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

Institute of Advanced Materials PPNM, NCSR "Demokritos", Athens 15310, Greece
Department of Materials Science and Engineering, University of Ioannina, Ioannina 45110, Greece
Pyrogenesis SA, Technological Park of Lavrion, Lavrion 19500, Greece
Author to whom correspondence should be addressed.
Coatings 2014, 4(2), 231-252;
Received: 31 October 2013 / Revised: 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)
PDF [1455 KB, uploaded 17 April 2014]


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. View Full-Text
Keywords: combustion-assisted flame spraying (CAFSY); combustion synthesis; flame spraying; intermetallic phases combustion-assisted flame spraying (CAFSY); combustion synthesis; flame spraying; intermetallic phases

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This is an open access article distributed under the Creative Commons Attribution License (CC BY 3.0).

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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.

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