Recently Patented Work on Thermally Sprayed Coatings for Protection Against Wear and Corrosion of Engineered Structures

Abstract

Advanced ceramic and metallic coatings for wear and corrosion protection of engineered structures applied by thermal spraying techniques have become a mainstay of surface engineering. Estimated global sales of thermally sprayed coatings are in the US$5 billion range per year, 50% of which are achieved by atmospheric plasma spraying. The development of suitable deposition equipment, sophisticated on-line process control, ease of application to complex surfaces, availability of a broad range of tailored feedstock materials, and sensitive characterization and quality assurance methods make novel surface coatings and their improved deposition techniques increasingly attractive. This review will cover patented progress in the field of wear-and corrosion-resistant coatings achieved during the past few years.

Tribological behaviour of nanostructured Al2O3 coatings

“…4 Plasma spraying is the most flexible or versatile thermal spray technique, and oxide ceramic coatings, such as alumina and chromia deposited by this technique, exhibit very high hardness, excellent wear resistance and high temperature stability, which are essential for tribological and high temperature erosion applications. 5,6 In recent times, nanostructured ceramic coatings are preferred due to their superior mechanical properties compared to conventional coatings (CCs). It is due to the effective hindrance to dislocation movements, which leads to the enhancement of strength and hardness.…”

“…In addition, the application of the coatings is usually easy and fast, a wide variety of materials can be deposited and minimal surface preparation is needed 4. Plasma spraying is the most flexible or versatile thermal spray technique, and oxide ceramic coatings, such as alumina and chromia deposited by this technique, exhibit very high hardness, excellent wear resistance and high temperature stability, which are essential for tribological and high temperature erosion applications 5,6 In recent times, nanostructured ceramic coatings are preferred due to their superior mechanical properties compared to conventional coatings (CCs).…”

Introduction to Advanced Ceramics

“…Currently, many airlines in the US are acquiring new aircraft, and demand is also increasing in Europe and Asia. Recent advances in the areas of wear -and corrosion -resistant ceramic coatings, as well as thermal barrier coatings, were reviewed by Heimann and Lehmann (2008) and Lehmann and Heimann (2008) . The market for other coating techniques, including spraying/dip -coating, sol -gel deposition, micro -arc oxidation ( MAO ) and laser -assisted thermal spraying, is expected to grow at an AAGR of 8.6% (Abraham, 2005 ).…”

Modeling of the Structure of Heat-Insulating Semi-Transparent Materials and Coatings for Industrial and Transport Power Plants

“…Different combination coatings, which define more uniform change in the coefficient of thermal expansion from the metal heat-resistant oxidized substrate (or the bonding ceramic-metal sublayer) to the surface of an opaque or semitransparent ceramic layer, solve this task [5][6]. Efficiency of indestructible thermal protection is usually associated mainly with low thermal conductivity [4][5][6][7][8][9][10][11][12][13][14][15][16].…”