TM

May 2008
Volume 3 Issue 2
I N T E R N A T I O N A L
Thermal Spray &
Surface Engineering
I N T E R N A T I O N A L
Thermal Spray &
Surface Engineering
T H E O F F I C I A L N E W S L E T T E R O F T H E A S M T H E R M A L S P R A Y S O C I E T Y
tss.asminternational.org
Your Thermal Spray
Information Partner
Industry
News
Diamond
Engine
Coatings
JTST
Highlights
TSS News
and Events
Industry
News
Diamond
Engine
Coatings
JTST
Highlights
TSS News
and Events
TSS
SM
ASM Thermal Spray Society
An Affiliate Society of ASM International

10 TSS Regional Events:

Aerospace Coatings and Improving
Reliability and Consistency in
Thermal Spray
14 Synthetic Diamond Coating
Helps Jet Engines
Withstand Hostile Environment
16 Application Note:
Corrosion Protection Back on
Ross-shire Engineerings Plate
Departments
2 Editorial
3 Industry News
9 ASM Thermal Spray Society News
18 JTST Highlights
20 Products/Technical Resources
ADVANCED MATERIALS & PROCESSES/MAY 2008 67
1
Editor Christopher C. Berndt
Managing Editor Ed Kubel
Art Director Barbara L. Brody
Production Manager Joanne Miller
Publisher Joe Zion
National Account Manager
Kelly Thomas, CEM.CMP
Materials Park, Ohio
tel: 440/338-1733
e-mail: kelly.thomas@asminternational.org
Thermal Spray Society
Executive Committee
Peter Hanneforth, President
Richard Knight, Past President
Mitchell Dorfman, Vice President
Charles Kay, Secretary/Treasurer
Thomas S. Passek, Executive Director
About the cover
Cryogenic nitrogen vapor maintains part
temperature within 20F during thermal
spray coating applications.
Courtesy of Air Products, Allentown, Pa.
International Thermal Spray & Surface Engineering
TM
is published quarterly by ASM International

,
9639 Kinsman Road, Materials Park, OH 44073;
tel: 440/338-5151; www.asminternational.org.
Vol. 3, No. 2. Copyright 2008 by ASM International

.
All rights reserved.
The acceptance and publication of manuscripts in
International Thermal Spray & Surface Engineering
does not imply that the editors or ASM International

