Thermal Spray Powders

Special Capabilities / Powder Mfg.

• Gas atomization– MCrAlYs, metal alloys,

superalloys & braze powders

• Sintering– Carbide and ceramic powders

• Casting– Carbide and ceramic powders

• Composite/Agglomerate – TBC, metal alloy & carbide

powders

• Physical Blending– Cr2C3-NiCr & others

• APT Technology– Chromium and tungsten based

Atomization

• Prepare raw materials• Vacuum induction melt• Pour molten metal• Break molten metal into

droplets and rapidly solidify (atomize)

• Collect powder

Atomization“Close-up”

Melt ChamberInduction Furnace

Collection Bucket

VIGA 250

Sintering

• Procedure– Mix raw materials– Place in furnace– Program furnace cycle

(heating & cooling)– Sinter– Breakdown sintered

mass

Composition A

Composition B

Composition C

to cause to become a coherent mass by heating without melting

Sinter:

Sintering

Cast & Crush

• Prepare raw materials• Heat raw materials until

molten (alloy)• Cast into crucible• Crush solidified mass

High Electric Current Melting

Composite / Agglomerated

• Mix raw materials into a liquid chemical suspension

• “Atomize” or drive-off binders to form agglomerates

• Collect dry agglomerated powder

Composition A

Composition BOrganic Binder

Composition BComposition A

Thermal Barrier Coatings

Physical Blends

• Prepare raw materials (previously manufactured)

• Blend

W-APT Powders

W-121 40 36 20 - 4 W-124 36 48 12 - 4 W-129 34 45 - 18 3.61350 1 81 4 10 - 5.21256 2 4.5 28 61 2.5 1.3

W Cr Co Ni C

Particle Size Distribution

180µ80 mesh

150µ100 mesh

125µ120 mesh

106µ140 mesh

90µ170 mesh

75µ200 mesh

63µ230 mesh

53µ270 mesh

45µ325 mesh

38µ400 mesh

22µ 16µ 11µ 5µ

PTA LPPS

PLASMA PLASMA

LASER HVOF-DJ

HVOF-JK

HVOF-JP

HVOF-HV

BRAZING/ADH BRAZING/ADH

Operational Excellence

Co-249 -22u

UCL=48.0

LCL=40.0

CEN=43.0

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