Arc Spray Wire- Excellent adhesive and bond strength

The module of elasticity is an essential mechanical property defining the strength of a material which is a prerequisite to design a component from its early stage of conception to its field of application. Mechanical properties of the deposited layers differ from the bulk material due to the anisotropy of the highly textured coating microstructure when a material is to be thermally sprayed. The overall performance of the coated component is influenced by the mechanical response of the deposited layers. Therefore the evaluation of the effective module of elasticity of the coating is necessary. Various conventional experimental methods have been investigated and their results vary due to inhomogeneous characteristics of the coating microstructure. 

An alternative method to determine the coating anisotropic elastic behavior dependence on crystallographic orientations is the synchrotron radiation coupled with a tensile test rig. Inconel 718 HVOF coatings sprayed on IN718 substrates were investigated. A deeper understanding of the nature of the HVOF coating Young’s modulus is yielded by a combination of these experimental techniques and thus a tool for Design Practice for repair applications.

Wire spray offers low cost, high porosity, unmelted particles, oxides and low to moderate bond strength. Arc spray wire has high adhesive and bond strength. It involves formation of a quasi alloy coating by using two pieces of dissimilar metal and alloy wire rods. It offers high spraying efficiency and spraying by all metals which can be wire rods possible. There is no deterioration and changes found on the materials to be sprayed due to low temperature spraying. It has excellent oil retaining property and sliding wear characteristic due to pores within coatings.

The properties of arc-sprayed aluminum on alloyed armor-grade steel were examined. EuTronic Arc Apray 4 wire arc sprayer was used to conduct a thermal arc spraying. Dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating were produced using an aluminum wire 1.6 mm in diameter. Aluminum coatings were characterized according to ASTM G 65-00 abrasion resistance test, ASTM C 633-01 adhesion strength, ASTM G 76-95 erosion resistance tests, HV0.1 hardness tests and metallographic analysis. Results showed the properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required.

Combustion with energy recovery of post-recycling municipal solid waste (MSW), also known as waste to energy (WTE), is the only proven alternative to landfilling. WTE avoids landfilling and methane emissions to atmosphere and reduces the volume of MSW by 90%. Corrosion on the superheater tubes is a major concern in the WTE industry which is related to the relatively high concentration of chlorine (0.47-0.72 wt %) in the flue gas and the formation of alkaline salts and sulfates. The operation of WTE plants is affected by the corrosion due to the cost and time needed to repair or replace the superheater tubes. High temperature corrosion (HTC) is prevented inside the WTE boilers by applying numerous coating techniques including laser claddings, thermal spray coatings, weld overlays and fused coatings.