Influential Factors of the Polymer Binder System in Filament HVOF

Using fine particles in thermal spraying provides several benefits. It allows for thinner and smoother coatings with enhanced mechanical and physical properties. This leads to more efficient material use and longer component lifespans. Since 2021, filament spraying has emerged as an alternative to suspension spraying of fine powders. In this method, a polymer serves as a solid dispersion medium for the coating material, similar to how a liquid medium functions in suspensions. The polymer acts only as a carrier and is burned off during the process. As filament spraying is a new technique, this study examines factors affecting the binder matrix of highly filled filaments used in High-Velocity Oxygen Fuel (HVOF) spraying (TopGun). Several filaments with Al2O3 filler material were created and sprayed using a modified TopGun system. Factors such as filament processability, binder combustion behavior, and coating quality were evaluated to identify key requirements for optimizing this method.