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         Reducing Wear by Using Thermal Spray Coatings
Thermal spray coatings have and are used in a very broad range of wear resisting surfaces and for the repair of wear resisting surfaces. The main advantage being that thermal spray coating can provide the surface properties and the component substrate material can be chosen from the bulk requirements be it strength, weight or cost without the need to consider it's inherent wear resistance or other surface properties.

Selection of the best coating for an application is not often straight forward. Selection based on hardness or from standard wear testing would indicate coatings like HVOF tungsten carbide/cobalt, plasma sprayed chromium oxide ceramic or fused coatings as giving the ultimate performance. Indeed, these coatings do provide the best solution to many applications, but they are certainly not universally suited to all applications. Other factors must be considered:

Cost
Life expectancy
Corrosion
Counter surface
Effect of process on substrate material
Surface finish or profile
Temperature
Lubrication
Abrasives
Loads and speeds
Impact, shock or fatigue
Ability to work harden
Severity and angle of attack
Coefficient of friction
Porosity
Other specific coating properties may be required
Thermal barrier or conductor
Electrical insulator or conductor
Non-magnetic
Special surface profiles
Abradable (requiring erosion resistance, but sacrificial to counter surface)
Abrasive (required to abrade or grip counter surface)
Very low coefficient of friction or non-stick properties
 

Wear
The mechanism of wear is very complex and the theoretical treatment without the use of rather sweeping simplifications (as below) is not possible. It should be understood that the real area of contact between two solid surfaces compared with the apparent area of contact is invariably very small, being limited to points of contact between surface asperities. The load applied to the surfaces will be transferred through these points of contact and the localised forces can be very large. The material intrinsic surface properties such as hardness, strength, ductility, work hardening etc. are very important factors for wear resistance, but other factors like surface finish, lubrication, load, speed, corrosion, temperature and properties of the opposing surface etc. are equally important.

Abrasive Wear
Wear due to hard particles or hard protuberances forced against and moving along a solid surface.

Adhesive Wear
Wear due to localised bonding between contacting solid surfaces leading to material transfer between the two surfaces or the loss from either surface.

Erosion
Wear due to mechanical interaction between that surface and a fluid, a multicomponent fluid, or impinging liquid or solid particles
 

 

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Shijiazhuang Mets Machinery Co., Ltd. Shijiazhuang Hi-tech Industry Development Zone Tel:0086-311-68058177 Fax:0086-311-68058178