NovDec_AMP_Digital

dvancements in technology ultimately benefit the whole of society. Cost reductions from longer equip-

ment life and efficiency improvements, cleaner environments, shorter recovery times for hospital patients,

and improved communication methods are among the many benefits routinely experienced today. Thermal

spray has become integrated in many products as an enabling technology and in manufacturing processes as

critical tooling, making it one of the most important surface modification methods available.

Countless research papers are published annually detailing new developments in thermal spray coatings for

the gas turbine market. Driving forces include efficiency and longevity enhancements. Even a 1% efficiency gain

can translate to millions of dollars in savings for utility providers. Typically, increases in gas inlet temperatures

enable efficiency improvements. As such, constant research and development in new low-conductivity thermal

barriers has resulted in recent implementation by some OEMs. Higher firing temperatures also require improve-

ments for other coatings used in the turbine such as abradables, bond coats, and wear coatings. Ceramic

components in next-generation turbines, especially SiC-SiC composite materials, will also require more reliant

environmental barrier coatings (EBCs) as protection in high moisture and molten salt environments.

Thermal spray coatings for medical applications offer further opportunities for improvement. Plasma sprayed

titanium and hydroxyapatite for implants as well as alumina for laparoscopic procedures are well established.

Generally, plasma sprayed titanium and hydroxyapatite are not hydrophilic, but next-generation coatings will

have this requirement to shorten recovery

times. This will likely require post pro-

cessing of sprayed coatings.

Coatings applied to tooling and fix-

tures used for semiconductor processing

always demand high-quality formulas to

decrease particulates and improve yield.

Higher density, highly adherent, cost ef-

fective yttria and alumina coatings will

need to be applied to better control par-

ticulate matter as the node size de-

creases. This may require better

application equipment such as cascading

guns, or at least pulse width modulated

power supplies, to improve upon conven-

tional spray systems.

In this final 2014 issue, yet another

emerging thermal spray technique is pre-

sented—an innovative direct write

method using plasma spray. A special

aperture system enables fabrication of

thermocouples, antennas, and other sen-

sors directly onto components thereby

creating “smart structures,” illustrating

the emerging markets and technologies

available for thermal spray. Also included

in this issue is the second part of a safety

article that reviews best practices in the

thermal spray industry.

Be sure to share all of your innova-

tions at next year’s International Thermal

Spray Conference and Exhibition. This

mega event is being co-Located with

AeroMat and Microstructural Characteri-

zation of Aerospace Materials and Coat-

ings from May 11-14 in Long Beach,

California. We hope to see you there!

Rajan Bamola

iTSSe co-editor

Surface Modification Systems Inc.

EDI TORIAL

ADVANCED MATERIALS & PROCESSES •

NOVEMBER-DECEMBER 2014

Thermal spray advances

into emerging markets

International Thermal Spray

Conference and Exposition

(ITSC) 2015

ITSC, taking place May 11-

14, 2015, in Long Beach, Calif.,

is the world’s foremost interna-

tional conference and exposition

for thermal spray technologists,

researchers, manufacturers, and

suppliers. The conference is co-

located with both AeroMat and

Microstructural Characteriza-

tion of Aerospace Materials and Coatings. Whether attendees are

thermal spray experts, experienced engineers or scientists, or new

to the field, the 2015 ITSC technical program features something

for everyone—from the latest in advanced technology, research,

and development to a wealth of resources about processes that can

be applied immediately to impact critical issues such as corrosion,

wear, and abrasion. The conference also features a special presen-

tation by John Grotzinger, chief scientist and head of strategic

planning for NASA’s Mars Exploration Rover mission. Visit

asminternational.org/web/itsc-2015/home

for more information.

EDUCATION

Introduction to Thermal Spray

Education Course

February 9-10, 2015

ASM Headquarters, Materials Park, Ohio

Instructor: Mr. Richard A. Sayman

Thermal spray has evolved from a technology designed to be a cost ef-

fective method of repairing worn components and machined parts to

a process used to provide improved part performance and add longer

life to components. As the thermal spray profession has changed, so

has the need to ensure safe and consistent methods for thermal spray

operators. ASM International brought together the leaders in the Ther-

mal Spray Society to compile their knowledge and experience in a

comprehensive, easy to understand course.

Visit

asminternational.org/education

for more details.