Latest Developments in Suspension and Liquid Precursor Thermal Spraying

The interest to manufacture onto large surfaces thick (i.e., 10-20 μm, average thickness) finely structured or nanostructured layers is increasingly growing since the past 10 years. This explains the interest for suspension thermal spraying (STS) and solution precursor thermal spraying (SPTS), both...

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Bibliographic Details
Published in:Journal of thermal spray technology 2010, Vol.19 (1-2), p.226-239
Main Authors: Fauchais, Pierre, Montavon, Ghislain
Format: Article
Language:English
Subjects:
Analytical Chemistry
Characterization and Evaluation of Materials
Chemistry and Materials Science
Corrosion and Coatings
Droplets
Evaporation
Injection
Liquid phases
Liquids
Machines
Manufacturing
Materials Science
Micrometers
Peer Reviewed
Precursors
Processes
Pyrolysis
Sprayers
Spraying
Sprays
Surfaces and Interfaces
Thermal spraying
Thin Films
Tribology
Vaporization
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Summary:The interest to manufacture onto large surfaces thick (i.e., 10-20 μm, average thickness) finely structured or nanostructured layers is increasingly growing since the past 10 years. This explains the interest for suspension thermal spraying (STS) and solution precursor thermal spraying (SPTS), both allowing manufacturing finely structured layers of thicknesses varying between a few micrometers up to a few hundreds of micrometers. STS aims at processing a suspension of sub-micrometer-sized or even nanometer-sized solid particles dispersed in a liquid phase. The liquid phase permits the injection of particles in the thermal flow (i.e., due to their size, a carrier gas cannot play this role). SPTS aims at processing a solution of precursors under the same conditions. Upon evaporation of the liquid phase, the precursor concentration increases until precipitation, pyrolysis, and melting of small droplets occur. Compared to conventional thermal spray routes, STS and SPTS are by far more complex because fragmentation and vaporization of the liquid control the coating build-up mechanisms. Numerous studies are still necessary to reach a better understanding of the involved phenomena and to further develop the technology, among which are injection systems, suspension and solution optimizations, spray kinematics, etc. This review presents some recent developments and our present knowledge in this field together with the available tools implemented to characterize the plasma-liquid interaction and the coating formation.
ISSN:1059-9630
1544-1016
DOI:10.1007/s11666-009-9446-7