A Review on Suspension Thermal Spray Patented Technology Evolution

Abstract

Since the introduction of suspension thermal spray (STS) in 1997, the rapid evolution of this technology has resulted in a critical number of inventions justifying a comprehensive review. Today STS is one of the most important research and development topics in thermal spray. Due to the efforts of different industries, universities, and governmental institutions, STS has reached a certain maturity for implementation in different applications. STS includes any thermal spray process that is based on injection of a suspension of solid particles in a liquid carrier into the gas jet, such as suspension plasma spray, suspension high-velocity oxy-fuel, and high-velocity suspension flame spray. This review is on the state of the art of the STS technology and includes an overview of the current patent situation including the number of patents published in English language, patenting institutions and invention domains. Apparatus and methods, feedstock, and new material systems and applications were identified as the three main domains of focus for the STS inventions. The presented patents show a general perspective of the current situation and present the technology advancements in each domain. It also shows the potential of implementing this technology in new applications based on the needs of thermal spray market through further technology development. Keywords suspension thermal spray Á suspension plasma spray Á suspension high-velocity oxy-fuel Á high-velocity suspension flame spray & Christian Moreau

Bioactive surface modifications through thermally sprayed hydroxyapatite composite coatings: a review of selective reinforcements

“…Thermal spraying is a widely employed technique for depositing HA and HA composite materials. 27,[63][64][65][66][67][68] Dental and orthopedic prosthetic devices, including hip and knee implants and bone fracture fixing devices such as bone plates, screws, and pins, are modified with HA coatings. 69 Currently, FDA approved the plasma-spray technique to deposit HA coatings on the metal substrate.…”

Thermal Spray Coatings for Electromagnetic Wave Absorption and Interference Shielding: A Review and Future Challenges

“…[103] This can then be followed by managing the process parameters of thermal spray to melt (or partially melt) the powder particles and preserve its fine-grained structures or use liquid feedstock (suspension, solution) to change the interaction between hot gases and feedstock in the way to enable obtaining finely grained coatings. [6,24,103,[170][171][172] Considering some examples where suspension-based plasma spray coating has been developed by Vaßen et al (2009), [93] Mauer, Guignard and Vaßen (2013), [111] Robinson et al ( 2015), [106] and Khatibnezhad et al (2021), [105] for photocatalytic (absorption) applications, future work may be promising in the current context, where suspension or solution spraying (SPS, SPPS) can allow convenient deposition of range of coatings to yield desirable EM wave propagation properties.…”

“…Recent trends have been to produce thermally sprayed ceramic coatings with nanostructures or refined microstructures and precision-engineered surface textures. [5,6] Thermal spray grade powder particle shape, geometry, size, orientation, and arrangement during thermal spraying of a chosen material can affect the EM waves in an unconventional manner, thereby creating material (surface) properties which are not achievable using conventional processes.…”

Mathematical Modeling of the Melting Process of Silicate Materials in a Plasma Reactor

“…Theoretical [11,12] and experimental studies [13,14] have demonstrated that the solid particle interaction with plasma includes a large number of different physical phenomena; therefore, its complete description is practically impossible. The physical and mathematical model of melting of a quartz particle in low-temperature plasma was developed in [15].…”