accept, approve, or endorse the data, opinions, and

conclusions of the authors. Although manuscripts
published in International Thermal Spray & Surface
Engineering are intended to have archival significance,
authors data and interpretations are frequently
insufficient to be directly translatable to specific design,
production, testing, or performance applications
without independent examination and verification
of their applicability and suitability by professionally
qualified personnel.
MAY 2008 Volume 3 Issue 2
Zirconia (synthetic diamond)
helps to protect jet engine
components against
high-temperature
corrosion.
Thermal spray coatings
provide corrosion protection
for a range of components
at water plants throughout
the UK.
TM
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FROM THE
EDITOR
e all make transitions in life, which allow revitalization and growth to occur. While such
opportunities arise in our personal environments, how does growth occur for a
technology? What are tipping points for the advancement of surfacing technologies such
as thermal spray, hardfacing, PVD, etc., and how can individuals play a role that suits their
personal career goals?
Is technology the driver or engine for innovation? The answer is no. The real drivers are
people who dedicate their careers to make the impossible possible, responding to an
intrinsic curiosity to do what is considered by their peers as undoable and the need to solve
specific engineering applications challenges.
Has thermal spray reached its technological limit? This often seems the case on a
year-to-year basis when new developments appear to progress at glacial speed. Yet a
literature and the state-of-the-art search in 5- or 10-year increments reveals that people who
appear within relatively old conference proceedings are still publishing, which suggests that
thermal spray provides a sustainable long-term career. There also is a steady progression of
people passing through the field of thermal spray technology, growing at an annual rate of
about 15-20%. Furthermore, there is growth in the number and diversity of companies
involved in both publishing and exhibiting at conferences, which indicates a healthy
prospect for thermal spray with new players and new associated technologies contributing
to synergistic growth.
Is there is a limited need for specialists in coatings technology? To survive as a relevant
technology, it is not enough to maintain (for example) a $3-billion annual global market.
This will not lead to sustainability, and thermal spray will devolve to essentially a boutique
technology for special applications rather than the household word that denotes true
acceptance. New basic and applied R&D programs are needed to achieve the above goal.
Furthermore, technology-savvy people are desirable to start, manage, and implement these
programs. Where will these people come from and what incentives are there for a young
professional to enter the surface engineering field? The answers to these questions are
disappointing. Many young people find science and engineering too hard, and surface
engineering technologies are suffering. On the positive side, professional societies including
TSS, ITSA, DVS, GTS, and many others are playing a significant role in specialized education
and training for technologists of all types.
The born-again technologist is a person who meshes the three themes presented so
next-generation products can be developed. This technologist, by keeping an open mind,
holds the key to the leap-frog technology that surface engineering continues to create.
Chris Berndt, FASM, Editor
Editor Emeritus: The Journal of Thermal Spray Technology
IRIS, Faculty of Engineering and Industrial Sciences
Swinburne University of Technology
Mail 66 PO Box 218
Hawthorn, Victoria 3122 AUSTRALIA
Tel: +61 (0)3 9214 8706
Tel: +61 (0)428 237 638
cberndt@groupwise.swin.edu.au
68 ADVANCED MATERIALS & PROCESSES/MAY 2008
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Born Again as a Technologist
Increasingly higher gasoline prices
are driving car manufacturers to im-
prove the fuel economy of motor ve-
hicles. To address this situation, Hi-
tachi Ltd., Tokyo, Japan, developed
a valve lifter incorporating a hy-
drogen-free DLC (diamond-like
carbon) coating. The coating has low
friction with very good conformity
to the engine oil, which improves fuel
economy in engine valve-train sys-
tems. Overcoming some of the many
hurdles in the way of developing a
coating based on existing coating
technology that has good adhesion
to the base metal, Hitachi claims to
have produced a highly reliable
coating through the development of
lapping and special washing tech-
nologies prior to the treatment.
www.hitachi.com.
DLC Coating
Boosts Valve Lifter
Performance
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Atomizing Systems Supplies
Anti-Satellite Gas Atomizer
Inert-gas atomization is supposed to produce spherical metal powders, but suffers
from a problem called satelliting, in which most particles have smaller particles stuck
to their surfaces, a problem that becomes worse as powders are made finer. This con-
dition results both in reduced flow properties and lower than expected packing density.
One way to avoid satelliting is to quench the gas-atomized powders in water, which
produces spherical powders, but produces excessive oxygen levels for certain applica-
tions and alloys. Standard dry gas atomizers produces lower oxygen content, but de-
grade sphericity.
Atomising Systems Ltd. (ASL), Sheffield, UK, delivered what is said to be the worlds
first anti-satellite gas-atomizing system
to Castolin Eutectic Ireland Ltd. (CEIL),
a division of the Messer group of com-
panies based in Frankfurt, Germany.
CEIL supplies a wide range of special
Ni, Co, and Fe alloy powders used in
thermal spray, welding, and brazing
processes. The 8-m (26 ft) high system,
fitted with two 350 kW, 250 kg (550 lb)
melters, incorporates ASLs anti-satel-
lite technology. The atomizer also is
fitted with an induction-heated tundish
to allow long pouring times. www.
atomising.co.uk.
Sulzer Metco Celebrates 75th Anniversary
This year, 2008, marks the 75th year of the founding of
the Metallizing Engineering Co., now known as Sulzer Metco.
Rea Axline opened the doors of Metallizing Engineering Co.,
Westbury, N.Y., in 1933 to meet industry needs of increasing
component service life by preventing corrosion and salvaging
worn parts to serviceable condition.
Today, customers continue to require surfaces that keep the
components they market in service longer, with better perform-
ance than ever before. Sulzer Metco, as part of its 174-year
old parent company, Sulzer, with more than 1,900 employees
worldwide, continues to take on the challenges of new
industries that require new surface solutions. www.sulzer.
com.
Many equipment advancements have occurred during
Sulzer Metcos 75-year history.
ASTM Metallic Coatings
Committee to Meet
ASTM Internationals Metallic and In-
organic Coatings Committee (B08) will
meet on October 23 at ASTM headquar-
ters in West Conshohocken, Pa. All inter-
ested individuals may attend ASTM meet-
ings. For more information about the
upcoming meetings, call Diane Rehiel,
ASTM International at 610-832-9717; e-
mail: drehiel@astm.org; or visit the com-
mittee Web page at http://www.astm.org/
COMMIT/B08.htm.
Accuwright Industries
Achieves ISO 9000
Certification
Accuwright Industries Inc., Gilbert, Ariz., a metal-spray tech-
nology company offering a wide range of flame spray services
including training and consultation was audited by QAS Inter-
national to the quality management systems, standards, and
guidelines for ISO 9001:2000 and achieved certification. Flame
spray processes are applied to a wide range of products in the
aerospace, automotive, electronics, and semiconductor markets.
ISO 9001 is the internationally recognized quality management
system that verifies that a company can provide a consistent
level of quality products. The system documents steps needed
to deliver such quality, from initial design through final delivery
and product support. Regular re-certification by a qualified
registrar ensures that the Quality System remains in place and
is effective. www.accuwright.com.
Raymor Acquires
SE Techno Plus
Raymor Industries Inc., Boisbriand, Quebec, Canada, a de-
veloper and producer of single-walled carbon nanotubes,
nanomaterials, and advance materials, announced that its
wholly owned subsidiary, Raymor Aerospace Inc. purchased
SE Techno Plus Inc., Saint-Leonard, Quebec, a company spe-
cializing in the manufacturing, repair, and precision grinding
with super finishing of industrial and aerospace components.
The acquisition allows Raymor Aerospace to implement its
one-stop-shop facilities for its coating services and develop
a larger market presence for Raymors other subsidiaries.
The aerospace sector includes commercial, regional, and
business aeronautics, and general and military aviation.
Boeing predicts the aeronautic world fleet will double over
the next 20 years, which should bring a demand of 28,600
new aeronautics during the period. www.raymor.com.
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Technogenia (headquartered in Seynod, France) opened a new office in Atlanta, Ga.,
to develop its business in North America. Aleader in hardfacing technology, Technogenia
offers a wide range of anti-abrasion material for use in wear applications such as in the oil
drilling, mining, foundry, aluminum, iron and steel, paper, food, ceramic and tile, and
waste-recycling industries. Anti-abrasion protection is imperative in industries that use
heavy-duty parts for mixing, grinding, or other techniques that subject the tools to signif-
icant wear. Replacing these parts can be costly and time consuming, slowing production
and reducing quality of results. Technogenia developed a special tungsten-carbide powder
known as Spherotene that provides very good anti-abrasion when deposited on a tools
surface. The carbide particles are applicable by means of a welded-on cast-nickel cord,
thermal spray, special castings, or precision laser, providing almost ten times longer service
life than that of traditional chrome-carbide hardfacing. Technogenia is represented by
Bolton Alloy LC in Houston, Tex. (tel: 713-460-8870). www.technogenia.com.
Technogenia Opens Business Office in Atlanta
New Technogenia office in Atlanta, Ga.
70 ADVANCED MATERIALS & PROCESSES/MAY 2008
4
Praxair Surface Technologies Inc., Indianapolis, Ind., a wholly
owned subsidiary of Praxair Inc., will complete a multi-million
dollar investment to add capacity for advanced coatings in early
2008. In response to strong global demand from industrial gas
turbine original equipment manufacturers, state-of-the art coat-
ings technology is being added to the companys facilities in
Charlotte, N.C., and Schluechtern, Germany. The capacity in-
crease is driven by strong demand for industrial gas turbine en-
gines in the power generation sector, as well as the increased
use of advanced coatings, according to David Brackins, vice
president of business development. Industrial gas turbine man-
ufacturers continue to produce engines having increased effi-
ciency, higher reliability, and reduced environmental emissions.
Thermal spray coatings applied using plasma coating processes
significantly enhance the ability of key components to operate
within the severe conditions of the engine.
In other news, Praxair Surface Technologies received Sup-
plier-of-the-Year honors from Dresser-Rand, providing the
company with thermal spray coatings for fluidic catalytic
cracking hot gas expanders and reciprocating process com-
pressors. Dresser-Rand cited its satisfaction with Praxairs
consistency and reliability in product quality, responsive-
ness to customer needs, and on-time delivery performance.
www.praxairsurfacetechnologies.com.
Praxair Surface Technologies to Expand Coating Capacity
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Researchers at John H. Glenn Research
Center, Cleveland, Ohio, discovered that at-
omization of a molten mixture of BaF
2
and
CaF
2
is superior to crushing of bulk solid
BaF
2
-CaF
2
as a means of producing eutectic
BaF
2
-CaF
2
powder for use as an ingredient of
the powder feedstock of a high-temperature
solid lubricant material known as PS304. The
material was developed to reduce friction and
wear in turbomachines that incorporate foil
air bearings, and is applied to metal substrates
using plasma spray. PS304 consists of an
