Coatings 2014, 4(2), 231-252; doi:10.3390/coatings4020231

Ni-Al and NiO-Al Composite Coatings by Combustion-Assisted Flame Spraying

1,* email, 1,2email, 1email, 2email and 3email
Received: 31 October 2013; in revised form: 9 April 2014 / Accepted: 10 April 2014 / Published: 17 April 2014
(This article belongs to the Special Issue Advanced Thermal Spray Coatings for Emerging Applications)
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.
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.
Keywords: combustion-assisted flame spraying (CAFSY); combustion synthesis; flame spraying; intermetallic phases
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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.

AMA 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(2):231-252.

Chicago/Turabian Style

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.

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