Elucidating optimal coating process parameters
Thermal spraying is a cost-effective way to deposit high-performance coating materials on various substrates to protect against corrosion, temperature and abrasion. The market for related products continues to grow steadily. However, setting parameters is largely a matter of trial and error, resulting in very low efficiency and loss of nearly half of the sprayed powder. Advancements made during the project 'Computational simulation to enhance technology development of thermal spray coating' (SIMUSPRAY) should facilitate cheaper and faster development of coating technology, and boost the EU's competitive position in a huge global market. With EU support, the University of Southampton joined forces with a small and medium-sized enterprise (SME) to do just that with a focus on high-velocity oxygen fuel (HVOF) plasma spraying. This has the advantage over other methods of accelerating particles to very high speeds without overheating, thus enabling more uniform coatings. SIMUSPRAY's focus on HVOF spraying provided the perfect backdrop to train researchers on the latest techniques in computational modelling and surface engineering. Excellent collaboration and hard work resulted in development of a range of new models describing nanoparticle behaviours at all stages of spraying. The team also developed new thermal spray processes and coating composites, all of which have led to numerous publications, a strong academia–industry partnership and an expanded circle of scientific partners. In addition to the project SME, thermal spray system manufacturers have demonstrated interest in pursuing commercialisation of some project concepts and follow-up actions are currently underway. Given the large global market for high-performance coatings and the previously lacking process simulation software, SIMUSPRAY outcomes should have significant impact on businesses, the EU economy and the quality of products offered to consumers.
Keywords
Protective coating, high-velocity oxygen fuel, thermal spraying, nanoparticle behaviour
