Thermal Spray 2001New Surfaces for a New Millennium

Proceedings of theInternational Thermal Spray Conference

28-30 May 2001Singapore

Edited byChristopher C. Berndt

Khiam A. KhorErich F. Lugscheider

Sponsored byASM Thermal Spray Society

DVS—German Welding SocietyInternational Institute of Welding

ASM International®Materials Park, OH 44073-0002

www.asminternational.org

UNIVERSITATSBIBUOTHEKHANNOvt-IR

TECHNiSCHEINFORMATIONSBIBUOTHEK

ASM Thermal Spray Society; German Welding SocietyI (Deutscher Verband furI Schweisstechnik - DVS)

InternationalInstitute of Welding

Contents

Invited Review

Quo Vadis Thermal Spraying? 1P. Fauchais, A. M. Vardelle, B. Dussoubs, Universite de Limoges, Limoges, France

Applications

HVOF-Sprayed Quasicrystal Composite Coatings for Bearing Applications 33A. Reimann, E. Lugscheider, Aachen University of Technology, Aachen, Germany

Functional Ceramic and Metallurgical Coatings on Magnesium Components 41D. Scherer, M. Buchmann, C. Friedrich, R. Gadow, A. Killinger, University of Stuttgart,

Stuttgart, Germany

Study on Zircon-Based Ceramic Coating for High Temperature OxidationResistant Application 49M. Suzuki, S. Sodeoka, T. Inoue, Osaka National Research Institute, Osaka, Japan

Tungsten Coatings for Divertor Wings 55W. Mallener, Institute for Materials Synthesis and Processing, Julich, Germany

Double Doped Ceria Electrolyte Synthesized by Solution Plasma Spraying with InductionPlasma Technology 61F. Gitzhofer, M-E Bonneau, M. Boulos, Universite de Sherbrooke, Sherbrooke,

Quebec, Canada

Replacement for Hard Chrome Plating in Printing Machinery 69C. Wasserman, R. Boecking, S. Gustafsson, Terolab Services Bernex GmbH,

Langenfeld, Germany

A Contribution to Engine Pistons Life Time Improving by Means of Thermal Spray Coatings 75M. Rosso, D. Ugues, F. Bechis, Polytechnic of Torino, Torino, ItalyR. Groppetti, A. Scrivani, University of Parma, Parma, ItalyU. Bardi, Universita di Firenze, Firenze, ItalyG. Rizzi, Flametal S.p.A., Parma, Italy

Plasma Spraying of Tin onto a Monocrystalline Lithium Fluoride Window 79J-P Beaulieu, F. Borit, V. Guipont, M. Jeandin, Ecole Superieure des Mines de Paris,

Evry FranceC. Mabire, DGA, Centre d'Etudes de Gramat, Gramat, France

Fabrication and Properties of TiO2 Photo-Catalytic Coatings by Thermal Spraying withTiO2-AI Agglomerated Powder 87S. Matsusaka, A. Ohmori, Y. Toki, Osaka University, Osaka, Japan

XRD and Rietveld Quantitative Phase Analysis of Radio Frequency SuspensionPlasma Sprayed Nano-hydroxyapatite Powders 93R. Kumar, P. Cheang, K. A. Khor, T. White, Nanyang, Nanyang Technological

University, Singapore

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HVOF Sprayed Hydroxyapatite Coatings: Powders' Melting State andMechanical Properties 99H. Li, K. A. Khor, P. Cheang, Nanyang Technological University, Singapore

In Vitro Changes on High-Pressure Plasma Sprayed Hydroxyapatite Coatings 105M. Espanol Pons, K. A. Khor, P. Cheang, Nanyang Technological University, SingaporeV. Guipont, M. Jeandin, Ecole Nationale Superieure des Mines de Paris, Evry FranceN. Llorca-lsern, Universitat de Barcelona, Barcelona, Spain

Corrosion Resistant Coatings for Gas Turbine Exhaust Stack Applications 113Z. Mutasim, Solar Turbines, Inc., San Diego, California, USA

Ceramic Abradable Coatings for Applications up to 1100 °C 119Y. Nava, Z. Mutasim, M. Coe, Solar Turbines, Inc., San Diego, California, USA

Production of Superplastic Foils by Thermal Spraying 127J. Wilden, A. Wank, Chemnitz University of Technology, Chemnitz, Germany

The Internal Plasma Spraying on Powerful Technology for the Aerospace andAutomotive Industries 135G. Barbezat, Sulzer Metco AG, Wohlen, Switzerland

A Contribution to the Production and Characterization of HVOF Coatings for Application inthe Petrochemical Field 141A. Scrivani, S. lanelli, R. Groppetti, University of Parma, Parma, ItalyS. Bertini, O. Lacorix, G. Rizzi, Flametal S.p.A., Parma, ItalyF. Casadei, Centro Sviluppo Materiali, Rome, Italy

Thermal Barrier Coatings

Process Modelling to Optimise the Structure of Hollow Zirconia Particles for Use in PlasmaSprayed Thermal Barrier Coatings 149T. Klocker, T. W. Clyne, University of Cambridge, Cambridge, United KingdomM. R. Dorfman, Sulzer Metco, Inc., Westbury New York, USA

Comparative Study of Different Sealing Methods for Thick Thermal Barrier Coatings 157S. Ahmaniemi, J. Tuominen, P. Vuoristo, T. Ma'ntyla, Tampere University of Technology,

Tampere, Finland

Influence of a Multi-Gas Mixture on the Performance of a HPPS Plazjet System for aThermal Barrier Coating 167J. Dhers, N. Goubot, T. David, J. Baudoin, CEA-Valrho, Pierrelatte, FranceM. Barthelet, J. Huet, Air Liquide, St Ouen I'Aumdne, FranceM. Ducos, Ducos Consultant, Mornas, France

Effect of Bond Coat Processes and Surface Characteristics On the Failure Mechanismof Thermal Barrier Coatings 173Z. Ding, Wuhan University of Technology, Wuhan, Hubei, People's Republic of ChinaR. Knight, Drexel University, Philadelphia, Pennsylvania, USAR. W. Smith, Materials Resource Internationals, Inc., Philadelphia, Pennsylvania, USA

