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Powders, Wires, Cords, and Rods

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Thermal Spray Fundamentals

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Abstract

The structure and properties of coatings obtained by thermal or cold gas spraying depend strongly upon different parameters among which the quality of the powder, wire, rod or cord used plays a key role. Powder quality can affect coating performance through different effects. First are presented the different powder manufacturing techniques: atomization, fusing and crushing, milling and sintering, ball-, attrition-, cryo-milling, mechanical alloying and milling, spray-drying, spheroidization, cladding, sol-gel and solutions, self-propagating high-temperature synthesis, cermets. The influence of powder morphologies on coating properties is discussed through examples. Then are presented powder classification methods and characterization: sampling, XRD, elements distribution, composition and purity, particle shape, size distribution, flow ability and surface area. The different types of powder feeders and the hazards related to particles are finally presented. Wires, cored wires, rods and cords are also presented and the chapter finishes with problems linked to polymer powders according to their physical, chemical and mechanical properties widely different from those of metals, alloys ceramics and cermets

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Abbreviations

APD:

Automatic powder diffraction

AS:

Agglomerated and sintered

ASTM:

American Society for Testing and Materials

CET:

Coefficient of thermal expansion

CNT:

Carbon nano tubes

D-gun:

Detonation gun

d.c.:

Direct current

DNA:

Deoxyribo nucleic acid

ECTFE:

Ethylene chlorotrifluoroethylene

EDS:

Energy dispersion spectroscopy

EDXA:

Energy dispersion X-ray absorption

EMAA:

Ethylene-methacrylic copolymer

EPMA:

Electron micro probe analysis

ETFE:

Ethylene tetrafluoroethylene

EVA:

Ethylene vinylene acetate

FC:

Fused and crushed

FEP:

Fluorinated ethylene propylene

GDC:

Gadolinia-doped ceria

GFA:

Glass forming ability

HA:

Hydroxyapatite

HOSP:

Hollow spherical particles

HVAF:

High-velocity air fuel

HVOF:

High-velocity oxy-fuel flame

ICPES:

Inductively coupled plasma emission spectroscopy

IMTA:

Integrated mechanical and thermal activation

JCPDS:

Joint Committee on Powder Diffraction Standards, USA

LCP:

Liquid-crystalline polymers

MA:

Mechanical alloying

NIST:

National Institute of Standards and Technology

OM:

Optical microscopy

PA:

Polyamides

PAEK:

Polyaryletherketone

PAS:

Polyarylene sulfide

PEA:

Polyether amide

PES:

Polyester

PC:

Polycarbonate

PE:

Polyethylene

PET:

Polyethylene terephthalate

PFA:

Perfluoroalkoxy

PMMA:

Polymethylmethacrylate

PP:

Polypropylene

PPS:

Polyphenylene sulfide

PEEK:

Poly-ether-ether-ketone

PTFE:

Polytetrafluoroethylene

PVDF:

Polyvinylidene fluoride

r.f.:

Radio frequency

SEM:

Scanning electron microscope

SHS:

Self-propagating high-temperature synthesis

SOFC:

Solid oxide fuel cell

SR:

Sedimentation ratio

UHMWPE:

Ultra high-molecular weight polyethylene

XRD:

X-ray diffraction

XRF:

X-ray fluorescence

YAG:

Yttrium aluminums garnet

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Authors and Affiliations

  1. Sciences des Procédés Céramiques et de Traitements de Surface (SPCTS), Université de Limoges, Limoges, France

    Pierre L. Fauchais

  2. Department of Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA

    Joachim V. R. Heberlein

  3. Department of Chemical Engineering, University of Sherbrooke, Sherbrooke, QC, Canada

    Maher I. Boulos

Authors
  1. Pierre L. Fauchais
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  2. Joachim V. R. Heberlein
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  3. Maher I. Boulos
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Nomenclature

Nomenclature

d p :

Particle diameter (m)

m p :

Particle mass (kg)

p :

Pressure (Pa)

p 0 :

Saturation vapor pressure (Pa)

r p :

Particle radius (m)

S :

Specific surface area (m2/g)

V m :

Adsorbate volume per unit mass of solid for monolayer coverage (m3 kg)

V a :

Adsorbate volume at relative pressure

α :

Dimensionless size parameter

λ :

Wavelength of incident radiation (nm)

θ :

Scattering angle (°)

ρ p :

Particle specific mass (kg/m3)

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Fauchais, P.L., Heberlein, J.V.R., Boulos, M.I. (2014). Powders, Wires, Cords, and Rods. In: Thermal Spray Fundamentals. Springer, Boston, MA. https://doi.org/10.1007/978-0-387-68991-3_11

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