Basics of Plasma Spray Coating Before Application


Plasma spray coating is a thermal coating process in which particles that have been softened by heat form a coating onto a substrate. This process aims to prevent corrosion or damage and allow materials that have been sprayed to last longer and have improved resistance. This popular form of thermal spraying can be used to coat any material and its flexibility can be used in many different industries such as medical, aerospace, automotive and agriculture.

How does Plasma Spraying work?

The coating material is in powder form and injected into a high temperature plasma jet which heats the powder before accelerating it out towards the substrate. The plasma gas acts as the spraying heat source and gets heated to such a high temperature that it ionizes and becomes electrically charged, meaning materials with high melting points can be sprayed.

The plasma gun itself comprises of a copper anode and tungsten cathode which the gas flows through and around, making plasma that is forced out through a constructing nozzle once mixed with the powder coating material. When combined, the powder becomes molten and fires out of the gun onto the substrate before cooling to form a coating.

What is Plasma Spraying used for?

Because plasma spray coating is so versatile, it is one of the most popular thermal spray coating techniques available for producing high quality coatings that provide resistance, insulation, control, prevention and restoration. Plasma spray solutions may be necessary to protect industrial equipment and it is used across many different applications in industry sectors such engineering, electronics, chemical and nuclear, household appliances and more.

Advantages

  • There is a wide range of coating materials that meet a wide variety of different needs, with nearly all materials available in a suitable powder form.
  • Higher quality coatings such as flame or electrical arc spraying.
  •  Many types of substrate material, including metals, ceramics, plastics, glass, and composite materials can be coated using plasma spraying.
  • The high temperature of a plasma jet makes it particularly suitable for spraying coatings of refractory metals and ceramics, including ZrO2, B4C and tungsten.
  • The high temperature of a plasma jet makes it particularly suitable for spraying coatings of refractory metals and ceramics, including ZrO2, B4C and tungsten.
  • Plasma spraying is a well-established coating process that is widely available and well understood. 


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