80 Ni-20 Cr alloy, Cr
2
O
3
, Ag, and the BaF
2
-
CaF
2
eutectic (specifically, 62 BaF
2
-38 CaF
2
.
Using atomization to produce eutectic
BaF
2
-CaF
2
powder produces more desirable
particle shape having significantly improved
powder flow properties: atomized powder is
more rounded compared with the angular particles produced
through crushing. PS304 feedstock powder containing the more
rounded particles flows more freely and more predictably, which
is preferable for plasma spray.
Gas and water atomization processes were compared with
crushing to produce eutectic BaF
2
-CaF
2
powders (see figure).
The particles produced by gas atomization are the most nearly
spherical, but each batch contains only a small proportion of
particles in the size range (20 to 100 Pm) suit-
able for plasma spray and a much larger pro-
portion of undesired finer particles. Water at-
omization yields particles that are less spherical
in character but still more rounded than those
produced by crushing, and it yields a greater
proportion of usable particles. The flow prop-
erties of PS304 powders containing water-at-
omized BaF
2
-CaF
2
are intermediate to those
of PS304 powders containing equal propor-
tions of gas-atomized BaF
2
-CaF
2
and those
containing equal proportions of crushed BaF
2
-
CaF
2
. Because water atomization is less ex-
pensive and better suited to high-volume pro-
duction than gas atomization, water
atomization could be preferable for applica-
tions in which the shapes of the eutectic BaF
2
-
CaF
2
particles are not required to closely ap-
proximate spheres and the intermediate flow properties are
acceptable. This work was done by Christopher DellaCorte of
Glenn Research Center and Malcolm K. Stanford of the Uni-
versity of Dayton. Inquiries concerning rights for the com-
mercial use of this invention should be addressed to NASAGlenn
Research Center, Innovative Partnerships Office; Attn: Steve
Fedor, Mail Stop 4-8, 21000 Brookpark Rd., Cleveland, Ohio
44135. Refer to LEW-17709-1.
Water-Atomized Metal Fluoride Powder
for Better Flow Characteristics
Water atomization produces
particles intermediate in shape to
those produced by gas
atomization and crushing.
72 ADVANCED MATERIALS & PROCESSES/MAY 2008
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ArcelorMittal, Luxembourg, Belgium, inaugurated its innova-
tive Arceo industrial prototype for a vacuum plasma steel coating
line located in Liege, Belgium. What is claimed as a break-
through technology, Arceo was developed by the Groups Re-
search and Development in partnership with the Walloon Re-
gion, and is expected to open up many new uses for flat steel
products. Coated steel can serve as a sensor, a reflector, an an-
tibacterial, or self-cleaning surface; can have improved corro-
sion resistance; or just simply be more aesthetic. The process is
environmentally friendly; it does not use solvents or chemical
preparations; neither does it generate effluents or gases that
require treatment. ArcelorMittal is the worlds number one steel
company, with 320,000 employees in more than 60 countries
with combined revenues (2006) of USD 88.6 billion and a crude
steel production of 118-million metric tons, representing around
10% of world steel output. www.arcelormittal.com.
ArcelorMittal Inaugurates Vacuum Plasma-Coating Line
Longevity Coatings, Pen Argyl, Pa., a thermal spray coating-
service company founded in 2005, relocated its production fa-
cility to a site near Allentown, Pa., occupying 8,800 ft
2
in two
buildings. The company specializes in the application of
thermal spray coatings (carbide, ceramics, and metals) to wear
and machine parts used in a wide variety of industrial appli-
cations. Various thermal spray coating processes,
including HVOF, plasma, twin wire arc, and com-
bustion flame spray and fused coatings (diffusion
bonded), are applied using computer-programmed
equipment.
Mark Purington, founder and president of
Longevity Coatings, notes that manufacturers de-
sire to extend the life of equipment has led to sig-
nificant growth for the company and for the thermal
spray industry in general. The new facility is
equipped to handle completely manufactured,
coated, and ground components, including parts in
excess of 18 ft long and up to 50 in. diameter (5.5
m and 1,270 mm). www.longevitycoatings.com.
Biomet Celebrates Hip Stems
25th Anniversary
Biomet Inc., Warsaw, Ind., celebrated the 25th anniversary of its Ta-
perloc hip stem. According to the company, the flat, tapered wedge de-
sign of the Taperloc stem with its porous plasma-spray coating continues
to offer surgeons and their patients consistent, reproducible results. The
hip stem is said to be one of the industrys best performing implants and
the milestone celebration is a tribute to its excellent long-term clinical
success. Biomet currently offers three stem options for the Taperloc hip,
including the original standard stem, a reduced distal stem, and the
Taperloc Microplasty stem. www.biomet.com.
Thermal Spray Coater Relocates, Expands Plant
74 ADVANCED MATERIALS & PROCESSES/MAY 2008
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Tribofilm Research Inc., Raleigh, N.C., received a patent
(U.S. Patent No. 7,264,669) for its StaClear abrasion-resistant
coating, claimed to be a breakthrough in hard-coat technology.
Test results of the abrasion resistance of the two-coat gradient
composition performed by Colts Laboratories, Clearwater, Fla.
(www.colts-laboratories.com) demonstrate very good abrasion
resistance. Three distinct coating properties of interest to coat-
ings and materials specialists that set it apart from most com-
mercially available hard coats are:
ABayer Index of 5.87
An anti-graffiti, easy-to-clean surface, which is both hy-
drophobic and oleophobic
Aminimal effect on the impact resistance of polycarbonate,
unlike many commercially available hard coats
StaClear is predominantly a water-based system, which, there-
fore, is not sensitive to humidity during coating. It can be di-
luted with water and clean up can be accomplished using aqueous
detergent. It also is resistant to common organic solvents and
has excellent impact resistance. Properties can be achieved with
a hard coat thickness as low as 3.5 mm. The coating is particu-
larly useful for use on substrates such as polycarbonate, CR-39,
biaxially oriented Mylar and many engineering polymers. Sta-
Clear basecoat has a long shelf life (>6 months at room temper-
ature). www.tribofilmresearch.com.
Breakthrough in Hard Coat Technology
FEI Co., Portland, Oreg., received a technology award at Nano
Tech 2008 in Tokyo, Japan, for technical excellence in evalua-
tion and measurement of its Titan 80-300 S/TEM (scanning/trans-
mission electron microscope). The award recognizes both in-
novative technology and the contributions the Titan S/TEM has
enabled nanotechnology research. Professor Tomoji Kawai,
chairman, Nano Tech Executive Committee, noted that FEI has
been a major contributor to the science of nanotechnology since
its inception. The introduction of aberration-corrected TEM is
a major breakthrough that gives scientists the ability to directly
visualize nanostructures with sub-Angstrom imaging resolu-
tion. Anew model with high resolution EELS (electron en-
ergy loss spectroscopy) that can provide analytical results with
the same high resolution has also
been put into practical use. Un-
like conventional S/TEMs,
which require complex compu-
tational procedures to recon-
struct high resolution images, the
Titan S/TEMs aberration-cor-
rected electron optics is said to
provide directly interpretable image resolution at the atomic
scale. FEI is involved in pioneering technologies and applica-
tions that deliver imaging solutions for three-dimensional char-
acterization, analysis, and modification/prototyping with reso-
lutions down to the sub-Angstrom level. www.fei.com.
Technology Award Recognizes Contributions
to Nano Research
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The Thermal Spray Society Board at its March 2008 meeting
unanimously approved the safety document Guidelines for the
Use of Personal Protective Equipment in Thermal Spraying,
which was created by the Thermal Spray Society Safety Com-
mittee (chaired by Greg Wuest). Personnel Protective Equip-
ment (PPE) is intended to provide information consistent with
the U.S. Occupational Safety and Health Administrations
(OSHA) Personal Protective Equipment Standard (29 CFR
1910.132-138). All information is presented in the context of
Thermal Spray.
These guidelines are written within the context of the pre-
vailing internationally accepted practices and standards, as well
as United States laws and regulations. They are intended to have
worldwide application.
The full document can be viewed on the TSS Community
Web site at www.ineedaurlthatworks.com
Student Board-Member
Program
The Thermal Spray Society Board unanimously approved the
creation of a TSS Student Board Member Program recommended
by the TSS Nominating Committee (chaired by Rick Knight).
The program and Board Mentor Guidelines are modeled after
the ASM Board of Trustees Student Member Program.
Looking for Candidates
TSS is looking for two student members. To be eligible, a
person must be a registered undergraduate or graduate student
during the 2009-2010 academic year studying or researching in
an area closely related to the field of thermal spray technology.
Student-Application Details
To apply, a student must submit an application package com-
prising:
Acurrent resume/CV
Atwo-page essay (typed and double-spaced, in English) ad-
dressing his/her interest in participating in the program, including
(1) what experiences led to his/her interest in this program, and
(2) what qualities, characteristics and skills he/she has that will
make them a strong candidate to serve as Student Representa-
tive to the TSS Board
What he/she hopes to learn/gain from this program
Two or three letters of recommendation from faculty
Applications will be reviewed by the TSS Nominating Com-
mittee, which will forward recommendations to the TSS Ex-
ecutive Committee for approval. Applications are due no later
than April 1, 2009. The two selected participants will be noti-
fied by May 1, 2009 and will each begin their nonrenewable and
Continued
TSS News
TS Safety Document Approved by TSS Board
ADVANCED MATERIALS & PROCESSES/MAY 2008 75
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non-voting, one-year term as Student Representatives to the
TSS Board of Directors, at the spring 2009 TSS Board meeting
in Las Vegas.
The application package should be submitted by mail to:
ASM World Headquarters
Attn: Sarina Pastoric
9639 Kinsman Rd.
Materials Park, OH 44073-0002
UPCOMING TSS REGIONAL
EVENTS
Aerospace Coatings Symposium
October 15-16 2008
Sheraton Bradley Hotel
Bradley (Connecticut) International Airport
Symposium organizers: Mr. Richard Bajan, BASF Catalysts
LLC, and Mr. Mitchell Dorfmann, Sulzer Metco (US) Inc.
This 2-day event will cover some of the latest developments
in thermal spray and other surface engineering technologies de-
signed specifically for use in the aerospace industry. The pro-
gram includes a Plenary Session, two technical sessions (coat-
ing design and coatings implementation), and panel discussions.
Plenary Session
Human Factors: The study of human capabilities and
limitations in the workplace
Mr. Andy Bordick
Manager, Continuous Improvement & Strategy Development
Pratt & Whitney
East Hartford, Conn.
Role of Thermal Spray Coatings in Advancing Systems
Approach to Turbine Airfoil Design for Gas Turbine Engines
Dr. Sudha Bose
Fellow of High Temperature Materials and Coatings in
Materials and Processes Engineering / Global Service
Engineering
Pratt & Whitney
East Hartford, Conn.
Aerospace Standards for Thermal Spray Coatings
Mr. Marc Froning
Manager of Engineering and Development
BASF Surface Technologies
East Windsor, Conn.
Role of Material and Equipment Thermal Spray Suppliers
in the Aerospace Industry
Dr. Markus Heusser
Executive Vice President
Sulzer Metco Thermal Spray
Winterthur, Switzerland
Reliability and Consistency in Thermal Spray Processes
Dr. Christian Moreau
Group Leader Surface Technologies
Industrial Materials Institute
National Research Council Canada
Boucherville (Montreal), Quebec, Canada
For more information, contact ASM Customer service at
customerservice@asminternational.org, or visit
www.asminternational.org/tssaerospace08/.
TSS News, continued
76 ADVANCED MATERIALS & PROCESSES/MAY 2008
1-877-293-NANO
Corrosion and Wear
Super Hard Steel

