Additive Manufacturing
capabilities
How our Coating Process Works
Plasma has been performing additive manufacturing (AM) before it was even considered additive manufacturing. We have the ability to make parts utilizing our plasma spray, cold spray, laser powder bed fusion (LPBF) 3D printing, and our most unique in-house capability, El-Form® electro-deposition. We utilize these capabilities to make things like electrodes/ignitors, nose tips, nozzles, thrust chambers, catalyst, pintles, throats/non-eroding throats, and many more types of components for SRM’s, DACS, commercial aerospace engines, and other types of assemblies. We have made hundreds of thrust chambers which have now flown in space, fabricated pintles and throats for DACS on interceptors, and many more capabilities utilizing unique in-house knowledge and processing from 30 years of expertise. We are well versed in being able to provide our customers with the exact process to meet their final performance and production needs. Our specialty and focus has been centered around refractory metals, platinum group metals, and other high-temperature or high-performance materials for extreme conditions.
El-Form Electrodeposition
EL-Form® electrodeposition is a versatile process producing extremely pure, dense and ductile refractory and platinum group metal structures, coatings and foam. Deposited from a non-toxic, molten salt electrolyte, EL-Form® products are virtually non-porous with typical densities greater than 99% and exhibit high ductility due to controlled grain growth and purity. EL-Form® is versatile, producing micron to millimeter thick coatings and net-shape components; and is well suited to metals including iridium, niobium, rhenium, ruthenium, tungsten, molybdenum, hafnium and boron. We currently house over 20+ machines varying from small, medium, and large units. We have built parts over 18 inches high and 12 inches in diameter within a unit. El-Form is an attractive alternative to 3D printing or other AM techniques when trying to get dense, high-performing products.
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LPBF/3D Printing
Plasma has on-site 3D printing capabilities for prototyping, tooling, and other needs. We specialize in refractory/platinum group metals such as niobium alloys like C103, FS-85, and others. Plasma has expanded this capability in recent years due to customer demands and growing requirements as well as providing alternative solutions to El-Form or Plasma formed components.
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Cold Spray and Plasma Spray Forming
We can use our Plasma capabilities to make components, mostly for propulsion systems. This provides another processing alternative to El-Form, machining, or 3D-Printing. We can provide the best process to meet our customers’ affordability, performance, and schedule requirements.
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METHODS
Coating Processes
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Plasma Spray (VPS)
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Cold Spray
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Wire-ARC Spray
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Shrouded Plasma Spray (SPS)
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
APPLICATIONS
What it’s used for
Plasma Processes offers innovative products and services for highly demanding markets and is dedicated to providing customers with advanced materials solutions and enabling capabilities. We drive technology with engineered products and coatings for emerging technologies through the implementation of unique materials and processes.