | medium |
| APS | Al2O3_TiO2_87_13 | Improved toughness vs pure Al2O3; wear + dielectric; textile industry; seal faces; hydraulic rods in corrosive environments | 38 | 20 | 28 | 40 | 20 | 30 | 1,050 | 800 | 900 | ceramic_oxide | 1,200 | 12 | 4 | 7 | 20 | 10 | 14 | 600 | 100 | medium |
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