Thermal Shock Characteristics of Functionally Graded Thermal Barrier Coatings 179C. T. Chia, K. A. Khor, H. W. Ng, L. Fu, Nanyang Technological University, Singapore

Xll

Kinetics of Thermally Grown Oxide at Interface Between Thermal Barrier Coatings andMCrAlY Bond Coatings 187K. Ogawa, T. Shoji, T. Masuda, Tohoku University, Sendai, Japan

Reaction Diffusion Behavior of Thermally Sprayed MCrAlY Coatings On Ni-BasedSuper Alloys 195T. Teratani, K. Tani, Y. Harada, Tocalo Company Ltd., Kobe, Japan

Optimization of Shop Practices for Thermal Barrier Coatings 199P. Sahoo, Cincinnati Thermal Spray, Inc., Cincinnati, Ohio, USA

Removal of Thermal Barrier Coatings From Turbine Blades: A Comparison of Mechanicaland Chemical Methods 207A. Scrivani, R. Groppetti, S. lanelli, Universita di Parma, Parma, ItalyU. Bardi, G. Ballerini, D. Bonacchi, Universita di Firenze, Firenze, ItalyM. Fantini, Galvanica Parmense, Parma, ItalyG. Rizzi, Turbocoating S.p.A., Parma, Italy

Ceramics, Intermetallics, and Metal Composite Coatings

Induction Plasma Synthesis of MoSi2 Ultrafine Powders 211S. Gutierrez, F. Gitzhofer, Plasma Technology Research Center, Sherbrooke,

Quebec, Canada

Improvements in HVOF Sprayed Cermet Coatings Produced from SHS Powders 221M. T. Blatchford, M. Jones, A. J. Horlock, D. G. McCartney, P. H. Shipway J. V. Wood,

University of Nottingham, Nottingham, United Kingdom

Composites Made of Metal Foams with Thermally Sprayed Coatings 231M. Maurer, E. Lugscheider, Aachen University of Technology, Aachen, Germany

Plasma Spray Dissociation of ZrSiO4 As The Basis of Forming ZrO2-Mullite Compositesfrom a ZrSiO4 + AI2O3 Mixture 237Y. Li, K. A. Khor, Nanyang Technological University, Singapore

HVOF Sprayed Hydroxyapatite/Titania Composite Coatings 245K. A. Khor, H. Li, P. Cheang, Nanyang Technological University, Singapore

Manufacture of SiC Composite Coatings by HVOF 251B. Wielage, J. Wilden, T. Schnick, Cheminitz University of Technology, Chemnitz, Germany

High Temperature Behavior of Plasma Sprayed ZrB2-SiC Composite Coatings 259C. Bartuli, T. Valente, University "La Sapienza," Rome, ItalyM. Tului, Centro Sviluppo Material!, Rome, Italy

Abradable Coatings for Low-Temperature Applications 263Y. Nava, Z. Mutasim, M. Coe, Solar Turbines, Inc., San Diego, California, USA

Developments of Plasma Sprayed Ceramic Coatings 269C. X. Ding, X. Y. Liu, X. B. Zheng, Chinese Academy of Sciences, Shanghai,

People's Republic of China

Properties of AI2O3Coatings Sprayed by HFPD 275/. Fagoaga, G. Barykin, J. de Juan, T. Soroa, C. Vaquero, Aerostar Coatings, Irun, Spain

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Structure & Properties of HVOF Sprayed NiCrBSi Coatings 281E. Calla, S. C. Modi, Metallizing Equipment Company Pvt. Ltd., Jodhpur, India

On the Tailoring of Spray Dried Thermal Spray Powders 285N. Keller, G. Bertrand, B. Comas, C. Coddet, LERMPS-UTBM, Belfort, France

Spray Powders and Coatings on the Basis of Titanium Suboxides 291L-M Berger, S. Thiele, M. Nebelung, Fraunhofer Institute of Ceramic Technologies and

Sintered Materials, Dresden, GermanyO. Storz, H. Gasthuber, Daimler Chrysler AG, Research and Technology, Ulm, Germany

A Comparative Study of the Deposition of Chromium Carbide Based Metal MatrixComposites by Axial Plasma Spray, Air Plasma Spray and High Velocity Oxygen Fuel 301A. Scrivani, R. Groppetti, S. lanelli, University of Parma, Parma, ItalyU. Bardi, G. Ballerini, University of Florence, Firenze, ItalyS. Bertini, Flametal S.p.A., Parma, Italy

Polymer Feedstocks and Coatings

Heating Effect of Flame Impingement on Polymer Coatings 307D. T. Gawne, T. Zhang, Y. Bao, South Bank University, London, United Kingdom

Mechanical Properties of Thermal Spray PEEK Coatings 315H. Liao, C. Coddet, L. Simonin, Universite de Technologie de Belfort-Montbeliard,

Belfort, France

Characterization and Mechanical Properties of Flame Sprayed Hydroxyapatite/PolymerComposite Coatings 321L Sun, C. C. Berndt, State University of New York at Stony Brook, SUNY, Stony Brook,

New York, USAK. A. Gross, Monash University, Victoria, Austrailia

Structure and Thermal Conductivity of Flame Sprayed Polyamide 11 Coatings FilledWith A12O3, AIN and BN Ceramics 327E. M. Leivo, T. H. Kellberg, P. M. J. Vuoristo, T. A. Mantyla, Tampere University of Technology,

Tampere, FinlandM. J. Kolari, VTT Manufacturing Technology, Tampere, Finland

Surface Modification of Recycled PET Plate by Particle Implantation and Deposition withPlasma Spraying 331T. Kanazawa, A. Ohmori, S. Matsusaka, Osaka University, Ibaraki, Osaka, Japan

Sprayed Composite Coating of High Performance Thermoplastics 337R. Kawase, Y. Tanaka, Ariake National College of Technology, Fukuoka, Japan

Nanostructured Materials

Processing and Characterization of Nanostructured Cermet Coatings 343B. R. Marple, J. Voyer, J. F. Bisson, C. Moreau, National Research Council of Canada,

