Surface Finishing Tutorial

#328 Types and Characteristics of Electric Spraying

Category : Thermal Spraying

January26, 2018

[Table] shows the types and characteristics of electric spraying method using electric power as the heat source.

[Table] Types and characteristics of electric spraying method

Type	Arc spraying	Plasma spraying		Wire explosion spraying	Spraying and fusing
Type	Arc spraying	Gas	Water	Wire explosion spraying	Spraying and fusing
Heat source	Arc	Plasma such as nitrogen- hydrogen, argon- hydrogen, argon-helium, and argon- oxygen air	Oxygen plasma jet generated by water decomposition	Discharge energy	Oxyacetylene flame, oxygen- hydrogen
Spraying materials	Steel materials, such as carbon steel and stainless steel, non- ferrous metals including molybdenum, nickel, aluminum, and copper, as well as their alloy metals	Most of the metals, high melting point oxides including AL₂O₃, Cr₂O₃, and ZrO₂, carbide cermet including CrC-NiCr and WC- Co, some organic materials	Mostly the oxides, such as AL₂O₃, ZrSiO₄, and ZrO₂	Carbon steel, stainless steel, copper, and the most metals including Mo, Ni, Ta, and W	Self-fluxing alloy, Ni-B-Si, Ni-Cr-B-Si, Co-NiCr-B-Si, Cr-Ni-W-B-Si
Shape of spraying materials	Wire	Powder, wire	Powder	Wire	Powder, string- shaped
Sprayed materials	Most of the metals; some glass, ceramics and two to three organic materials		Most of the metals; ceramics with some limitations	Most of the metals	Mostly ferrous materials
Base material temperature (％)	Can be controlled under 200°C				Around 1050°C
Porosity (%)	5-15	3-15	10-20	1 or less	0
Characteristics	Relatively thick film can be formed by thermal spraying.	Thermal spraying of high melting point materials can be done easily.	Thick films can be formed by spraying oxides. Shapes and dimensions of the machined components are limited.	Thermal spraying can be applied on the inner surfaces.	Thermal deformation occurs.

Note）Description for the types of thermal spraying methods

	1.	The arc spraying is a method that dissolving spraying materials using heat from arc discharge.
	2.	The plasma spraying is a method that generating high-temperature plasma gas of nitrogen or the mixture of nitrogen and hydrogen using arc discharge, supplying spraying materials in it, and then spraying it to workpiece.
	3.	The explosion spraying is a method that causing an explosion using the mixture of oxygen and acetylene or the discharge energy, concentrating the energy into one direction, and then spraying it with powder materials using that energy.

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