The Science and Engineering of Thermal Spray Coatings

Brad grew up in the countryside of Michigan on the outskirts of the small town of Tecumseh. Surrounded by corn and wheat fields, it was there he learned to harness his imagination. In sixth grade, he was selected for the Young Authors Program, which sparked his urge to write. Later, he graduated from Michigan State University, where he also studied martial arts and started writing his first novel. His home is now Chelsea, MI, where he lives with his wife, two daughters, and many rescued animals. Brad is the author of the epic science fiction adventure trilogy War of the Harbingers.

Thermal spraying has become the most versatile coating method in materials engineering. This text describes the state of art o f this technology in a logical way: starting from the feedstock used to spray and the methods of manufacturing, u to the present and potential future industrial applications of sprayed coatings. The book, based on then successful first edition published in 1995, describes new topics in thermal spray technology such as nanostructured deposits, the cold spray method, advanced mathematical methods of process modelling, and many others. This entirely rewritten new edition also covers the advanced methods of coatings characterization and their different mechanical, electrical, physical and chemical properties.
 
Converge includes:
* Methods of powder manufacturing including emerging methods of high temperature synthesis, their characterization and the problems related to the transport and injection of a powder into a jet or flame.
* The technical basis of the coating preparation processes, including pre-spray treatment of a substrate with the methods of surface activation by sand blasting, laser ablation and water jet and the methods of masking the elected areas of the coated surface.
* The physics and chemistry of thermal spraying and the metallurgy of coating formation as well as a discussion on coating build-up from the individual particles.
* The methods of coatings characterization such as advanced microstructural investigations including scanning electron microscope; X-ray diffraction; transmission electron microscope; mercury intrusion porosimetry, etc.
* Application of castings in numerous industrial sectors such as aeronautics, automobiles, chemicals and mechanical engineering, including the status of research of emerging applications in electronic and energy generating sectors.
 
This book is addressed to graduate and PhD students wishing to familiarize themselves with thermal spraying. Professionals working in the area will find it useful as a reminder of the scientific fundamentals of the deposition process, whilst academic and industrial researchers will find up-to-de information on the most important research areas of this rapidly growing field.

Beginning with coverage of materials used, pre-spray treatment, and the techniques used, The Science and Engineering of Thermal Spray Coatings, Second Edition explores the physics and chemistry of spraying and discusses coatings build-up. Characterization methods and the properties of the applied coatings are presented, and the book concludes with a lengthy chapter on thermal spray applications, including aeronautics and space, automobiles, ceramics, chemicals, civil engineering, decorative coatings, electronics, energy generation and transport, iron and steel, medicine, mining, and the nuclear industries.

Preface to the Second Edition.
 
Preface to the First Edition.
 
Acronyms, Abbreviations and Symbols.
 
1 Materials Used for Spraying.
 
1.1 Methods of Powders Production.
 
1.2 Methods of Powders Characterization.
 
1.3 Feeding, Transport and Injection of Powders.
 
References.
 
2 Pre-Spray Treatment.
 
2.1 Introduction.
 
2.2 Surface Cleaning.
 
2.3 Substrate Shaping.
 
2.4 Surface Activation.
 

2.5 Masking.
 
References.
 
3 Thermal Spraying Techniques.
 
3.1 Introduction.
 
3.2 Flame Spraying (FS).
 
3.3 Atmospheric Plasma Spraying (APS).
 
3.4 Arc Spraying (AS).
 
3.5 Detonation-Gun Spraying (D-GUN).
 
3.6 High-Velocity Oxy-Fuel (HVOF) Spraying.
 
3.7 Vacuum Plasma Spraying (VPS).
 
3.8 Controlled-Atmosphere Plasma Spraying (CAPS).
 
3.9 Cold-Gas Spraying Method (CGSM).
 
3.10 New Developments in Thermal Spray Techniques.
 
References.
 
4 Post-Spray Treatment.
 
4.1 Heat Treatment.
 
4.2 Impregnation.
 
4.3 Finishing.
 
References.
 
5 Physics and Chemistry of Thermal Spraying.
 
5.1 Jets and Flames.
 
5.2 Momentum Transfer between Jets or Flames and Sprayed Particles.
 
5.3 Heat Transfer between Jets or Flames and Sprayed Particles.
 
5.4 Chemical Modification at Flight of Sprayed Particles.
 
References.
 
6 Coating Build-Up.
 
6.1 Impact of Particles.
 
6.2 Coating Growth.
 
6.3 Microstructure of the Coatings.
 
6.4 Thermally Sprayed Composites.
 
References.
 
7 Methods of Coatings' Characterization.
 
7.1 Methods of Microstructure Characterization.
 
7.2 Mechanical Properties of Coatings.
 
7.3 Physical Properties of Coatings.
 
7.4 Electrical Properties of Coatings.
 
7.5 Magnetic Properties of Coatings.
 

7.6 Chemical Properties of Coatings.
 
7.7 Characterization of Coatings' Quality.
 
References.
 
8 Properties of Coatings.
 
8.1 Design of Experiments.
 
8.2 Mechanical Properties.
 
8.3 Thermophysical Properties.
 
8.4 Electric Properties.
 
8.5 Magnetic Properties.
 
8.6 Optical Properties.
 
8.7 Corrosion Resistance.
 
References.
 
9 Applications of Coatings.
 
9.1 Aeronautical and Space Industries.
 
9.2 Agroalimentary Industry.
 
9.3 Automobile Industry.
 
9.4 Ceramics Industry.
 

9.5 Chemical Industry.
 
9.6 Civil Engineering.
 
9.7 Decorative Coatings.
 
9.8 Electronics Industry.
 
9.9 Energy Generation and Transport.
 
9.10 Iron and Steel Industries.
 
9.11 Machine Building Industry.
 
9.12 Medicine.
 
9.13 Mining Industry.
 
9.14 Non-ferrous Metal Industry.
 
9.15 Nuclear Industry.
 
9.16 Paper Industry.
 
9.17 Printing and Packaging Industries.
 
9.18 Shipbuiding and Naval Industries.
 
References.
 
Index.

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