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ADVANCED MATERIALS & PROCESSES • MAY 2014 46
T he power generation industry comprises a complex array of technologies based on the energy source:
fossil fuels, diesel, nuclear, biomass, solar, wind, and hydro. It is this complexity that has led to, per-
haps, the most comprehensive integration of thermal spray technology found in any industry. By inte-
grating thermal spray, we are referring to combining specially formulated material with the appropriate
spray device to deposit coatings with desired surface characteristics for the particular application. The
most common example might be depositing thermal barrier coatings on gas turbine buckets and vanes
to enhance inlet temperatures to improve power efficiencies.
Estimates of the total dollar value of this market based on new orders accepted by major OEMs for
power generation equipment are not an accurate indicator of the growth or contraction of thermal spray
applications for this industry. A very robust and substantial aftermarket exists for repairs and spare
parts. Numbers are further complicated by new concepts such as solar farms and alternate energy
systems that are not included in OEM turbine data. Suffice it to say that as these alternate sources grow,
thermal spray applications will also expand. Growth for thermal spray materials, equipment, and serv-
ices will likely continue in the aftermar-
ket arena as new power plants near
completion and transition to spare
parts and repairs.
This issue is illustrated in the devel-
opment of two newer technologies: A
modified plasma torch and cold spray.
In the first article, a case study of im-
proved deposition efficiency of yttria
stabilized zirconia using a modified
commercially available plasma torch is
presented. The authors claim a 40%
savings in labor, materials, and energy
costs compared with a conventional
plasma gun. In the other article, a low-
pressure cold spray system is de-
scribed, which can be used for 3D
manufacturing. In terms of its applica-
tion to power generation equipment,
one can visualize use of these devices
for localized repairs, for example, stel-
lite wear shields for LP steam turbine
blading for water droplet erosion.
Learn about these and other excit-
ing new thermal spray technologies at
this year’s International Thermal Spray
Conference being held in Barcelona,
Spain, on May 21-23. It offers many
opportunities to interact and learn
about advanced materials and tech-
niques for improvements in current and
future applications in the power gener-
ation and other industries. We hope
those attending and presenting will
offer insights in upcoming issues. To
contribute an article, please email me
at
Rajan Bamola
iTSSe co-editor
Surface Modification Systems Inc.
Thermal spray plays
major role in power generation
North American Cold Spray 2014
September 16-17
Bromont, Quebec, Canada
The North American Cold Spray Conference and Exposition offers atten-
dees a basic understanding of cold spray, information on global R&D cold
spray technology programs, firsthand information on industrial applications,
and networking opportunities with international experts. A student poster
presentation and prize competition will be an exciting highlight of the 2014
North American Cold Spray Conference. The competition includes a review
by expert judges and prizes for students with the best posters. For more in-
formation, visit
Aerospace Coatings: Development and Manufacturing
Trends for the 21st Century
October 8-9
Hartford, Conn.
This symposium brings together thermal spray professionals involved in
a wide range of responsibilities. Gain key perspectives with presentations
from invited speakers including Rolls Royce, PWA, Curtiss-Wright Sur-
face Technologies, LLC Surface Technologies, Delta Airlines Inc.,
Lufthansa Technik AG, Naval Aviation Department, Pratt and Whitney,
KLM Engineering and Maintenance, and other leading organizations. Visit
to learn more.
6th Asian Thermal Spray Conference
Hyderabad, India
November 24-26
This is the first time the event will be held in India and is organized by the
International Advanced Research Centre for Powder Metallurgy and New
Materials (ARCI) and the Asian Thermal Spray Society (ATSS). ATSC pro-
vides an ideal platform to exchange information, share technology advances,
and gather new ideas for further research. Technical sessions address thermal
spray processes, new application areas, novel material systems, simulation
and modeling, emerging characterization and diagnos-
tic techniques, and much more. Abstracts are now being
accepted for consideration for both oral and poster pre-
sentations. Abstract submission deadline is June 15.
A two-day thermal spray course taught by Christo-
pher Berndt precedes the event on November 22-23.
The exhibition offers an opportunity to showcase prod-
ucts and equipment. For more information, visit
.
CONFERENCES • EXPOSITIONS • SYMPOSIUMS