| COATING MATERIAL SELECTION TABLE |
| Coating Function | Application | Material Selection | Adhesive Wear
| Bearings, Impeller, Shafts, Piston Rings | Babbit Metal, Aluminum Bronze, Cast Iron-Molybdenum, Molybdenum-based self-fluxing alloy, alumina-Titania. | | Abrasive Wear | Couplings, Cutting Blades | Tungsten Carbide, Chromium Carbide, Aluminum Oxide, Chromium Oxide, Self-fluxing Alloys. | | High-Temperature Oxidation | Exhaust Mufflers | Aluminum, Nickel Chromium, Aluminum Alloy. | | Atmospheric and Salt Water | Exposed Steel Structures | Alumina, Zinc. | | Restoration of Dimension | Mismachined Parts and Castings | Carbon Steel, Stainless Steels, Nickel Alloys, Aluminum. | | Clearance Control | Compressor Housing | Aluminum Graphite, Nickel Graphite, Aluminum Polyester. | | Thermal Barrier | Blades, Vanes, Burner Cans | Yttria Zirconia. | | Electrical Conductivity | Grand Connectors | Cooper. | | Electrical Resistivity | Heater Tube Insulation | Aluminum Oxide. |
PROPERTIES OF COATINGS
Comparison of Major Thermal Spray Coating Processes | Property or Characteristic | Coating
Type | Wire Flame
Spray | Powder Flame
Spray | Electric
Arc | Plasma
Spray | High-Velocity Oxy-Fuel (HVOF) | Bond Strength
(MPa 103 psi) | Ferrous metals
Non-ferrous metals
Self-fluxing alloys
Ceramics
Carbides | 14 (2)
21 (3)
--
--
-- | 28 (4)
21 (3)
69 + (10+)
14-34 (-5)
34-48 (5-7) | 41 (6)
41 + (6+_
--
--
-- | 34 + (5+)
34 + (5+)
--
21 + (3+)
55-69 (8-10) | 62 (9)
70 (10.2)
62 (9)2
--
83 + (12+) | | Density, pct that of equivalent wrought material | Ferrous metals
Non-ferrous metals
Self-fluxing alloys
Ceramics
Carbides | 90
90
--
--
-- | 90
90
1001
95
90 | 90
90
--
--
-- | 95
95
--
95+
95 | 98+
98+
1001
1001
98+ | | Hardness | Ferrous metals
Non-ferrous metals
Self-fluxing alloys
Ceramics
Carbides | 84Rb-35Rc
95RH-40Rc
--
--
-- | 80Rb-35Rc
30RH-20Rc
30-60Rc
50-65Rc
50-60Rc | 95Rb-40Rc
40RH-80Rb
--
--
-- | 80Rb-40Rc
40RH-40Rc
--
50-70Rc
-- | 90Rb-50Rc
100RH-55Rc
50-60Rc
--
55-65Rc | | Permeability | Ferrous metals
Non-ferrous metals
Self-fluxing alloys
Ceramics
Carbides | Medium
Medium
--
--
-- | Medium
Medium
None1
Medium
Low | High
High
--
--
-- | Low
Low
--
Low
-- | Negligible
Negligible
None1
--
Negligible | | Coating-thickness limitation, mm(in) | Ferrous metals | 1.25-2.5
(0.05-0.1) | 1.25-2.5
(0.05-0.1) | 1.25-2.5
(0.05-0.1) | 1.25-2.5
(0.05-0.1) | 1.25-5
(0.05-0.2) | | | Non-ferrous | 1.25-5
(0.05-0.2) | 1.25-5
(0.05-0.2) | 1.25-5
(0.05-0.2) | 1.25-5
(0.05-0.2) | 2.5-5
(0.1-0.2) | | | Self-fluxing alloys | -- | 0.4-2.5
(0.015-0.1) | -- | -- | 1.250.4
(0.05) | | | Ceramics | -- | 0.4
(0.015) | -- | 0.4
(0.15) max. | -- | | | Carbides | -- | 0.4
(0.015) | -- | 0.4
(0.15) max. | 0.6
(0.025) |
1 Fused coating
2 Unfused coating |
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