Boucherville, Quebec, Canada

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Synthesis and Properties of Multimodal WC-12 Co Coatings 353L. Ajdelsztajn, E. J. Lavernia, University of California at Irvine, Irvine, California, USAF. L. Bastian, COPPE, Universidade Federal do Rio de Janeiro, Rio de Janeiro, BrazilG. Skandan, Nanopowder Enterprises, Inc., Piscataway, New Jersey, USA

Structure and Properties of HVOF Sprayed Amorphous Polymer MatrixNanocomposite Coatings 361R. Knight, X. Fang, T. E. Twardowski, Drexel University, Philadelphia, Pennsylvania, USA

Properties of HVOF Sprayed Multi-Scale Polymer/Silica Nanocomposite Coatings 369T. E. Twardowski, M. Reilly R. Knight, Drexel University, Philadelphia, Pennsylvania, USA

Control of the Injection of an Alumina Suspension Containing Nanograins in a dc Plasma 375K. Wittmann, F. Blein, CEA, Le Ripault, Monts, FranceJ. F. Coudert, P. Fauchais, Universit de Limoges, Limoges, France

Cold Sprayed Nanostructured WC-Co 383J. Karthikeyan, C. M. Kay, J. Lindemann, ASB Industries Inc., Barberton, Ohio, USAR. S. Lima, C. C. Berndt, State University at Stony Brook,SUNY, Stony Brook, New York, USA

Low Pressure Plasma Spraying of Sol-Gel AI2Oa/SiC Nanocomposite Coatings 389S. Jiansirisomboon, S. G. Roberts, P. S. Grant, University of Oxford, Oxford, United Kingdom

Cold Spray Processes and Coatings

Effects of Shockwaves on Impact Velocity of Cold Spray Particles 399B. Jodoin, University of Ottawa, Ontario, Canada

Optimization of the Cold Spray Process 409T. Stoltenhoff, H. Kreye, University of the Federal Armed Forces, Hamburg, GermanyH. J. Richter, Dartmouth College, Hanover, New Hampshire, USAH. Assadi, Taribat Modarres University, Teheran, Iran

Kinetic Powder Compaction Applying the Cold Spray Process—A Study on Parameters 417J. Vlcek, H. Huber, H. Voggenreiter, European Aeronautic Defense and Space Company,

Ottobrunn, GermanyA. Fischer, E. Lugscheider, Aachen University of Technology, Aachen, GermanyH. Hallen, G. Pache, Hoganas GmbH, Dusseldorf, Germany and Hoganas AB,

Hoganas, Sweden

Experimental Study of Interaction of Supersonic Gas Jet With a Substrate Under ColdSpray Process 423A. N. Papyrin, Ktech Corporation, Albuquerque, New Mexico, USAA. P. Alkhimov, V. F. Kosarev, S. V. Klinkov, Russian Academy of Science, Novosibirsk, Russia

Microstructure and Properties of Cold Spray Nickel 433M. K Decker, BuehlerLtd., Lake Bluff, Illinois, USAR. A. Neiser, Sandia National Laboratories, Albuquerque, New Mexico, USAD. Gilmore, H. D. Tran, University of New Mexico, Albuquerque, New Mexico, USA

Improvement in Wire Arc Spray by Super Sonic Cold Gas Jet 441K. Sakaki, Y. Shimizu, Shinshu University, Nagano-shi, Japan

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Equipment and Systems

Effects of Operating Parameters on High Definition Single Wire Arc Spraying 447ft Carlson, J. Heberlein, University of Minnesota, Minneapolis, Minnesota, USA

HVOF Wire (HIJET) Sprayed Coatings of 0.8% C Steel - Its Structure & Applications 455S. C. Modi, E. Calla, Metallizing Equipment Company Pvt. Ltd., Jodhpur, India

High Velocity Combustion Wire Spraying - Systems and Coatings 461H. Kreye, A. Kirsten, F. Gartner, X. Qi, University of the Federal Armed Forces,

Hamburg, GermanyW. Krommer, Linde Gas AG, Unterschleiss Beim, Germany

Technique and Application of High Velocity Arc Spraying 467H. Wang, B. Zha, X. Su, H. Yang, L-Y Wang, Xi'an Research Institute of High-Tech,

Xi'an Shaanxi, People's Republic of China

Influence of Anode Nozzle and External Torch Contour on the Quality of the AtmosphericDC Plasma Spray Process 471R. H. Henne, E. Bouyer, V. Borck, G. Schiller, Institute of Technical Thermodynamics, Stuttgart,

Germany

Process-Microstructure-Property Relationships in Controlled Atmosphere PlasmaSpraying (CAPS) of Ceramics 479S. Beauvais, V. Guipont, F. Borit, M. Jeandin, Ecole des Mines de Paris, Evry, FranceM. Espanol Pons, K. A. Khor, Nanyang Technological University, SingaporeA. Robisson, R. Saenger, Schlumberger, Clamart, France

Process Features During the Plasmajet CVD Synthesis of Si-C-N Coatings 487J. Wilden, A. Wank, Chemnitz University of Technology, Chemnitz, Germany

Impact of Self Propagating High Temperature Synthesis of Spraying Materials on CoatingsBased on Aluminium and Metal-Oxides 497Fr.-W. Bach, Z. Babiak, T. Duda, T. Rothgardt, G. Tegeder, University of Dortmund, Dortmund,

Germany

Process Study of Thin Coating Deposition by Low Pressure Plasma Spray 503X. Q. Ma, F. Borit, V. Guipont, M. Jeandin, Ecole des Mines de Paris, Evry, France

Reactive HVOF Thermal Spraying of Nanocrystalline Ni Powders 511J. Lee, University of California at Irvine, Irvine, California, USA and Pohang University of

Science and Technology, Pohang, South KoreaL. Ajdelsztajn, E. J. Lavernia, University of California at Irvine, Irvine, California, USAN. J. Kim, Pohang University of Science and Technology, Pohang, South Korea

Role of Some Fuel Gases on Properties of HVOF Metallic Coatings 519V. Gourlaouen, E. Verna, Air Liquide-C.T.A.S, StOuen I'Aumone, FranceK. Kho, P.S.T. Quek, SOXAL Re., Ltd., Singapore

