Plasma spraying is a super-efficient thermal coating process. It is characterised by the use of an extremely high-temperature heat source, an inert spraying medium such as argon, and high particle velocities. ‘Plasma’ here refers to a gas that has been elevated to such an extreme temperature that it becomes ionised and conducts electricity.
Understanding plasma spray
This technology allows many different materials, such as metals and special ceramics, to be applied to various substrates (surfaces). It creates an incredibly strong bond between the added material and the original substrate without changing the original material. Plasma spraying is an extremely flexible method that allows both small and larger components to be coated effectively. For those seeking expert plasma spraying, specialists such as www.poeton.co.uk/standard-treatments/plasma-coatings/ will be happy to assist.
Plasma spray is hugely adaptable in its range of applications. There are a whole host of benefits to choosing this method, including enhanced corrosion protection, resistance to wear, control of clearances for abrasives and abradables, electrical properties, and oxidation/heat resistance.
Let’s take a look at some examples of plasma spray applications:
Fretting wear in gas turbines
This involves spraying tungsten carbide/cobalt seal ring grooves, ensuring durability and longevity in high-stress environments.
Thermal barrier coatings for gas turbines
These coatings protect combustion hardware from high temperatures, enhancing the longevity and efficiency of gas turbines.
Wear resistance in printing rolls
By spraying chrome oxide ceramics onto printing rolls used in laser engraving, the process significantly extends their lifespan.
Anti-galling in industrial diesel engines
Molybdenum alloy coatings are applied to piston rings, reducing friction and preventing galling in high-pressure diesel engines.
Erosion and corrosion protection in oil and gas tools
In down-hole tools for oil and gas extraction, plasma spray coatings provide exceptional resistance against erosion and corrosion.
Aerospace components
Plasma spray coatings can help turbine blades and components of jet engines to withstand extremes.
The plasma spray process is an extremely adaptable one, as plasma spray can deliver superior performance in both low- and high-temperature environments. This makes it a cornerstone treatment in the world of modern coating technologies.