What is APS coating?
Air Plasma Spray (APS) is an innovative technique used to create protective coatings on surfaces exposed to extreme conditions.
The process uses electrical energy to ionize a stream of gas, such as argon or helium, generating a "plumb" of high-temperature plasma that reaches up to 10,000°C. This plasma heats and accelerates particles of material, often in the form of powder, which are projected at high speed onto the surface to be treated.
La "piuma" di plasma è particolarmente efficace nel riscaldare materiali con un alto punto di fusione e una bassa conducibilità termica, rendendo l'APS la scelta ideale per la spruzzatura di ceramiche e ossidi.
Materials Used in APS Coatings
One of the most commonly applied materials through APS is zirconia. Due to its exceptional thermal barrier properties, zirconia is ideal for protecting components exposed to high temperatures, such as blades and nozzles in gas turbines. This material helps improve the resistance to thermal stress, increasing the life and reliability of critical components.
Another key material is chromium oxide, a high-hardness ceramic known for its tribological properties. Chromium oxide coatings offer excellent wear resistance and are used in industries where components are subjected to abrasive conditions.
In addition to zirconium oxide and chromium oxide, APS can be used to apply a wide range of materials, including:
- Tungsten or chromium carbides: Ideal for resisting abrasion.
- Aluminum oxide: Used for its hardness and corrosion resistance.
- Titanium dioxide: Valued for its thermal stability and resistance to oxidation.
- Metal superalloys: Used in applications requiring a combination of strength and durability.
Air Plasma coating is used in:
Advantages of Air Plasma coating
Air Plasma Spray coatings offer numerous advantages that make them an optimal solution for protecting and improving the performance of industrial components:
- Thermal Fatigue and Wear Protection: APS coatings create a barrier that protects components from thermal and mechanical stress, extending their service life.
- Oxidation and Corrosion Resistance: Ideal for environments where components are exposed to aggressive chemicals or high temperatures.
- Application Versatility: Coatings can be applied to complex shapes and surfaces, providing uniform, seamless coverage.
- Durability in Harsh Environments: APS coatings are extremely durable, resisting challenging environmental conditions such as high temperatures, abrasive materials and chemicals.
Air Plasma Spray Coating Applications
Thermal Fatigue and Wear Protection: APS coatings create a barrier that protects components from thermal and mechanical stress, extending their service life.
- Power Generation: Protective coatings for gas turbines and components exposed to extreme heat.
- Aerospace: Improved thermal and mechanical properties of critical components.
- Automotive: Protection of engine components and exhaust systems against wear and corrosion.
- Petrochemical: Chemical resistance and erosion protection for equipment and pipelines.
- Transportation: Coatings for components requiring high durability in extreme operating conditions.
- Paper and Printing: Improved anti-wear properties for rollers and other surfaces in contact with abrasive materials.
Conclusions
Air Plasma Spray (APS) coatings are a cutting-edge solution for protecting and improving the life of components exposed to harsh conditions. Due to their versatility and the many benefits they offer, APS coatings are widely used in many industries, ensuring superior performance and increased longevity of critical components. If you are looking for a coating that offers resistance, protection and durability, Air Plasma Spray is the right choice for your industrial needs.
Results
Bring us your problems, our experience will provide the answers
We support and advise you in selecting the most suitable technology and materials to meet your specific needs.
Contact us now to have an engineer at your disposal, and together, we’ll find the solution to your biggest problems. We understand urgent, an engineer can be immediately available, call us, email us, and if necessary, you’ll have a proposal within 24 hours.
Air Plasma F.A.Q.
Plasma sprayed coatings typically utilize higher temperatures and lower velocities (compared to HVOF High Velocity Oxygen Fuel) allowing a larger variety of coatings to be used. However, HVOF is ideal for parts facing severe wear and abrasion stress, as it provides a hard, wear-resistant surface that improves also Hot corrosion resistance. Ultimately, the choice between Air Plasma Coatings and HVOF coatings depends on the specific requirements of the application, and both technologies offer benefits in improving the performance and reliability of products.
Coating thickness depends heavily upon the thermal spray process used to apply it and the material being applied. Thickness can range from 50 microns (0.002”) to 2 mm (0,08”) thick, like in the case of the thick Thermal barrier coatings.
Air Plasma Coatings also require proper surface preparation for the coating to bond with the substrate effectively. Just like thermal spray coatings, grit blasting is the industry standard method used to prepare the surface for Air Plasma Coatings. The surface to be coated is physically deformed to create a rough anchor tooth profile, which is tested for acceptability before the coating process commences. Ultimately, the choice of surface preparation method depends on the specific requirements of the application.
Yes, Plasma Spray and HVOF (High-Velocity Oxy-Fuel) are two different types of thermal spray processes used for the application of coatings. In Plasma Spray, a plasma jet is used to heat and melt the coating material, which is then propelled onto the substrate being coated. On the other hand, HVOF uses a combustion process to heat the coating material and propel it onto the substrate at high velocity. While both processes can produce high-quality coatings with excellent adhesion, the choice of equipment depends on the specific application requirements.