Abstract: A new, cost-efficient and on-site-applicable thermal spraying process for depositing NiAl metallic overlay or bond-coat coatings for high temperature applications by synthesizing the desired intermetallic phases in-flight during oxy-acetylene flame spraying is presented. Base-metal powders were used for spraying and, by adjusting the spraying conditions, excellent NiAl-based coatings were achieved on various substrates, including mild steel, stainless steel and aluminium alloys. Expensive, pre-alloyed or agglomerated powders are avoided and the method is very promising for in-situ work and repairs. We call the new method “Combustion-Assisted Flame Spraying” (CAFSY) and its viability has been demonstrated at a pre-industrial level for coating metallic substrates. The NiAl-based coatings produced by CAFSY exhibit very high integrity with good adhesion, very low porosity, high surface hardness and high erosion resistance at a substantially lower cost than equivalent coatings using pre-prepared alloy powders.
This is an open access article distributed under the
Creative Commons Attribution License which permits unrestricted use, distribution,
and reproduction in any medium, provided the original work is properly cited.
Export to BibTeX
MDPI and ACS Style
Xanthopoulou, G.; Marinou, A.; Vekinis, G.; Lekatou, A.; Vardavoulias, M. Ni-Al and NiO-Al Composite Coatings by Combustion-Assisted Flame Spraying. Coatings 2014, 4, 231-252.
Xanthopoulou G, Marinou A, Vekinis G, Lekatou A, Vardavoulias M. Ni-Al and NiO-Al Composite Coatings by Combustion-Assisted Flame Spraying. Coatings. 2014; 4(2):231-252.
Xanthopoulou, Galina; Marinou, Amalia; Vekinis, George; Lekatou, Aggeliki; Vardavoulias, Michalis. 2014. "Ni-Al and NiO-Al Composite Coatings by Combustion-Assisted Flame Spraying." Coatings 4, no. 2: 231-252.