Microstructure refined to a nanoscale

Strength performance up to 4x better
than conventional steels
Conventional application processes,
including HVOF & Twin Wire Arc Spraying
Corrosion and Wear
Cost-Effective Coating Solutions for
Super Hard Steel

Microstructure refined to a nanoscale

Strength performance up to 4x better
than conventional steels
Conventional application processes,
including HVOF & Twin Wire Arc Spraying
1-877-293-NANO
www.nanosteelco.com
10
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We aim to please.
Extend equipment life and improve the reliability
of your entire operation with ASB Industries. Using
the latest thermal spray technology, ASB develops
custom solutions for unusual wear and quality issues,
from repairing mis-machined parts to meeting OE design
specications for new ones. All in an effort to increase
your production efciencies.
Get on target. Sign up for our Enewsletter at
asbindustries.com today!
2008 ASB Industries, Inc.
ASB Industries, Inc. 1031 Laubert St. arberton, 0h 11203 uSA
330.753.8158 info@asbindustries.com
Sponsorships Available. To learn more about tabletop ex-
hibiting and sponsorship opportunities, or to discuss customizing
a program to meet your specific needs; contact Kelly Thomas,
Exposition Sales Manager at 440-338-1733; or e-mail kelly.
thomas@asminternatinal.org.
Pre-Event Seminar
Materials and Processes for High Temperature Gas
Turbine Components
October 13-14, 2008
Sheraton Bradley Airport
Instructor: Dr. Donald Boone, President, BWD Turbines Ltd.,
Walnut Creek, Calif.
Seminar focuses on thermal spray and other surface modi-
fication processes critical to the aerospace industry. The course
is aimed at developing a firm understanding of materials,
processes, and applications of gas turbine components oper-
ating at the highest temperatures in the turbine section.
For more information, contact ASM Customer service at
customerservice@asminternational.org, or visit www.
asminternational.org/tssaerospace08/.
Symposium on Improving Reliability and
Consistency in Thermal Spray
December 2-3, 2008
Hyatt Regency Montreal
Quebec, Canada
Co-sponsored by ASM Thermal Spray Society and National
Research Council Canada
Symposium features presentations by invited speakers cov-
ering reliability and consistency of thermal spray processes and
coatings, poster session of recent research findings, and table-
top exhibit. For more information, contact customerservice@
asminternational.org.
CALLFOR POSTERS: Submit 200-word abstract for con-
sideration of presenting at the event to Lyso Russo at lysa.russo
@sunysb.edu. DEADLINE for submission is October 15, 2008.
To learn more about tabletop exhibiting and sponsorship op-
portunities, or to discuss customizing a program to meet your
specific needs; contact Kelly Thomas, Exposition Sales Man-
ager at 440-338-1733; or e-mail kelly.thomas@asminternatinal.
org.
ADVANCED MATERIALS & PROCESSES/MAY 2008 77
OBITUARY
Paula A. Didier, 48, of West Bend, Wis.,
passed away January 30, 2008. She
began her career in materials engi-
neering at J.I. Case in Wausau, Wis.;
moved on to Praxair Surface Technolo-
gies (formerly Miller Thermal Inc.) in
Appleton, Wis., where she honed her
engineering and management skills; and
joined Harley-Davidson Motor Co. at
its Product Development Center in Wauwatosa, Wis., in 2001,
where she remained until her death. Paula was a member
of the ASM Thermal Spray Society, and served as chair-
person for the ASM/TSS Recommended Practices Com-
mittee, Subcommittee on Metallography.
11
Grinding The Toughest Jobs
To Exacting Precision!
Lees Grinding delivers precision
solutions to impossible grinding
challenges. We tackle impossible jobs
every daygrinding thermal spray
coated parts, grinding polygons and
many other non-round configurations to
precision tolerances! Challenge us. Try
us on your next impossible job. Youll be
pleasantly surprised at our world-class
solution. Call us today at 440.572.4610
or e-mail us at sales@leesgrinding.com.
Thermal Spray Coated Parts
Polygon Grinding
Non-Round Grinding
Close Tolerances
Lees Grinding delivers precision
solutions to impossible grinding
challenges. We tackle impossible jobs
every daygrinding thermal spray
coated parts, grinding polygons and
many other non-round configurations to
precision tolerances! Challenge us. Try
us on your next impossible job. Youll be
pleasantly surprised at our world-class
solution. Call us today at 440.572.4610
or e-mail us at sales@leesgrinding.com.
Thermal Spray Coated Parts
Polygon Grinding
Non-Round Grinding
Close Tolerances
Grinding The Toughest Jobs
To Exacting Precision!
iTSSe
78 ADVANCED MATERIALS & PROCESSES/MAY 2008
12
EVENTS
2008 International Thermal Spray Conference and Exposition
(ITSC 2008) Thermal Spray Crossing Borders
June 2-4, 2008
MECC Maastricht Congress Centre
Masstricht, The Netherlands
ITSC, the worlds foremost
international conference and
exposition for thermal spray
technologists, researchers,
suppliers, and end-users will be
held this year in Maastricht,
The Netherlands. ITSC 2008 follows
the successful path of the previous
events in Basel (2005), Seattle
(2006), and Beijing (2007), and will
present the latest status of
application, research and
development in the field
of thermal spray.
ITSC 2008 will take place at the
MECC Maastricht Congress Centre,
a state-of-the-art conference and
exhibition center designed with the
conference attendee in mind.
Visitors can attend ITSC 2008, dine,
and also have their room
accommodations at the center.
Everything is under one roof.
This outstanding annual event in
the world of thermal spray
technology is jointly organized by
the German Welding Society (DVS),
the ASM Thermal Spray Society
(TSS) and the International Institute
of Welding (IIW). Event sponsors are
NIL - Netherlands Institute of
Welding and VTS - Vereniging voor
Thermische Spuittechnieken.
The organizing team looks for-
ward to meeting you in Maastricht.
ITSC 2008 is an event not to be
missed!
For more in formation about
ITSC 2008, contact
Customer Service Center,
ASM International Materials
Park, Ohio,
tel: 800-336-5152 (ext. 0),
or 440-338-5151 (ext. 0);
e-mail: customerservice
@asminternational.org,
or visit
www.asminternational.org.
Thermal Spray Courses at ITSC 2008
(All courses held at Maastricht Expositie & Congres Centrum Maastricht, The Netherlands,
prior to the technical conference)
For registration details, visit
http://asmcommunity.asminternational.org/portal/site/ASM/ITSC2008/.
Instruction Language: All course instruction and materials will be in English.
Thermal Spray Technology
May 29-31
8:00 a.m. 5:00 p.m.
This course provides: (1) a thorough grounding and understanding of thermal spray processes,
(2) depicts the quite complex scientific concepts in terms of simple physical models, and (3) in-
tegrates this knowledge to practical engineering applications and commonly accepted thermal
spray practices. Participants receive the Handbook of Thermal Spray Technology and hard-
copy of the instructors presentation materials. The instructors have been collaborating on this
course since 1996.
Instructors: Dr. Christoper C. Berndt, FASM, TSS HoF, Professor, Swinburne University of
Technology, Hawthorn, Victoria, Australia; Dr. Richard Knight, FASM, Auxiliary Prof., Drexel
University, Philadelphia, Pa.
Registration Fees (US$): ON or BEFORE May 14 (AFTER May 14)
TSS/DVS/IIW Member 995 (1,045)
ASM Member 1,055 (1,105)
Non-Member 1,195 (1,245)
Student 295 (345)
Understanding and Improving Thermal Spray Technology
May 30-31
8:00 a.m. 6:30 p.m.
This course will review the processing science of a wide range of thermal spray coating
processes. The theory of operation and practice of the coatings will be presented, including
thermal spray process control, coating application, characterization, and testing. Practical
coating systems for electric arc, combustion, and plasma spray will be reviewed using case
studies.
Instructors: Dr. Maher Boulos, TSS HoF, Prof., University of Sherbrooke, Sherbrooke, Quebec,
Canada; Dr. Pierre Fauchais, FASM, TSS HoF, Prof., Universit de Limoges, Limoges, France;
Dr. Joachim Heberlein, FASM, TSS HoF, University of Minnesota, Minneapolis, Minn.
Registration Fees (US$): ON or BEFORE May 14 (AFTER May 14)
TSS/DVS/IIW Member 795 (845)
ASM Member 835 (885)
Non-Member 975 (1,025)
Student Fee 255 (305)
The Metallographic Preparation of Gas Turbine Coatings
May 31
8:00 a.m. 5:00 p.m.
This course covers a wide range of topics relating to the metallographic preparation and
evaluation of gas turbine coatings with emphasis on equipment and consumables selection
and how these choices influence the observed coating structure. Common issues encoun-