Oxidation of HVOF Sprayed Alloy Coatings and Its Control by a Gas Shroud 527T. Fukushima, S. Kuroda, National Institute for Materials Science, Ibaraki, Japan

Cryogenic Cooling in High Power Plasma Spraying 533J. Dhers, N. Goubot, T. David, J. Baudoin, CEAA/alrho, Pierrelatte, France

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A New Powder Feeder for the Transport of Ultrafine Powders "539M. D. Dvorak, DACS Dvorak Advanced Coating Solutions, Thun, SwitzerlandF. Dietrich, Ingenieur-conceil FEANI, Le Mont-Pelerin, Switzerland

Coatings and Applications Produced by "Purecoat™"an Improved Shrouding Technique 543T. Lester, Metallisation Ltd., Dudley, United Kingdom

On the Adhesion Mechanisms of Thermal Spray Deposits Manufactured WhileImplementing the PROTAL® Process 553M. Verdier, G. Montavon, S. Costil, C. Coddet, LERMPS-UTBM, Belfort, France

A Comparative Study on HVOF, Vacuum Plasma Spray and Axial Plasma Spray forCoNiCrAlY Alloy Deposition 561A. Scrivani, R. Groppetti, University of Parma, Parma, ItalyU. Bardi, A. Lavacchi, University of Florence, Florence, ItalyG. Rizzi, Rubbiano di Solignano, Parma, Italy

Coating Treatments

In situ Structural Modification of Thermal Spray Grey Alumina Coatings ImplementingLaser Ablation 567G. Montavon, M. Verdier, C. Coddet, LERMPS-UTBM, Sevenans, France

Surface Modification of Plasma Sprayed Coating by Using YAG Laser Equipped With aKaleidoscope 575S. O. Chwa, A. Ohmori, H. Yang, Osaka University, Osaka, JapanZ. Zhou, The Advanced Materials Processing Institute Kinki Japan, Hyogo, Japan

Influence of Laser Glazing on the Characteristics and Tribological Performance of Plasmaand Detonation Sprayed WC-Co Coatings 583S. V. Joshi, G. Thawari, L. S. Kumar, D. Sen, G. Sundararajan, ARCI- International Advanced

Research Centre, Hyderabad, India

Preparation of Bioactive and Porous Titanium Coating by Vacuum Plasma Sprayingand Chemical Treatment 593J. M. Shi, C. X. Ding, Chinese Academy of Sciences, Shanghai, People's Republic of ChinaX. Q. Wu, Shanghai Teacher's University, Shanghai, People's Republic of China

Formation of Hard Surfacing Layers Using Powder and an Electron Beam 599J. Morimoto, M. Tomie, F. Kuriyama, Kinki University, Higashiosaka, JapanN. Abe, Osaka University, Ibaraki, Osaka, Japan

Microstructural Study of Plasma Sprayed Chromium Oxide Coatings: Effect ofAluminum Phosphate Sealing 607M. Vippola, S. Ahmaniemi, P. Vuoristo, T. Lepisto, T. Mantyla, Tampere University of Technology,

Tampere, Finland

Alumina Duplex Coating by Multiprocesses: Air Plasma Spraying and PlasmaEnhanced Chemical Vapor Deposition 613T. Haure, A. Denoirjean, P. Tristant, H. Hidalgo, C. Leniniven, J. Desmaison, P. Fauchais, Laboratoire

Sciences des Procedes Ceramiques et Traitements de Surface/ENSIL, Limoges, France

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Evaluation of Sealants on Al-Zn Alloy Sprayed Coating by Galvanostatic Technique 621M. Tanaka, Tocalo Company, Ltd., Hyogo, JapanY. Takatani, Hyogo Prefectural Institute of Industrial Research, Hyogo, Japan

Microstructural Focused Studies

Analysis of Porosity and Cracks in Cross Sections of Plasma Sprayed Oxide Coatings 627T.Koschlig, University of Applied Sciences, Wildau, Germanyft Lallement, Rolls-Royce Deutschland Ltd. and Co. KG, Dahlewitz, Germany

On the Microstructure of Vacuum Plasma Sprayed Cu-3%Ag Alloy 633L. Dembinski, T. Grosdidier, C. Coddet, LERMPS-UTBM, Belfort, France

Study of Microstructure and Atomization Forming Process of Ultrasonic Arc Sprayed TiAlAlloy Coatings 639H. Wang, P. Li, Q. Guo, H. Yang, Xi'an High-Tech Research Institute, Xi'an, Shaanxi,

People's Republic of China

Microstructure - Property Relationships and Cross-Property-Correlations of ThermalSprayed Ni-Alloy Coatings 643N. Margadant, S. Siegmann, J. Patscheider, EMPA-Swiss Federal Laboratories for Materials

Testing and Research, Thun, SwitzerlandT. Keller, W. Wagner, Paul Scherrer Institute, Villigen, SwitzerlandJ. llavsky, University of Maryland at College Park, College Park, Maryland, USAJ. Pisacka, Academy of Sciences of the Czech Republic, Prague, Czech RepublicG. Barbezat, Sulzer Metco AG, Wohlen, SwitzerlandP. Fiala, Skoda Research, Plzen, Czech Republic

Microstructural Studies of Thermally Sprayed Deposits by Neutron Scattering 653T. Keller, W. Wagner, Paul Scherrer Institute, Villigen, SwitzerlandJ. llavsky, University of Maryland at College Park, College Park, Maryland, USAN. Margandant, S. Siegmann, EMPA-Swiss Federal Laboratories for Materials Testing and

Research, Thun, SwitzerlandJ. Pisacka, J. Matejicek, Academy of Sciences of the Czech Republic, Prague,

Czech RepublicG. Barbezat, Sulzer-Metco AG, Wohlen, SwitzerlandP. Fiala, Skoda Research, Plzen, Czech RepublicT. Pirling, Institute Laue-Langevin, Grenoble, France

A Microstructural Study of HVOF and VPS Sprayed MCrAlY Coatings 661S. Nuutinen, P. Vuoristo, S. Ahmaniemi, T. Mantyla, Tampere University of Technology,

