Suspension Feed Thermal Spray Technology – an Enabler for the Creation of Unique Surface Structures

Engineered surfaces for demanding applications, characterized by sub-micron or nano-scale structures typically require the use of thermal spray powder materials with very fine particle size distributions. Conventional, carrier-gas driven powder feed techniques haven shown to be of limited use for such fine powder materials; liquid-suspension feeding, however, has emerged as a reliable, and viable option for the delivery of sub-micron powders into thermal spray systems.

This new technology is slowly gaining recognition for its ability to enable to creation of unique surface structures, for applications ranging from thermal barrier coatings for gas turbine hot path parts, to hydrophobic surface coatings for aircraft wings, and has the potential to be a truly disruptive technology for thermal spray.

In this paper, the authors present various applications for suspension feed thermal spray technology, and introduce and discuss pathways towards productization of this promising technology, including but not limited to setup of suspension feed thermal spray systems.