tered with various coating families (hardcoats, ceramic TBCs, etc.) also will be discussed.
Instructor: Mr. Douglas G. Puerta, Director of Metallurgical Engineering, IMR Test Labs,
Lansing, N.Y.
Registration Fees (US$): ON or BEFORE May 14 (AFTER May 14)
TSS/DVS/IIW Member 475 (525)
ASM Member 525 (575)
Non-Member 645 (695)
Student Fee 195 (245)
iTSSe
Nitin Padture
Department of Materials Science and Engineering
Ohio State University, Columbus
E
ngineers at Ohio State University, Columbus, are de-
veloping a technology to coat jet engine turbine blades
with zirconia (zirconium dioxide, or ZrO
2
) to protect
the components against high-temperature corrosion.
Zirconia (or synthetic diamond) chemically converts sand and
other corrosive particles that build up on the blade into a new
protective outer coating; the surface of the engine blade in ef-
fect continually renews itself. Ultimately, the technology could
enable manufacturers to use new kinds of heat-resistant mate-
rials in engine blades, so that engines will be able to run hotter
and more efficiently.
The project came to light when Nitin Padture, currently pro-
fessor of materials science and engineering at the university,
thought about needing such protection for military aircraft op-
erating in a desert climate when he was a professor at Univer-
sity of Connecticut, Storrs. In the desert, sand is sucked into the
engines during takeoffs and landings, and there also are dust
storms. Even in a non-desert environment, commercial aircraft
and power turbines encounter small bits of sand or other parti-
cles, which can damage turbine blades.
Because jet engines operate at very elevated temperatures,
blades in the most advanced engines are coated with a thin layer
of heat-resistant, thermally insulating ceramic to protect the
metal blades. These thermal-barrier coatings are designed to ex-
pand and contract with the metal. However, when sand hits
the hot engine blade, it melts and becomes glass, and molten
glass is extremely aggressive and can dissolve nearly any
material.
The hot glass attacks the ceramic coating, but the real damage
happens after the engine cools, and the glass solidifies into an
inflexible glaze on top of the ceramic. When the engine heats
up again, the metal blades expand, but the ceramic coating cannot
expand because the glaze has locked it in place. The result is
that the ceramic breaks off, shortening the life of the engine
blades.
The new diamond-like coating forces the glass to absorb chem-
icals that convert it into a harmless (even helpful) ceramic. The
key, according to Padture, is that the coating contains aluminum
and titanium atoms inside the zirconia crystals. When the glass
consumes the zirconia, it also consumes the aluminum and ti-
tanium. Once the glass accumulates enough of these elements,
it changes from a molten material into a stable crystal, and it
stops eating away at the ceramic. The glass literally becomes a
new ceramic coating on top of the old one. When new glass is
formed, the process repeats itself, continually renewing the
coating on the surface of the turbine.
Padture notes that the technology is in its infancy. The coat-
ings have not yet been applied to complex shapes, and cost is
a barrier as well as the process is energy-consuming. However,
if process costs can be reduced and the technology matures, the
payoff could be hotter engines that burn fuel more efficiently
and create less pollution. In addition, manufacturers would be
able to use more sophisticated ceramics that boost the heat re-
sistance of engines. Eventually, the technology could go beyond
aircraft and power-generator turbines and extend to automobiles
as well.
The University of Connecticut has applied for a patent on the
technique that Padture devised for embedding the aluminum
and titanium into the zirconia. Padture is partnering with In-
framat Corp., a nanotechnology company in Farmington, Conn.
(www.inframat.com) to further develop the technology.
The research was funded by the Office of Naval Research
(www.onr.navy.mil) and Naval Air Systems Command
(www.navair.navy.mil). For more in formation, contact Nitin
Padture; tel: 614-247-8114; e-mail: Padture.1@osu.edu. iTSSe
Synthetic Diamond Coating
Helps Jet Engines
Withstand Hostile Environment
An airplanes engines draw sand from a runway. Image courtesy
of the Department of Defense.
Conventional ceramic coating destroyed by molten glass (left)
and ceramic coating (in a thin layer on top) designed to resist
molten glass (right). The field of view of both images is about 0.5
mm. Both images by Aysegul Aygun and Nitin Padture, courtesy
of Ohio State University.
80 ADVANCED MATERIALS & PROCESSES/MAY 2008
14
iTSSe
Ross-shire Engineering Ltd., based in
the Highlands of Scotland, has pur-
chased new Flamespray Mark 73
equipment from Metallisation Ltd. (Dudley, West Midlands,
UK) as part of its strategic decision to once again provide cor-
rosion protection solutions to customers. Ross-shire Engineering,
a long-time Metallisation customer, provides a complete turn-
key industrial engineering service to its clients, from small fab-
rication to power-station refurbishment. With the purchase of
the Flamespray Mark 73, the company also
can provide long-term anticorrosion pro-
tection to its customers.
Ross-shire Engineering has been using
Metallisation Arcspray equipment for
around 20 years, producing engineered
coatings for shaft repairs and to replace
worn bearing surfaces in the water industry,
with Scottish Water and Scottish Southern Energy plc being well-
established clients. The new Flamespray equipment will be used
to provide long-term corrosion protection for tubes/pipework,
framework structures, security gates, and a range of general struc-
tural fabrications at water plants throughout the UK.
In the late 1990s, Ross-shire provided corrosion protection
solutions, but as demand diminished, they ceased providing such
services. Now, as customers are demanding higher standards of
finish and the extended lifetime of capital equipment, the need
for superior corrosion protection is increasing. Generally, cus-
tomers want to extend the life of their assets by protecting them
against corrosion, which, in turn, means minimum maintenance
requirements and reduced lifecycle costs. According to the British
and other International Standards Institutes, metal-spray coat-
ings will protect structures from corrosion for up to, and over,
20 years, depending upon the coating thickness applied and the
surrounding environment.
In the Flamespray process, the raw material, which is in the
form of a single wire, cord or powder, is melted in an oxygen
fueled gas flame. The molten material is atomized by a cone
of compressed air and propelled towards the work piece. The
molten spray solidifies on the component surface and forms a
dense, strongly adherent coating, suitable for corrosion protec-
tion or component reclamation. The coating can also be used to
provide wear resistance, electrical and thermal conductivity
or insulation, or freestanding shapes. Advantages of the Flame-
spray process are that the coatings are available for almost in-
APPLICATION
NOTE
Corrosion Protection Back on
Ross-shire Engineerings Plate
Thermal Spray Industry
Crosses Borders.
Attend ITSC 2008 in Maastricht,
The Netherlands, June 2-4, 2008.
ITSC brings together the global thermal spray community
to meet, exchange information and conduct business.
Learn the latest in applications, research and
developments across the field of thermal spray from
experts from around the world.
Register today for these outstanding pre-conference
education courses. Choose from the following courses
to complete your ITSC experience.
Thermal Spray Technology
May 29-31, 2008
8 a.m. - 5 p.m.
Instructors: Dr. Christopher C. Berndt, FASM and
Dr. Richard Knight, FASM
Understanding and Improving Your
Thermal Spray Processes
May 30-31, 2008
8 a.m. - 6:30 p.m.
Instructors: Dr. Maher Boulos, TS-HoF;
Dr. Pierre Fauchais, FASM, TS-HoF; and
Dr. Joachim Heberlein, FASM, TS-HoF
The Metallographic Preparation of Gas
Turbine Coatings
May 31, 2008
8 a.m. - 5 p.m.
Instructor: Douglas G. Puerta
Make important business
contacts at the expo. Exposition
and custom sponsorship
opportunities are still available.
Contact Kelly Thomas, National Account Manager today
to customize the package that best meets your needs.
kelly.thomas@asminternational.org or 440.338.1733.
From materials knowledge to innovationITSC 2008.
Visit www.asminternational.org/events today to register
for the conference, education courses and to take
advantage of expo opportunities.
ASM International