Tampere, FinlandJ. Takeuchi, Tocalo Company, Ltd. Kobe, Japan

The Effect of Off-Angle Spraying on the Structure and Properties of HVOFWC/CoCr Coatings 671P. F. Ruggiero, E. Strock, D. Reynolds, Engelhard Corporation, East Windsor,

Connecticut, USA

Effect of Spraying Distance on Plasma Deposit's Behavior 677P. Ctibor, P. Rohan, P. Chriska, Institute of Plasma Physics AS CR, Prague, Czech Republic

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Influence of Alloy Composition on the Thermal Expansion Coefficient ofFe-Ni(-Co) Coatings 683J. Wilden, A. Wank, Chemnitz University of Technology, Chemnitz, GermanyF. Schreiber, DURUM VerschleiBshutz GmbH, Krefeld, Germany

Atmospheric Plasma Spraying of Ti Particles — In-Flight Particle Reactivity —Coating Properties 691C. Ponticaud, A. Grimaud, A. Denoirjean, P. Lefort, P. Fauchais, SPCTS, University

de Limoges, Limoges, France

Mechanisms of High Hardness in Cr3C2-NiCr Cermet Coatings Formed by VacuumPlasma Spraying 699T. Tomita, Y. Takatani, Hyogo Prefectural Institute of Industrial Research, Hyogo-ken, JapanK. Tani, Y. Harada, Tocalo Co. Ltd., Kobe, Japan

Diagnostics and Process Control

Ensemble In-Flight Particle Diagnostics Under Thermal Spray Conditions 705J. F. Bisson, M. Lamontagne, C. Moreau, National Research Council of Canada,

Boucherville Quebec, CanadaL. Pouliot, J. Blain, F. Nadeau, TECNAR Automation Ltee, St. Bruno, Quebec, Canada

Effect of Plasma Fluctuations on In-Flight Particle Parameters 715J. F. Bisson, B. Gauthier, C. Moreau, National Research Council of Canada, Boucherville,

Quebec, Canada

Significant Increase in the Sensitivity of In-Flight Particle Detector ThroughImprovements and Innovation 723L. Pouliot, J. Blain, F. Nadeau, TECNAR Automation Ltee, St. Bruno, Quebec, CanadaM. Lamontagne, J. F. Bisson, C. Moreau, National Research Council of Canada,

Boucherville, Quebec, Canada

Optimisation and Monitoring of Spray Parameters by a CCD Camera Based ImagingThermal Spray Monitor 727P. Vuoristo, S. Ahmaniemi, S. Nuutinen, T. Mantyla, Tampere University of Technology,

Tampere, FinlandE. Hamalainen, N. Arola, J. Vattulainen, Oseir, Ltd., Tampere, Finland

Control of Plasma Sprayed Particles Temperature and Velocity by Chamber Pressure 737S. Sodeoka, M. Suzuki, T. Inoue, Osaka National Research Institute, Osaka, Japan

On-Line Monitoring (SDC) Through Coating Surface Temperature of Residual Stressesin APS WC-Co17wt% Coatings on Hastelloy X 743T. Renault, M. Vardelle, P. Fauchais, Universite de Limoges, Limoges, FranceH. Hoffmann, F. Braillard, SNECMA Services, Chatellerault, France

Diagnostic of In-Flight Particle Properties and Resulting Coating Qualities onAtmospheric Plasma Spray Process 751E. Lugscheider, A. Fischer, D. Koch, N. PapenfuB, Aachen University of Technology,

Aachen, Germany

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Plasma Jet Properties in a New Spraying Process at Low Pressure for Large Area ThinFilm Deposition 759J. L. Dorier, M. Gindrat, C. Hollenstein, EPFL-CRPP, Lausanne, SwitzerlandM. Loch, A. Refke, A. Salito, G. Barbezat, Sulzer Metco AG, Wohlen, Switzerland

The Benefit of an On-Line Diagnostic System for the Optimization of Plasma SprayDevices and Parameters 765A. Refke, G. Barbezat, M. Loch, Sulzer Metco AG, Wohlen, Switzerland

The Relationships Between In-Flight Particles Characteristics and Coating PropertiesUnder Plasma Spraying Conditions 771M. P. Planche, B. Normand, E. Suzon, C. Coddet, LERMPS-UTBM, Belfort, France

IR Thermographic Imaging - A Powerful Tool for On-Line Process Control ofThermal Spraying 779C. J. Friedrich, ft Gadow, A. Killinger, C. Li, University of Stuttgart, Stuttgart, Germany

Verification of Particle Flux Imaging (PFI), an In-Situ Diagnostic Method 787J. Zierhut, W. Pellkofer, A. Sagel, T. Haug, DaimlerChrysler, Ulm, GermanyK. D. Landes, UniBw-Munchen, Neubiberg, Germany

HVOF Process Control Using Almen and Temperature Measurement 791J. P. Sauer, Sauer Engineering, Cincinnati, Ohio, USAP. Sahoo, Cincinnati Thermal Spray, Inc., Cincinnati, Ohio, USA

Formation Impact and Solidification of Droplets

Capture and Evaluation of HVOF Thermal Sprayed Particles by a Gel Target 797H. Yamada, H. Yumoto, Science University of Tokyo, Noda, JapanS. Kuroda, T. Fukushima, National Institute for Materials Science, Tsukuba, Japan

Visualization of the Impact of Drops on a Substrate in Plasma Spraying: Depositionand Splashing Modes 805C. Escure, M. Vardelle, A. M. Vardelle, P. Fauchais, SPCTS-Universitd de Limoges,

Limoges, France

Effect of Substrate Properties on the Formation of Plasma-Sprayed Alumina Splats ..813V. Pershin, M. Pasandideh-Fard, J. Mostaghimi, S. Chandra, University of Toronto,

Toronto, Ontario, Canada

Oxidation of Iron Particles During APS: Effect of the Process on Formed Oxide; Wettingof Droplets on Ceramic Substrates 821G. Espie, P. Fauchais, J. C. Labbe, A. M. Vardelle, SPCTS, Universite' de Limoges,

Limoges, FranceB. Hannoyer, LASTSM, University of Rouen, Mont Saint Aignan, France

