Plasma spray coating: the process and its advantages and disadvantages.
The plasma spray coating process uses high-temperature plasma jets to coat a substrate. The coating material, usually in powder form, is melted and sprayed onto the surface where it quickly cools forming a strong, protective bond.
The large number of different coatings on the market makes plasma spray coating an extremely versatile way of adding extra protection to components and substrates. Depending on the application, it can provide such advantages as resistance to wear, resistance to extreme temperature, resistance to oxidation, or control of electrical conductivity. Plasma spray coating can be tailored to individual needs in a way that few other coating techniques can even begin to match.
Advantages and Disadvantages.
As a means of improving the functionality and performance of a basic substrate, it is hard to beat plasma spray coating. The consistency of the finish and the speed with which it can be applied make it invaluable across a broad spectrum of industries. Sometimes known as, ‘the cold process’, even quite delicate materials can be plasma sprayed because the substrate or components are not heated or over-exposed to high temperatures.
Plasma polymer composite, which combines polymer techniques and thermal spraying, is the next generation of plasma spraying, a sign of how this technology will develop. To see how this creates an even tougher surface, check out specialists such as www.poeton.co.uk/advanced-treatments/apticote-810-plasma-polymer-composite.
The main downside to plasma coat spraying is that it can be a hazardous process and needs a dedicated environment with safety procedures and trained, skilled operatives, making it quite an expensive business to get started in. In addition, if not managed well the process can be wasteful, and quality control needs to be good to ensure procedures are followed exactly. For an in-depth read, see:
The future
While there are some drawbacks to plasma spray coating, the advantages are clear. With the new technologies of renewables gathering pace, components for turbines and solar panels will benefit greatly from plasma polymer composite and thermal spraying in general. It will no doubt remain at the forefront of coating techniques long into the future.