9639 Kinsman Road

Materials Park, Ohio 44073-0002
800.336.5152
www.asminternational.org
82 ADVANCED MATERIALS & PROCESSES/MAY 2008
16
iTSSe
Gain More Thermal
Spray Knowledge.
ASM International and the Thermal Spray Society
present two regional events designed to further enhance
specific knowledge within the thermal spray industry.
TSS Aerospace Coatings
Symposium
October 15-16, 2008
Sheraton Bradley Hotel
Bradley International Airport
Hartford, CT
Scientists and engineers will learn new trends in technology,
coatings application requirements and analyze case studies.
Applicators, technicians and process engineers will focus on
environmental health, safety issues, testing and characterization,
quality and process improvements, metallography and pre/post
processing challenges.
Add value to your symposium experience. Register for
this specially-designed pre-conference education course.
Materials and Processes for High Temperature
Gas Turbine Components
October 13, 8:30 a.m. - 4:30 p.m. and
October 14, 8:30 a.m. - 4 p.m.
Instructor: Dr. Donald Boone
Learn design requirements, materials and processing details,
protection system requirements degradation sequences, and
repair and refurbishment strategies.
TSS Symposium on Improving Reliability
and Consistency in Thermal Spray
December 2-3, 2008
Hyatt Regency Montreal
Montreal, Quebec
This event will focus on identifying technologies, best practices,
training and certification processes related to improving reliability
and creating more consistency in the thermal spray industry.
Engineers, scientists, educators, practitioners and suppliers will
all benefit from attending this specialized symposium.
Exhibit and custom sponsorship opportunities are available.
Contact Kelly Thomas, National Account Manager today,
kelly.thomas@asminternational.org or 440.338.1733 to
customize the package that best meets your needs.
Visit www.asminternational.org/events today to register for
the conferences, education course and to take advantage of
exhibit and sponsorship opportunities.
Sponsored by iTTSE magazine.
ASM International

