What Is Your Favorite Metallic Powder For Surface Treatment?

In the world of thermal and protective coatings, there is an extensive selection of alloy powders that are pure metal-based. These are used in complex to simple coatings that protect against oxidation and high-temperature wear. Also available in a variety of choices are the manufacturing techniques used to produce custom and standard powders. Powders manufactured through physical blending, agglomeration, vacuum sintering, and AGA (argon gas atomization) provide specific coating properties made to meet the demands of particular applications and clientele.

Surface Treatment – Metallic Powder Selections

There are a handful of metallic powders that can be used for surface treatment. These consist of the following:

  • Nickel-based
  • Molybdenum Based
  • Iron Based
  • Copper-based
  • Aluminum Based

Let’s take a look at the characteristics involved in the various powders included in each metallic powder-based choice. Keep in mind that various specific powders are included in each group, but all will not offer identical characteristics. These characteristics are a generalization that applies to the metallic based powder group.

Nickel Based

  • Excellent high-temperature performance and provides tough, strong joints
  • Excellent erosion resistance
  • Good for clearance control
  • Good readability offered by flame spraying
  • Perfect for friction applications, coatings are lubricious
  • Excellent properties for corrosion and high-temperature oxidation
  • Good for buildup and repair of chemistry super alloy components
  • Many exhibit characteristics similar to Rene 80 or Alloy 718
  • With some, thick coatings are possible, stainless steel-like coatings are machinable, smoke-free spray ability is offered, and they are bondable with most metallic surfaces
  • Some can be used for a ceramic bond coat
  • Temperature limitations for usefulness vary

Molybdenum Based

  • Low coefficient resistance
  • High wear resistance
  • Self-bonds to many metallic surfaces
  • High hardness and natural lubricity
  • Oil retention is promoted by certain coating structures
  • In most cases, they are useful up to 316°C/600°F

Iron Based

  • Excellent corrosion and wear resistance
  • Good against erosion, cavitation, and fretting
  • Moderately hard coating
  • Many are useful below 649°C/1200°F
  • Good for dimensional buildup and repair
  • Offer a coating that is easily machined and smooth

Copper Based

  • Pure, atomized Cu for some
  • Coating is easily machined
  • Offer resistance to galling and fretting at low temperatures
  • Excellent bearing material
  • Some offer dense, low oxide content coatings

Cobalt Based

  • Useful for brazing applications
  • CO-222’s low melt temperature version
  • Some comparable to MAR-M-509+B, FS X-414, CM-64, Tribaloy 800, or Alloy 6, (or some variation of these)
  • Used primarily for repair applications
  • Advantages include oxidation resistance and high-temperature strength
  • Some are super alloy brazing designed
  • Various powders are aerospace application’s superalloys
  • Some offer suitability for cobalt-based part repair thanks to denseness and hardness
  • Low friction coefficient
  • Some, when spray coated, offer a smooth finish

Aluminum Based

  • Usability for some is up to 325°C/600°F
  • Unbreakable, high quality material
  • Some are electrophoretic material used exclusively by Rolls-Royce Allison
  • Certain powders offer finishes that are shiny, smooth, and bright
  • Gas path seal coating that is turbine engine abradable
  • Denser and harder than pure aluminum
  • Excellent for repair of Mg and Al based parts
  • Good electrical conductivity
  • Offer a dense coating that protects against corrosion

If you are looking for surface treatments involving metallic powders, look no further. A & A Coatings is the go-to thermal spray, protective coating service for any number of today’s industries and applications. Contact us today to see how we can help you with your surface coating needs.

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