Coating Processes
Capabilities
Coating Services, Processes and Equipment
Plasma has been a leading supplier of aerospace grade coatings for 30+ years. We started with one vacuum plasma spray (VPS) system and one Atmospheric Plasma Spray (APS) system which we have expanded into 10+ fully operational systems comprised of VPS and APS booths. In addition to APS and VPS, we also have HVOF, Cold Spray, flame-spray (or combustion flame-spray), Wire-Arc Spray, Shrouded Plasma Spray, and other coatings (intumescent, paint, primer, powder, etc.) processes. Our ability to take on customer requirements and provide the best process in both R&D and production settings is our core competency. Let us help you figure out the best engineered solution to hit your products performance requirements in extreme environments.
Coating Processes
Leveraging our extensive expertise, Plasma delivers customized plasma coating solutions optimized to meet each customer’s unique performance goals, budget constraints, and timeline requirements.
Vacuum Plasma Spray (VPS)
Vacuum Plasma Spray is also cost effective for the spray forming of specialized materials, refractory metals and reactive materials (e.g. titanium). Vacuum Plasma Spray offers the following advantages over conventional atmospheric plasma process:
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stress
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Applications:
- Planar and cylindrical sputter targets
- Thermal Barrier Coatings
- Medical Device and Implant Coatings
- Refractory Metals
- Dense Ceramics
- Superalloys
- Rocket Nozzles
Cold Spray
A distinguishing feature of the cold spray process compared to conventional thermal spray processes is its ability to produce coatings without melting the applied material (i.e. coating). Consequently, deleterious effects of high-temperature oxidation, evaporation, melting, recrystallization, residual stress, debonding, and other concerns associated with thermal spray methods with a liquification step are minimized or eliminated. Cold Spray coatings are typically limited to ductile materials like aluminum, stainless steel, copper, titanium and alloys. Hard and brittle materials like ceramics cannot be depositd in the pure form to thicknesses of more than 25 microns but may be applied as composites with a ductile matrix phase. Substrate materials are also limited to those that can withstand the aggressive action of the spray particles. Soft or friable substrates will erode rather than be coated.
Applications:
- Additive/3D Printing
- Aerospace (MCrAlY)
- Automotive; corrosion protection for automotive body and chassis structures (Al and Zn)
- Chemical (Ti, Ta)
- Rapid Prototyping
- Rapid Tooling Repair
- Dimensional Restoration (Al, Mg, Cu, Steel)
- Corrosion protection
- Electrical connections (Au, Cu, Ag)
Wire-ARC Spray
Wire arc spray works by placing an electric arc between two consumable electrodes of a coating material, then using compressed gas to atomize and propel the material to the substrate. Wire Arc Spray occupies an important niche in thermal spray technology and is particularly suited to high-rate deposition.
Applications:
- Corrosion Protection
- Non-skid surfaces
- Low-temperature-capability for coatings onto substrates such as polymers and paper
- Erosion- and wear-resistant coatings
- Dimensional restoration
- Metalizing
- Electromagnetic shielding
Shrouded Plasma Spray (SPS)
A shroud of protective gas surrounds the plasma jet and reduces the amount of oxygen available to oxidize the material being deposited. Shrouded Plasma Spray is used for oxygen-sensitive applications where functionality, size and budget do not require vacuum plasma spray deposition.
Applications:
- Oxidation-resistant coatings
- High-Z radiation shielding of electronics
- Thermal barrier coatings (TBC’s)
- Corrosion-resistance
- Neutron absorbing materials
- Medical device and implant coatings
Atmospheric Plasma Spray (APS)
A strong electric arc is generated between a positively charged pole (anode) and a negatively charged pole (cathode). This ionizes the flowing process gases into the plasma state. Powdered feedstock material is injected into the plasma jet, melting the powder particles and propelling them to the surface of the workpiece.
Applications:
- Oxidation-resistant coatings
- Thermal barrier coatings
- Corrosion-resistance
- Neutron absorbing materials
- Medical device and implant coatings
- Wear resistant coatings
- Electrical contacts
- Emissivity Coatings (both high and low)
- Thermal protection
High-Velocity OxyFuel (HVOF)
Coatings applied by HVOF usually have better mechanical properties than those applied by air plasma spray. The HVOF process is now widely used to apply tungsten carbide coatings as an environmentally friendly alternative to chromium plating on high strength steel aircraft structural components.
Applications:
- Application of wear-resistant coatings such as tungsten carbide and nickel chromium carbide
- Corrosion-resistant coatings such as titanium, Hastelloy® and Inconel®
- Dimensional restoration (journal and shaft repair)
- Non-carcinogenic, hard chrome replacement
Coating Equipment
We have enough vacuum and atmospheric plasma spray equipment, trained operators, and specialized engineers in-house to perform research and development (R&D) and high-rate production efforts.
We have:
- 10+ APS and VPS systems
- 20+ El-Form® units of various sizes
- Wire-arc spray
- Cold-spray
- HVOF
- Flame-spray
- Other systems that allow us to meet schedule requirements of our customers in any situation.
We provide supporting equipment such as furnaces to help with post processing. We have coated parts up to 4-5 ft high and 4 ft in diameter in our VPS chambers and up to 20 ft long in our APS systems; but don’t be afraid to ask about our true limits as we always have creative ways to meet our customers’ needs. We are expanding on end effector/gun capabilities as well to increase ability to perform surface prep, repair, and full coating in complex geometries. Our team is dedicated to providing automated robotic solutions that allow us to transition from R&D into high-rate production efforts. Our engineers assist customers in providing best practices and materials for their products.
Plasma also provides supporting surface prep and testing for our coating processes such as grit blast, bond coats, microhardness, and more.
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 material solutions with engineered products and coatings for emerging technologies through the use of unique processes.