Project Abstract

Thermal spraying is a technology that enhances or restores the surface of a solid material. The process can be used to apply coatings to a variety of materials and components in order to provide resistance to wear, erosion, cavitation, corrosion, abrasion or heat. It is defined as a group of coating processes in which finely divided metallic or non-metallic materials are deposited in a molten, semi-molten, or solid condition to form a coating.

The thermal spray processes can be categorised into three basic groups according to the method of energy generation, such as (1) combustion (flame spray, HVOF) and (2) plasma spraying (wire-arc spraying), and (3) compressed gas expansion (cold spray). There are several challenges to obtaining high-quality functional deposits because (1) every material combination (coating and substrate) is unique based on its intended applications, (2) dependent on the selection of complex process parameters, and (3) it requires an in-depth understanding of their microstructure and mechanical properties.

These investigations need to be systematically carried out to ensure the deposited coating can be useful for the automotive and aerospace industries.