Plasma Spraying

Plasma spraying process utilises highly energetic plasma jet to melt and accelerate sprayed material particles allowing  deposition of the coating. In this process the heat source (plasma) is formed by generation of high density arc current in the space between cathode and anode filled with molecular or mono-atomic gases such as H2 or Ar. Ionised gases heat up to the temperatures of about 15000 degC and expand outside the nozzle reaching supersonic velocities. Properties of the plasma stream can be controlled by cathode-nozzle arrangement(geometry), kind and mixture ratio of gases and electric arc settings. As the results, these parameters also greatly influence the degree of melting and acceleration of plasma sprayed materials injected into the plasma allowing deposition of coatings with tailored microstructural properties to specific industrial application.

Plasma Spraying Process sketch

Coatings applied with plasma spraying:

  • Pure metals (Cu, Al, Zn, Ni, Mo, W,…)
  • Alloys (NiCr, NiAl, NiMoAl, NiCrSiB, Tribaloy, Inconel, Stellite, …)
  • Carbides (WC/Co, CrC/NiCr, …)
  • Ceramics (Al2O3, TiO2, Cr2O3, ZrO2/Y2O3, …)
  • Abradables (Ni/Graphite, AlSi/Polyester, …)

Vast varaiety of material combinations allow plasma spraying to be used in wide spectrum of industrial applications providing:

  • wear reststance,
  • corrosion resistance,
  • oxidation resistance,
  • thermal and electrical insulation,
  • electrical conductivity,