Plasma Spray 101

At Hannecard-ASB Industries, we offer plasma spray coating services focused on ceramic coatings. This highmelting spray technology is used to apply high-performance coating materials to industrial equipment and components to protect against wear and high temperatures. But how does the plasma spray process work, and how can it benefit your application? This guide provides an overview of plasma spray coatings, including the technology's benefits, compatible materials, and common industrial uses.

Plasma Spray Coating

What is Plasma Spray?

Plasma spray is a type of thermal spray process used to apply powdered coating materials to a substrate. The plasma coating process uses a high-temperature plasma torch that heats and sprays the powdered material onto a component. The material cools when it makes contact with the surface, forming a uniform coating on the finished component that provides a range of enhanced properties. Plasma coatings are dense, long-lasting, and compatible with a wide range of materials, making plasma spray a superior option for equipment in many different industrial applications.

The Plasma Coating Process

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  The substrate is cleaned and prepped to make sure the coating adheres properly.
• An inert gas is introduced to a plasma torch, where an electric arc ionizes the gas, creating a plasma jet that reaches extremely high temperatures.
• The coating materials in powder form are fed into the plasma jet. The heat melts the powders into a molten state.
• The molten particles are then propelled to the substrate using a plasma spray gun. The particles rapidly cool and solidify upon impact, forming a dense coating.

Plasma Spray Coatings Materials

Plasma spray coating operates at high temperatures, allowing for the use of ceramics and other materials with high melting points. Common materials Hannecard–ASB Industries uses in our plasma spray processes include:

• Aluminum Oxide
• Chrome Oxide
• Zirconium Oxide
• And more

What Benefits Do Plasma Coating Technologies Offer?

Due to its numerous benefits, the plasma spray process is the most common method used to create protective coatings on industrial components. It is an exceptionally versatile process, compatible with a range of coating materials, including materials with high melting points. Plasma spray can apply coatings to components of different sizes, from large machinery and equipment to small parts. The plasma spray process also provides a range of performance improvements for industrial components, including:

• Wear Resistance: Significantly improves the durability of a component
• Corrosion Resistance: Protects against corrosion from chemicals or harsh environments
• Heat & Oxidation Resistance: Creates a protective barrier against high temperatures and oxidation
• Dialectric Shielding: Plasma spray coatings prevent current from harming critical components by acting as a shield against electrical corrosion and arcing
• Increased Component Lifespan: The enhanced durability and overall performance created by plasma spray coatings result in significantly longer lifespans for components, making it a cost-justified process

Advantages of the Plasma Spray Process Compared to Other Thermal Sprays

The plasma spray process offers several key advantages compared to other thermal spray methods. Plasma spraying can achieve much higher temperatures than conventional thermal spray, allowing for compatibility with a wider range of coating materials with very high melting points, including ceramics. Plasma sprays are dense thermal spray coatings. This increased density creates superior wear and corrosion resistance. Additionally, the plasma spray process can typically achieve a high bonding strength with the substrate, resulting in a long-wear coating.

Industrial Applications for Plasma Coatings

Plasma spray coatings are highly versatile. They are used to provide superior protection and enhance the performance of components used in many industries, including:

• Steel Industry: Rollers, machinery parts
• Fluid Handling: Pumps, valves, engine parts, propellers
• Mechanical Engineering: Clamps, blocks
• Petrochemical: Valves, mandrel components, pumps, shaft seals
• Power Generation: Turbines, equipment components
• And many others

Contact Us to Get Plasma Spray Coatings for Your Components

If you need plasma spray coating services for your components, Hannecard-ASB Industries is your solution. Submit your project online for a free quote, or contact us, and our staff will assist you. We will provide custom plasma spray coating solutions designed to improve your operations while lowering maintenance costs. For industry-leading spray coating and surfacing technologies, choose Hannecard-ASB Industries.