Splat Morphology and Graphite Formation in Plasma-Sprayed Cast Iron 829M. F. Morks, Y. Tsunekawa, M. Okumiya, Toyota Technological Institute, Nagoya, JapanM. A. Shoeib, Central Metallurgical Research and Development Institute, Cairo, Egypt

Splat Morphology in Spray Pattern of Plasma Spraying 835S. Oki, Kin-Ki University, Osaka, Japan

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Proposal of New Criterion for Splashing of Thermal Sprayed Particle onto FlatSubstrate Surface 841M. Fukumoto, E. Nishioka, T. Nishiyama, Toyohashi University of Technology, Toyohashi,

Aichi, Japan

The Interrelationship Between Particle Velocity and Temperature, Splat Formationand Deposition Efficiency in Detonation Sprayed Alumina Coatings 849G. Sundararajan, G. Sivakumar, D. Srinivasa Rao, ARCI-lnternational, Hyderabad, India

Impact, Deformation and Cooling Down of Atmospheric Induction Plasma SprayedCeramic Particles and Their Influence on Coating Properties 859B. Dzur, G. Nutsch, TU llmenau, llmenau, Germany

Formation and Layering of Alumina Splats: Thermal History of Coating Formation,Resulting Residual Stresses and Coating Microstructure 865P. Fauchais, A. M. Vardelle, M. Vardelle, A. Denoirjean, B. Pateyron, M. El Ganaoui,

Universite de Limoges, Limoges, France

Modeling and Simulation

Microstructure Simulation of Thermally Sprayed Particles 875J. Wilden, H. Frank, T. Muller, Chemnitz University of Technology, Chemnitz, Germany

Correlation Between Simulations and Plasma Spray Coatings Properties 883ft Bolot, V. Monin, C. Coddet, LERMPS-UTBM, Belfort, France

Application of CAD to CFD for the Wire Arc Spray Process 889ft Bolot, ft Bonnet, G. Jandin, C. Coddet, LERMPS-UTBM, Belfort, France

Computer Simulation of Shrouding on the Profile of a Plasma Jet 895T. Zhang, B. Liu, Y. Bao, D. T. Gawne, South Bank University, London, United Kingdom

Calculated and Measured Oxygen Contents in the Gas Flow of a Shrouded ThermalSpray Process 903S. Jamais, M. Creaven, ESIL International, Dublin, IrelandC. Rinaldi, CESI-Segrate, Milan, Italy

Modeling of the Natural Gas HVOF Process 911ft Bolot, M. P. Planche, C. Coddet, LERMPS-UTBM, Belfort, France

Modeling of the Acceleration and Behavior at Impact of Ceramic Suspension Dropletsin Aerosol Flame Spraying 917T. Poirier, Universidad Simon Bolivar, Caracas, VenezuelaA. M. Vardelle, M. F. Elchinger, M. Vardelle, A. Grimaud, University de Limoges,

Limoges, FranceH. Vesteghem, Ecole Nationale Superieure de C4ramique Industrielle, Limoges, France

Computer Simulation and Control of Plasma Spraying Processes 925S. Kundas, Belarusian State University of Informatics and Radioelectronics, Minsk, BelarusA. llyushenko, Research Institute of Powder Metallurgy, Minsk, Belarus

3-D Modeling of Gas Flow and Particle Spray Jet in Plasma Spraying 933G. Mariaux, C. Baudry, A. M. Vardelle, Universite de Limoges, Limoges, France

XXI

Finite Element Analysis on Residual Stress in a Plasma-Sprayed Functionally GradedThermal Barrier Coating 943A. M. Limarga, S. Widjaja, T. H. Yip, Nanyang Technological University, Singapore

Deposition Model of Thermal Spray Coatings 951ft Ghafouri-Azar, J. Mostaghimi, S. Chandra, University of Toronto, Toronto, Ontario, Canada

Mathematical Modeling of Deformation and Solidification of Molten Droplet on a FlatSubstrate in a Plasma Spray Process 959A. llyuschenko, A. Lakubenya, Belarusian Scientific Research Institute of Powder

Metallurgy, Minsk, BelarusG. Gromyko, G. Zayats, Belarusian National Academy of Sciences, Minsk, Belarus

Microstructural Evaluation of Plasma Sprayed Coatings Using Fractal Characterization 967L. Bianchi, CEA-Le Ripault, Monts, FranceN. Llorca-lsern, G. Bertran, Universitat de Barcelona, Barcelona, Spain

Development of a Coupled Model to Predict Droplet Deformation and SolidificationDuring Splatting 975D. L. Hale, ft A. Berry, Idaho National Engineering and Environmental Laboratory,

Idaho Falls, Idaho, USA

Mechanical Properties

Mechanical Fatigue Testing of Thermal Spray Coated Specimens: A Summary ofRecent Developments 985ft T. ft McGrann, Edison Welding Institute, Columbus, Ohio, USA

Mechanical Properties of Thermal Spray Coatings 993T. Varis, E. Rajamaki, VTT Manufacturing Technology, Espoo, FinlandK. Korpiola, Metorex International Oy, Espoo, Finland

Dynamical Mechanical Analysis of the Mechanical Properties of Al- and Fe-BasedThermal Spray Coatings 999G. Burkle, H. J. Fecht, University of Ulm, Ulm, GermanyA. Sagel, C. Wanke, DaimlerChrysler AG, Ulm, Germany

Mechanical and Tribological Characterization of APS and HVOF Sprayed TiO2 Coatingson Light Metals 1003M. Buchmann, ft Gadow, University of Stuttgart, Stuttgart, Germany

Influence of Coating Thickness and Contact Stress On the Fatigue Failure ofHVOF Coatings 1009R.Ahmed, Heriot-Watt University, Edinburgh, United KingdomM. Hadfield, Bournemouth University, Bournemouth, United Kingdom

Bonding Strength Test and Biological Evaluation of Plasma Sprayed HA-BasedComposite Coatings 1017X. B. Zheng, C. X. Ding, Chinese Academy of Sciences, Shanghai, People's

