The earliest commercial applications for thermal sprayed coatings,
performed over seventy-five (75) years ago, were for repair and
maintenance. Components worn or corroded were coated, machined
and returned to service thereby saving the costs of replacement.
Coatings for dimensional restoration are selected for their similarity
and compatibility to the base metal rather than their ability
to improve wear resistance. Selection is based on likeness in
chemistry, color and performance. Galvanic corrosion is avoided
by matching base metal chemistry especially with copper, aluminum
and magnesium alloy parts. Self-bonding underlayments for surface
preparation are seldom used on either aluminum or magnesium parts
and never on copper, but are frequently used on iron, steels and
superalloys.
Consumables, based upon base metal composition
and service requirements, often used to repair machine element
components include:
· Pure aluminum
· Aluminum-silicon alloy
· Aluminum-iron-chrome-nickel composite
· Aluminum bronze
· Pure copper
· Copper-nickel alloy (Monel)
· Iron-chrome-aluminum-molybdenum composite
· Iron-aluminum-molybdenum-carbon-boron composite
· Iron-nickel-aluminum composite
· Iron-nickel-aluminum-molybdenum composite
· 304 stainless steel
· 316 stainless steel
· 410 stainless steel
· 420 stainless steel
· 431 stainless steel
· 17-4 PH
· Incoloy 800
· Incoloy 909
· Low carbon steel
· Pure molybdenum
· Nickel-aluminum alloys and composites
· Nickel-chrome-aluminum alloys and composites
· Nickel-chrome-aluminum-molybdenum-iron composites
· Nickel-chrome-aluminum-molybdenum-silicon-boron-iron-titania
composites
· Nickel-chrome-iron alloy
· Various Stellites
· Inconel 625
· Inconel 718
· René 41
· René 80
· René 95
