Thermal Spray Process Training-a New Perspective

Training courses for thermal spray operators have been developed with limited success due to the main emphasis on theory and classroom lecture.  As has been observed in Coating Evaluation training like course taught at IMR in Ithaca, NY, the key to successful training is the hands-on or in this case the actual work with the guns, powder, and control consoles for the thermal spray process being taught.  Proper spray methods will be taught in any course.  However, students often learn more from “improper” techniques and examples, really understanding concepts such as why the change in a gas flow or powder feed rate ultimately affects the final coating result.  The use of plume sensors like the Accuraspray from Tecnar can also be used to significantly illustrate these principles.  Students are taught to become” problem solvers”, filling their    thermal spray “toolbox” with troubleshooting techniques developed by first hearing the theory in the classroom and then having that concept demonstrated in hands-on sessions.  Courses are usually one week in length at the company’s facility and customized to the vendor needs.   Cases studies for both improved production and cost savings will be presented.