Republic of China

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Influence of Coating Thickness on Fatigue Properties of Sprayed Co-Based Self-FluxingAlloy with Fusing Treatment 1023J. Oh, M. Shimizu, J. Komotori, Keio University, Yokohama-shi, Kanagawa, Japan

The Influence of the Process Parameters on the Properties of Detonation SprayedWC-12CO Coatings 1031G. Sivakumar, L. Ramakrishna, V. Jain, D. Srinivasarao, G. Sundararajan, ARC-lnternational,

Hyderabad, Andhra Pradesh, IndiaG. M. Reddy, Defence Metallurgical and Research Laboratory, Hyderabad, India

Mechanical and Electrical Properties of A12O3-TiO2 Coating as Electrical Insulator 1039M. Nakamichi, H. Kawamura, Japan Atomic Energy Research Institute, Ibaraki-ken, Japan

Elastic Modulus Measurements of Air Plasma Sprayed Yttria Partially StabilizedZirconia Coatings Using Laser Ultrasonics and Indentation Techniques 1045D. L Vasquez, A. Kucuk, ft S. Lima, U. Senturk, C. C. Berndt, State University of New York

at Stony Brook, SUNY, Stony Brook, New York, USA

Wear and Erosion

HVOF Process Optimization for the Erosion Resistance of WC-12Co andWC-10Co-4Cr Coatings 1051B. Arsenault, J. G. Legoux, H. Hawthorne, J. P. Immarigeon, P. Gougeon, C. Moreau,

National Research Council of Canada, Boucherville, Quebec, Canada

Wear Resistance of HVOF-Sprayed Carbide Coatings 1061M. A. Rodriguez, J. Klisans, L. Bavaresco, Central University of Venezuela, Caracas,

VenezuelaA. Scagni, Plasmatec Ingenieros C.A., Caracas, VenezuelaF. Arenas, Instituto University of Technology, Caracas, Venezuela

Ceramic and Metallurgical Composite Coatings With Advanced Tribological PropertiesUnder Dry Sliding Conditions 1069ft Gadow, D. Scherer, University of Stuttgart, Stuttgart, Germany

Thermal Sprayed Hard Cr3C2-Ni Cr Coatings for Wear Protection 107577 Valente, C. Bartuli, University of Rome "La Sapienza," Rome, ItalyM. Tului, Centro Sviluppo Material!, Rome, Italy

Cavitation Erosion Resistance of Co-Based Alloy Thermally Sprayed Coatings 1085M. Adachi, K. Tani, Y. Harada, Tocalo Company, Ltd., Hyogo, JapanK. Ogino, Kinki University, Osaka, Japan

Effect of WC Content on the Wear Resistance of Ni-Base Alloy Spray Fusing Overlays 1089Z Ding, H. Zhao, Wuhan University of Technology, Wuhan, Hubei, People's Republic

of ChinaJ. Wang, Wuhan Ditong Surface Engineering Technology Inc., Ltd., Wuhan, People's

Republic of China

Improvement of Wear Resistance of Thermal Sprayed Molybdenum Coating byDiamond Deposition Using Combustion Flame CDV 1093Y. Ando, K. Fukuda, S. Tobe, Ashikaga Institute of Technology, Ashikaga, Tochigi, Japan

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Characterization and Tribological Properties of Electroless Plated Ni-Co onPlasma-Sprayed Cr3C2-NiCr Coating 1099J. Li, C. Ding, Chinese Academy of Sciences, Shanghai, People's Republic of China

Scratch Testing of Nanocrystalline Alumina+13%Titania+Zirconia 1105M. ft Gold, C. C. Berndt, State University of New York at Stony Brook, SUNY,

Stony Brook, New York, USA

Study of Slide-Wear Resistance of Ultrasonic Arc Sprayed TiAl Alloy Coatings 1111H. Wang, P. Li, Q. Guo, H. Yang, Xi'an High-Tech Research Institute, Xi'an, Shaanxi,

People's Republic of China

Tribological Behaviour of Abradable Coatings Obtained by Atmospheric PlasmaSpraying (APS) 1115J. M. Guilemany J. Navarro, C. Lorenzana, S. Vizcaino, J. M. Miguel, CPT-Universitat de

Barcelona, Barcelona, Spain

Investigation of Composite Powders with a Carbide Phase for Plasma Spraying ofWear Resistant Coatings 1119A. llyuschenko, A. I. Shevtsov, V. A. Okovity, Powder Metallurgy Research Institute,

Minsk, BelarusS. Steinhauser, Cheminitz University of Technology, Chemnitz, Germany

Corrosion Properties and Characteristics

Importance of the Adhesion of HVOF Sprayed Coatings for Aqueous CorrosionResistance 1123S. Kuroda, J. Kawakita, T. Fukushima, National Institute for Materials Science,

Ibaraki, JapanS. Tobe, Ashikaga Institute of Technology, Tochigi, Japan

Development of Ultra Thin Carbide Coatings for Wear and Corrosion Resistance 1131F. F. Fischer, WOKA SchweiBtechnik GmbH, Barchfeld, GermanyM. D. Dvorak, DACS Dvorak Advanced Coating Solutions, Thun, SwitzerlandS. Siegmann, EMPA-Swiss Federal Laboratories for Materials Testing and Research,

Thun, Switzerland

Corrosion Behaviour of HVOF Sprayed Coatings in Seawater 1137J. Kawakita, T. Fukushima, S. Kuroda, T. Kodama, National Institute for Material Science,

Tsukuba, Japan

Relationship of Corrosion Resistance-Coating Structure of HP/HVOF Carbide andMetallic Coatings 1143T. Shmyreva, D. Wang, ft Thorpe, Praxair-TAFA, Inc., Concord, New Hampshire, USA

Microstructure Characteristics and Corrosion Behaviour of HVOF Sprayed MetallicCoatings 1149A. J. Sturgeon, TWI Ltd., Great Abington, Cambridge, United Kingdom

A Summary of Recent Developments of HVOF Sprayed Ceramic-Metallic Coatings forCorrosion and Wear Resistance 1157J. Berget, T. Rogne, SINTEF Materials Technology, Trondheim, Norway

