Thermal Spray Coatings: COLD_SPRAY
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) | oxide content pct max | oxide content pct min | oxide content pct typical (%) | 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 |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| COLD_SPRAY | Aluminum_99 | Cold spray Al; aircraft structure repair; corrosion protection; AA repair (NAVAIR, Army RDECOM); no heat-affected zone | 70 | 35 | 50 | 90 | 70 | 80 | 150 | 80 | 110 | metallic | 350 | 0.2 | 0 | 0.1 | 1 | 0.1 | 0.5 | 4.5 | 1.5 | 2.5 | 2,000 | 100 | medium |
| COLD_SPRAY | Copper_99 | Cold spray; no oxidation; high purity Cu; electrical bus repair; additive manufacturing; no thermal degradation | 80 | 40 | 60 | 90 | 70 | 80 | 200 | 100 | 150 | metallic | 300 | 0.2 | 0 | 0.1 | 1 | 0.1 | 0.5 | 4 | 1 | 2 | 2,000 | 100 | medium |
| COLD_SPRAY | Inconel_625 | Cold spray Inconel 625; aerospace MRO repair; corrosion protection; restoration of worn superalloy components | 75 | 45 | 60 | 75 | 55 | 65 | 420 | 250 | 330 | metallic | 980 | 0.5 | 0 | 0.2 | 1.5 | 0.2 | 0.8 | 5 | 2 | 3 | 1,000 | 100 | medium |
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