9639 Kinsman Road

Materials Park, Ohio 44073-0002
800.336.5152
www.asminternational.org
stant use, with no
drying or curing time
required, and there is no
risk of damaging the
component.
The Flamespray process
produces a fine coating
finish having low porosity,
ideal for steel structures
and surfaces. Structural
steelwork can be sprayed
using a variety of different
coatings (pure zinc and pure
aluminium and their
alloys) depending on the cir-
cumstances. The specific system
supplied to Ross-shire will spray 0.1875 in. (4.76 mm) diam-
eter zinc and aluminium wires, supplied in 25 kg (55 lb) coils.
The design of the Mark 73 pistol allows the sprayer to intermit-
tently stop and start the spraying without extinguishing and re-
lighting the main flame. This, coupled with the large diameter
wire, enables fast, efficient application of a high quality coating
with minimal wastage.
To ensure the highest standards of quality are offered to their
customers, Ross-shire also employed Metallisation to fully train
their spray operators at their Muir of Ord site. The training was
carried out in a new blast and spray facility, specifically built to
ensure the highest quality coatings combined with the safety of
the operators and local environment. The single-day training
course included basic principles of metal spray, health and safety,
operation of the system, and routine maintenance. All operators
attending the course received a certificate of competence.
Ross-shire can provide metal spray solutions on-site or in-
house, depending upon the customers requirements. Projects
can include the refurbishment or the reclamation of equipment
and metal spraying new equipment within the distilling, water,
power, and manufacturing industries. The new Flamespray equip-
ment adds another dimension to the companys services.
According to Allan Dallas, operations director at Ross-shire
Engineering, Metallisations existing arc spray system had a
proven track record in the company, and their knowledge, ex-
pertise, and understanding of corrosion solutions, coupled with
their after-sales service, fit perfectly with the objectives of Ross-
shire Engineering. The Flamespray Mark 73 is reliable, easy to
use, and offers flexibility. www.metallisation.com. iTSSe
ADVANCED MATERIALS & PROCESSES/MAY 2008 83
17
iTSSe
JTST
HIGHLIGHTS
The Journal of Thermal Spray
Technology (JTST), the official journal
of the ASM Thermal Spray Society,
publishes contributions on all
aspectsfundamental and practical
of thermal spray science, including
processes, feedstock manufacture,
testing, and characterization. As the
primary vehicle for thermal spray
information transfer, its mission is to
synergize the rapidly advancing
thermal spray industry and related
industries by presenting research and
development efforts leading to
advancements in implementable
engineering applications
of the technology.
JTST editor Christian Moreau has
announced that the June issue 17(1) is
a special issue focusing on
suspension/solution thermal spray, an
emerging technology. Guest editor for
this issue is Prof. Pierre Fauchais,
University of Limoges. Several articles
are highlighted here.
In addition to the print publication,
JTST is available online through
www.springerlink.com.
For more information, please visit
www.asminternational.org/tss.
Room Temperature
Impact Consolidation
(RTIC) of Fine Ceramic
Powder by Aerosol
Deposition Method and
Applications to
Microdevices
Jun Akedo
Ceramic integration technology requires
downsizing and/or improvement of device per-
formance in many applications, such as in the
fabrication of microelectromechanical sys-
tems, display devices, fuel cells, optical de-
vices, and RF components. For these applica-
tions, realization of high-speed deposition rate,
low process temperature, and fine patterning
in ceramic coating are very important. The
aerosol deposition (AD) method has many ad-
vantages for above requirements compared
with conventional thin-film method or thermal
spray coating technology. In this article, ad-
vantages of the AD method are highlighted by
realizing a comparison with conventional thin-
film methods and thermal spray technology.
Challenges are also highlighted. Examples of
integration of AD method in the fabrication of
electronic components are also given to show
the ease of use and integration of this method
in the device process flow.
Technical and
Economical Aspects of
Current Thermal Barrier
Coating Systems
For Gas Turbine Engines
by Thermal Spray and
EBPVD: A Review
Albert Feuerstein,
James Knapp, Thomas Taylor,
Adil Ashary, Ann Bolcavage,
and Neil Hitchman
The most advanced thermal barrier coating
(TBC) systems for aircraft engine and power-
generation hot-section components consist of
EBPVD applied yttria stabilized zirconia and
platinum-modified diffusion aluminide bond
coating. Thermal spray ceramic and MCrAlY
bond coatings, however, are still used exten-
sively for combustors and power-generation
blades and vanes. This paper highlights the key
features of plasma spray and HVOF, diffusion
aluminizing, and EBPVD coating processes.
The coating characteristics of thermal spray
MCrAlYbondcoat, as well as low density and
dense vertically cracked (DVC) Zircoat TBC,
are described. Essential features of a typical
EBPVD TBC coating system, consisting of a
diffusion aluminide and a columnar TBC, are
also presented. The major coating cost elements
such as material, equipment, and processing
are explained for the different technologies,
with a performance and cost comparison given
for selected examples.
Rare Earth/Metal
Composite Formation by
Cold Spray
Peter C. King, Saden H. Zahiri,
and Mahnaz Z. Jahedi
Nd
2
Fe
14
B permanent magnet/aluminum
composite coatings were produced by cold
spray deposition. Isotropic Nd
2
Fe
14
B powder
was blended with aluminum powder to make
mixtures of 20-80 vol% Nd
2
Fe
14
B, and these
mixtures were sprayed at temperatures between
200-480C. The hard Nd
2
Fe
14
B particles
tended to fracture and fragment on impact,
while aluminum underwent severe plastic de-
formation, eliminating pores, and trapping
Nd
2
Fe
14
B within the coating. It was found that
higher spray temperatures and finer Nd
2
Fe
14
B
particle sizes improved the retention rate of
Nd
2
Fe
14
B within the composite structure. This
was explained from a contact mechanics view-
point by calculating the effect of process pa-
rameters on the rebound momentum of
Nd
2
Fe
14
B particles. The magnetic properties
of Nd
2
Fe
14
B remained unaffected by the cold
spray process.
Schematic of aerosol deposition (AD)
apparatus.
EBPVD TBC, featuring a plurality of
vertical, loosely-bonded columnar grains.
As-deposited aluminum cold spray
surface following exposure to cold
sprayed Nd
2
Fe
14
B particles at 480C
stagnation temperature; backscattered
image.
84 ADVANCED MATERIALS & PROCESSES/MAY 2008
18
iTSSe
Tensile Test Specimens with a
Circumferential Precrack for Evaluation
of Interfacial Toughness of
Thermal-Sprayed Coatings
Akio Kishi, Seiji Kuroda, Tadanobu Inoue,
Takeshi Fukushima, and Hisami Yumoto
Anew testing procedure to evaluate the interfacial toughness of
thermal spray coatings has been developed. The newly designed test
specimen is a modification of the pin test with an artificially introduced
weak interface, which is expected to open up easily under tensile loading
and serve as a circumferential precrack along the interface between a
coating and the substrate. This configuration makes it possible to cal-
culate the stress intensity factor K
Int
at the tip of the precrack, which
can be expressed as:
K
Int
= V
0
Sa F
I
(a/R)
where V
0
is the apparent average stress, a the crack length, R the spec-
imen radius, and F
I
the geometrical correction function. Finite-ele-
ment analysis was carried out to calculate the correction function F
I
for various values of
a/R. In the experiments,
the flat surface of a pin
was grit-blasted and a
ring-shaped area from
the periphery was cov-
ered with carbon using a
pencil and set into a
mating dice. SUS316L
stainless steel was
plasma-sprayed onto the
flat surface of the pin and
the dice. Then, tensile load was applied to the pin to break the weak in-
terface containing the carbon and finally the unmodified coating-
substrate interface. The load required to pull out the pin was measured
for various specimen parameters such as a and R. The results indicate
that the adhesion of the tested coatings can be represented by interface
toughness of 1.9 0.1 MPa m
1/2
. As a consequence, this testing pro-
cedure can be considered as a viable method to evaluate adhesion of
a thermal-spray coating on a substrate.
Microstructure and Creep Behavior of
Plasma-Sprayed Yttria Stabilized
Zirconia Thermal Barrier Coatings
Reza Soltani, Tom W. Coyle,
and Javad Mostaghimi
The purpose of this study was to determine the creep/sintering char-
acteristics of thermal spray zirconia coatings and attempt to understand
the influence of microstructure on the
creep resistance of deposits. The
major modification, compared with
more typical practice, was employ-
ment of a new powder feedstock with
agglomerated submicron size parti-
cles (Nanox), which is compared to
one of the best commercially avail-
able powders (HOSP). Thick plasma
spray coatings were prepared, and
their physical and mechanical prop-
erties were characterized. Creep/sin-
tering experiments were then conducted to investigate the response of
the materials when exposed to high temperatures under load. The re-
sults showed that it could be possible to correlate the splat thickness to
the creep behavior of the coatings.
Procedure and configuration of the pin
test
SEM images of etched
Nanox and HOSP coatings
showing splat boundaries.
ADVANCED MATERIALS & PROCESSES/MAY 2008 85
19
iTSSe
804 Newcombe Avenue Hampton, VA 23669
Phone: 757-723-6531 Fax: 757-723-3925
www.teledyne-hi.com
Repeatability
Accuracy
Fast Consistent Response
Surface Masking Resins
