Thermal Spray Methods and Splat Formation

Abstract

This chapter describes how surface coatings play a significant role in manufacturing industries due to improvements in the properties of the engineering components that lead to longer service life and reliability. Thermal spray is well suited for large structures and can be easily repaired. Previous publications concerning the principle of thermal spray processing; powder and their fabrication methods; the effect of substrate surface conditions on splat formation and morphologies; the effect of process parameters on splat formation and morphology; and thermal spray coating morphology are reviewed. Also described in detail is physical behaviour, such as thermal conductivity and wetting ability at impact between the thermal spray particle and the substrate, influences the individual splat geometry and coating build-up and, consequently, the coating properties.