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Influence of Thermal Treatments in the Corrosion Behaviour of HVOFCr3C2-NiCr Coatings 1165J. M. Guilemany J. Fernandez, J. Delgado, CPT, Universitat de Barcelona, Barcelona, SpainA. V. Benedetti, Instituto de Quimica da Universidade Estadual Paulista, Araraquara, Brasil

Corrosion Fatigue Properties of A1203 Plasma-Sprayed SUS316L Stainless Steel in aPhysiological Saline Solution 1171M. Sugano, U. Somboon, H. Kisuki, T. Satake, Z. Tanaka, Yamagata University, Yonezawa, JapanA. Ohmori, Osaka University, Osaka, Japan

Arc SprayedTi-N Coatings for Protection Against Corrosion and Wear 1179Fr.-W. Bach, Z. Babiak, G. Tegeder, University of Dortmund, Dortmund, Germany

Extensive Characterization of Dense and Corrosion Resistant Coatings Produced byImproved Shrouded Techniques 1185C. Rinaldi, L. Ferravante, F. Uberti-Paci, P. Bianchi, CESIArea Generazione, Segrate,

Milan, Italy

Modification of Ceramic Thermal Spray Deposit Microstructure ImplementingLaser Treatment 1195G. Montavon, C. Coddet, LERMPS-UTBM, Sevenans, France

Corrosion Properties of HVOF Sprayed and Nd-YAG Laser Remelted High-ChromiumNickel-Chromium Coatings 1203J. Tuominen, P. Vouristo, T. Mantyla, S. Ahmaniemi, J. Vihinen, P. H. Andersson, Tampere

University of Technology, Tampere, Finland

Non Destructive Testing and Quality Control

On-Line Microstructure and Property Control of aThermal Sprayed Abrasive Coating 1213P. Nylen, J. Wigren, J. Idetjarn, L Pejryd, Volvo Aero Corporation, Trollhattan, SwedenM. Friis, University Trollhattan, Trollhattan, SwedenP. Moreno, Institute for Advance Materials Joint Research Centre, Petten, Holland

Some Considerations for the Routine Testing of Thermal Sprayed Coatings 1221J. Wigren, K. Tang, Volvo Aero Corporation, Trollhattan, Sweden

Non Destructive Testing for the Estimation of the Adhesion of Plasma Sprayed Coatings 1229S. Costil, C. Coddet, LERMPS-UTBM, Belfort, FranceG. Rosa, P. Psyllaki, ft Oltra, LRRS, Universite de Bourgogne, Dijon, France

Properties of Thermal Sprayed Coatings Characterized by Lock-in Thermography 1235B. Wielage, U. Hofmann, Chemnitz University of Technology, Chemnitz, Germany

Quality Assurance for Thermal Spraying by Implementation of New QM Standardsand Regulations for Personnel Qualification 1239D. G. F. Bohme, ft Huber, SLV Munchen GmbH, Munchen, Germany

Acoustic Emission Techniques for Life Prediction of TBCs Under ThermalCycling Conditions 1247P. Robin, F. Gitzhofer, M. I. Boulos, Universite de Sherbrooke, Sherbrooke, Quebec, Canada

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Online Quality Control of Thermally Sprayed Coatings 1255M. Dvorak, DACS Dvorak Advanced Coating Solutions, Thun, SwitzerlandC. Florin, FLIR AG, Kriens, SwitzerlandE. Amrhein, FLIR ASIA, Kuching Sarawak, East Malaysia

Commercial Aspects

Integrated Thermal Spray Systems—Some Practical Considerations 1261ft C. Tucker, Jr., The Tucker Group, Brownsburg, Indiana, USA

Thermal Coating In Europe: A Business Prospective 1267M. Ducos, J-P Durand, Magetex, Sevres, France

The Evolution of the Plasma Spraying Technology During the Last Ten Years 1273G. Barbezat, Sulzer Metco AG, Wohlen, Switzerland

New Developments in Thermal Spray Gas Supply Systems 1277M. Cole, J. Gabzdyl, BOC Gases Europe, Guildford, Surrey, United Kingdom

What Influence Does the Purity of Industrial Gases Have on the Quality ofThermal Spraying? 1283W. Krommer, P. Heinrich, Linde Gas AG, UnterschleiBheim, Germany

Plasma Spray: The Job Shop Perspective 1289M. Bhusari, Praxair Surface Technologies, Inc., Concord, New Hampshire

SHS Powder Materials for Protective Coatings in Power Industry 1299A. llyuschenko, P. Vitiaz, A. Beljaev, T. Talako, Powder Metallurgy Research Institute,

Minsk, Belarus

Extra Papers

Blast Erosion Properties of Erosion-Resistant Thermally Sprayed Coatings 1303K. Sonoya, Ishikawajima-Harima Heavy Industries Company, Ltd., Yokohama, Japan

Process Window for Plasma Spray Processes 1313M. Friis, University of Trollhattan, Trollhattan, SwedenC. Persson, Lund University, Lund, Sweden

PROTAL® Processing of Titanium Alloys as an Alternative to Degreasing and Grit-BlastingPrior to Thermal Spraying 1321C. Coddet, G. Montavon, M. Verdier, S. Costil, LERMPS-UTBM, Belfort, FranceG. Barbezat, Sulzer-Metco AG, Wohlen, Switzerland

Corrosion and Wear Properties of Different Weld Overlays 1329T. Rogne, J. Berget, H. Fostervoll, N. I. Nilsen, SINTEF Materials Technology, Trondheim, Norway

Fracture Machanics Approach to Delamination of Thermally Cycled ThermalBarrier Coatings 1339Y. Liu, C. Persson, S. Melin, Lund University, Lund, Sweden

XXVI

Influence of Process Variables on the Plasma Sprayed Coatings: An Integrated Study 1345A. Vaidya, G. Bancke, S. Sampath, H. Herman, State University of New York at

Stony Brook, SUNY, Stony Brook, New York, USA

Historical Endnote

The Origins of Thermal Spray Literature 1351

C. C. Berndt, State University of New York at Stony Brook, SUNY, Stony Brook, New York, USA

Title Index 1361

Author Index 1367

Company Index 1371

KeyWord Index 1375

The Last Page 1381

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