Dymax Corp., Torrington, Conn., offers its SpeedMask masking
resins that provide reliable protection from most surface finishing
processes including grit blast, peening, plating, acid cleaning, anodizing,
plasma spray, high-friction polishing, and painting. SpeedMask resins
are 100% solids, have no nonreactive solvents, and are VOC free. They
are quickly applied by syringe or through dipping, spraying, and screen-
printing, and cure in seconds allowing for immediate use. Residue-free
removal is achieved through peelable, water soluble, and burn-off
grades. Dymax also manufactures equipment to process SpeedMask
light-curable temporary masking resins. www.dymax.com.
Knoop/Vickers Hardness Testers
Wilson Instruments, an Instron company, Norwood,
Mass., offers its 400 Series Knoop/Vickers hard-
ness testers, which are used to test metals, ceramics,
and other nonmetallic materials.The testers are
available with manual or automatic turrets for greater use
flexibility, and feature eight dial-selectable test forces
ranging from 10 to 1,000 g. An optional 2,000-g test force
system is also available. Optics offer total magnifica-
tion of 100 and 400, which allows clear, effortless
measurement of the test indention. For easy sample
mounting and test point location, the instruments are
equipped with a 100 mm 100 mm precision x-y
axes stage with a 25 mm movement in each direc-
tion. www.wilsoninstruments.com.
NeoScope Benchtop SEM
Nikon Instruments, Melville, N.Y., and JEOL, Tokyo, Japan, in-
troduce the NeoScope benchtop
SEM that extends the depth of field
and resolution far beyond the opti-
cal microscope. The NeoScope, tar-
geted at the bioscience research and
industrial inspection communities,
fills the optical microscopists need
for advanced imaging capability that is both affordable and easy to use.
Offering higher magnification without loss of depth of focus, the Neo-
Scope will help accelerate the pace of research in the life sciences,
forensics, and failure analysis of manufacturing materials. The Neo-
Scope images both conductive and nonconductive samples without
special preparation. It operates in both low and high vacuum modes
and has three settings for accelerating voltage suitable for a variety
of applications. www.nikonusa.com.
SiC Sputtering Targets
The CVD Materials business of
Morgan Advanced Ceramics (MAC),
Bedford, Ohio (North American of-
fice), introduces high-purity silicon-
carbide (SiC) sputtering targets for
physical vapor deposition (PVD) ap-
plications. The sputtering targets en-
able the deposition of high-purity SiC
thin films for demanding applications such as the manufacturing of
magnetic disk drive heads. Dielectric SiC films deposited from these
targets have higher density and thermal conductivity and lower expan-
sion coefficient than dielectric aluminum oxide films, enhancing de-
vice performance and enabling new device design structures. The high
thermal conductivity allows using high-power process conditions to
achieve a fast SiC film deposition rate via RF diode and RF or DC mag-
netron sputtering. www.morganadvancedceramics.com.
Expanded Line of Sputtering Targets
Goodfellow Corp., Oakdale, Pa., the North American subsidiary
of Goodfellow Cambridge Ltd., offers sputtering targets in 62 different
metals and alloys, as well as compounds such as borides, carbides, flu-
orides, nitrides, oxides, selenides, silicides, sulphides, and tellurides.
In addition, the surfaces of flat sheets up to 80 mm 400 mm (3 15.75
in.) can be heat treated, remelted, or alloyed using a continuous thermal
process. Thin layers of metals or oxides can also be melted onto
the surface, which is especially suited for the creation of double-layer
sheets and foils, or for ceramic superconductors on metallic or ceramic
substrates, and for the creation of thin layers of solder on metals.
www.goodfellow.com.
TECHNICAL
RESOURCES
Masking Tapes for Thermal Spray
DeWALIndustries, Saunderstown, R.I., offers a color brochure de-
scribing a broad range of high performance masking tapes widely used
in the thermal spray industry to cover both sharp edges and intricate
part shapes. The brochure provides specifications and lists pertinent
features of non-carbonizing, aggressive-adhesion tapes used for grit
blasting, ceramic, plasma and arc spraying, as well as HVOF. High-
temperature applications are described for tapes as different as double-
sided adhesive-coated glass fabric and silicone-coated double-ply com-
posites of glass fabric and aluminum foil. The brochure also illustrates
the masking of channels and the application of elasticity-controlled
plasma tapes. For a free brochure or more information, visit www.
dewal.com.
Theres nothing common
about this Cold (HpCS).
Extend your equipments life with High Pressure
Cold Spray (HpCS) technology from ASB Industries.
ASB partners with CGT for North American equipment sales and
Linde Gas to optimize coating properties and extend the range of
possible materials from copper, nickel, metal matrix composites
and tantalum to niobium, titanium and more. All to produce the
most oxide-free tenacious surface coatings possible.
2008 ASB Industries, Inc.
ASB Industries, Inc. 1031 Laubert St. arberton, 0h 11203 uSA
330.753.8158 info@asbindustries.com
Catch the Cold. Sign up for our Enewsletter at
asbindustries.com today!
PRODUCTS
PRODUCTS
86 ADVANCED MATERIALS & PROCESSES/MAY 2008
20
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ways in which todays business professional accesses information to make buying decisions.
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6.19 hours per week are spent by professionals in editorial media and vendor content
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Only one sponsor per month.
TSS SprayTips
Tutorial for the Thermal Spray
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Launching May 2008. Twice monthly.
Exclusive sponsorship opportunity.
Only one sponsor per TSS SprayTips.
Celebrating 75 Years of Teamwork
This year, 2008, marks the 75th year of the founding of the Metallizing
Engineering Company, now known as Sulzer Metco.
We could tell you about our history, and the many thermal spray visionaries
who founded the many companies that later became Sulzer Metco, but
for that, you can read the history page on our web site. We could tell you
how young we are compared to our 174 year old parent corporation, Sulzer.
We could tell you about all of the technological innovations Sulzer Metco,
and our founding companies before us, brought to the thermal spray indus-
try. Or, we could tell you about the dedication and talent of our more than
1900 employees worldwide. Without doubt, all of these things dene
Sulzer Metco.
Instead, we want to tell you about the foundation of any successful
company you, our customer. Your continuing patronage, and devoted
loyalty to our organization throughout our 75-year history, have defined
Sulzer Metco and our extensive product portfolio.
When Rea Axline opened the doors of the Metallizing Engineering Compa-
ny during the Great Depression of 1933, industry needed a way to increase
component service life by preventing corrosion and salvaging worn parts
to serviceable condition. During World War II, our customers needed alter-
natives to materials that were difcult to source. As the size of passenger
aircraft grew, so did the critical concepts of fuel-to-weight ratios and un-
precedented safety, prompting the need for new classes of thermal spray
materials that included abradable materials and MCrAlYs. Many of these
materials have chemistries that were specically developed by our
customers.
To apply these new materials and achieve the surface properties that our
customers needed led to new thermal spray processes such as atmosphe-
ric plasma spray, chambered plasma spray and HVOF. In each case, a Sulzer
Metco company, such as Metco, Alloy Metals or EPI, in partnership with our
customers, brought these technologies to the marketplace. As customers
demanded better process control and repeatability, Plasma Technik, another
company that is part of Sulzer Metcos heritage, developed the rst truly
automated spray cells.
Today, our customers tell us they need faster processing speeds, less mate-
rial waste and even greater reliability. In addition, customers must meet
evermore stringent environment and safety regulations. To remain competitive,
our customers also require surfaces that keep the components they market
in service longer, with better performance than ever before. An example are
cylinder bore coatings on aluminum engine blocks, for automobiles that are
lighter, more fuel efcient and have improved on-road life. To apply these
coatings with the highest efciency, fully automated, in-line production
systems were developed, that feature our MultiCoat

controller and multiple

spray guns manipulated by Sulzer Metcos RotaPlasma

. TriplexPro

-200,
our new triple cathode plasma spray gun, can apply coatings at speeds and
deposit efciencies that are up to 300% better than previous technologies,
and go more than 200 hours without maintenance.
As our world continues its technological advance, new industries arise that
need new surface solutions. Such is the case with solid oxide fuel cells.
Here, our customers need very thin, very dense ceramic coatings that can
be quickly applied to large surface areas. Sulzer Metcos LPPS

-TF techno-
logy shows great promise in meeting these needs, applying fully dense ce-
ramic coatings that are only 10 m thick at the rate of one square meter
per minute.
As you can see, the challenges set before us by our customers over the
past 75 years are our legacy. As our future is fully reliant on helping our cus-
tomers to succeed, we hope you will continue to present us with new and
exciting surface technology challenges in the future. We certainly look
forward to it.
The employees of Sulzer Metco join together to say,
www.sulzermetco.com
2008 Sulzer Metco