1、Thermal Spraying Practice, Theory, and ApplicationThermal Spraying Practice, Theory, and ApplicationThermal Spraying Practice, Theory, and Application Prepared by AWS Committee on Thermal Spraying Under the Direction of AWS Technical Activities Committee Approved by AWS Board of Directors AMERICAN W
2、ELDING SOCIETY, INC. 550 N.W. LeJeune Road P.O. Box 351040 Miami, Florida 33135Statement on Use of AWS Standards All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society are voluntary consensus standards that have been develop
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6、Box 351040, Miami, Florida 33135 1985 by American Welding Society. All rights reserved Printed in the United States of America Reprint: May 1993 Note: The primary purpose of AWS is to serve and benefit its members. To this end, AWS provides a forum for the exchange, consideration, and discussion of
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11、n official interpretation. This standard is subject to revision at any time by the AWS Thermal Spraying Committee. It must be reviewed every five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may b
12、e of use in improving this standard are requested and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS Thermal Spraying Committee and the author of the comments will be informed of the Committees response to the comments. Guests are invited to atte
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14、lding Society, 550 N.W. LeJeune Road, P. O. Box 351040, Miami, Florida 33135.Contents Personnel vii Foreword ix Chapter 1. Fundamentals of the Process 2 1.1 General 2 1.2 Definition 2 1.3 Process Variations 2 1.4 Nature of Sprayed Coatings 2 1.5 Applications 4 Chapter 2. Methods of Deposition 6 2.1
15、Basic Methods 6 2.2 Combustion 6 2.3 Electrical Heating 9 2.4 Controlled Atmosphere 10 Chapter 3. Surface Preparation 16 3.1 General 16 3.2 Cleaning and Handling 16 3.3 Roughening 17 3.4 Abrasive Grit Blasting 18 3.5 Macroroughening 24 3.6 Roughening Applications 26 3.7 Cleanliness After Roughening
16、26 3.8 Bond Coatings 27 Chapter 4. Coating Characteristics 30 4.1 Introduction ; 30 4.2 Formation and Structure of Coatings 31 4.3 Coating Properties 37 4.4 Coatings Produced Under Controlled Atmospheres 46 Chapter 5. Coating Selection and Application 50 5.1 Introduction 50 5.2 Bonding 50 5.3 Electr
17、ical Applications 51 5.4 Antifretting and Wear 51 5.5 Reclamation 51 5.6 Clearance Control Coatings 52 5.7 Environment 52 5.8 Decorative Coatings 54 5.9 Materials Classification 55 5.10 Applications 69 iiiCONTENTS Chapter 6. Training, Testing, and Quality Control 76 6.1 Introduction 76 6.2 Operator
18、76 6.3 Consumables 79 6.4 Equipment 84 6.5 Quality Control of Coatings 84 Chapter 7. Finishing of Coatings 94 7.1 Introduction 94 7.2 Finishing Methods 94 7.3 Grinding Wheel Selection 95 7.4 Grinding Variables 104 7.5 Superfinishing 105 7.6 Honing 105 7.7 Lapping 105 7.8 Overall Guidelines 105 Chapt
19、er 8. Post Treatment 108 8.1 Sealers 108 8.2 Fusing of Self-Fluxing Coatings 109 8.3 Other Post Treatments Ill Chapter 9. Ancillary Equipment 114 9.1 Introduction 114 9.2 Blasting 114 9.3 Air 118 9.4 Furnaces and Handling 119 9.5 Spray Booths and Rooms 122 Chapter 10. Economics 130 10.1 Introduction
20、 130 10.2 General Considerations 130 10.3 Installation 130 10.4 Government Regulations 131 10.5 Capital and Operating Costs 131 10.6 Job or Project Costing Formulas 134 10.7 Case History #1 Small Spring Spraying 136 10.8 Case History #2 Mandrel Repair 137 10.9 Case History #3 EMI Shielding of Plasti
21、c Cabinets 137 10.10 Case History #4 Diesel Engine Connecting Rod Bearings 138 10.11 Case History #5 Farm Machine Blades 140 10.12 Case History #6 Gripping Fingers Paper Bag Machines 140 10.13 Case History #7 Grinder Spindles 141 10.14 Case History #8 Automotive Valve Seats 142 10.15 Case History #9
22、 Antifretting Coatings on Jet Engine Stator Vanes 142 10.16 Case History #10 Abradable Clearance Control Coatings for Gas Turbine Compressors 143 10.17 Case History #11 Corrosion Protection 144 IVCONTENTS Chapter 11. Safety 148 11.1 Scope 148 11.2 Fire Prevention and Protection 148 11.3 Safe Operati
23、ng Considerations 148 11.4 Flame Spray Equipment 149 11.5 Plasma and Arc Equipment 150 11.6 Abrasive Blast Machines 150 11.7 Protection of Personnel 150 11.8 Ventilation 155 11.9 Toxic Material 156 11.10 Safety Standards 157 Appendix: Commonly Used Metric Conversions Conversions for Fahrenheit Celsi
24、us temperature scales 159 Abbreviations 163 Glossary 165 Bibliography 175 Index 181Personnel AWS Committee on Thermal Spraying F. N. Longo, Chairman M. L. Thorpe, 1st Vice Chairman J. Ritchie, 2nd Vice Chairman F. X. Neary, Secretary K. J. Altorfer A. D. Arnaut J. E. Baber R. Bajan C. Bishop* J. N.
25、Childs* G. Creeger G. Durmann R. J. Dybas D. Filippis F. W. Gartner P. F. Gerbosi H. S. Gonser* S. R. Goodspeed R. D. Green* A. J. Grubowski* J. Haas* E. S. Hamel J. O. Hoyden E. Hayes, Jr. S. N. Hayes H. Herman F. J. Hermanek G. M. Herterick D. L. Houck K. T. Janssen J. G. Johnston, HI A. E. Kuhar
26、F. Kvaska, Jr. * L. LaBossier S. G. Lee* K. Leovich M. A. Levinstein* M. Levy* C. R. McElroy R. E. Mahood* METCO Incorporated TAFA Incorporated Bender Machine, Incorporated American Welding Society Kidd Creek Mines, Limited Wall Colmonoy Corporation Naval Sea Systems Command Coatings Technology Corp
27、oration Bender Machine Incorporated Metal weld, Incorporated Special Metals Udimet Eutectic Corporation General Electric Company Plasma Coating Corporation F. W. Gartner Company METCO Incorporated Wall Colmonoy Corporation Bay State Abrasives Mapp Products David Taylor Naval Shipyard R some require special techniques. Substrate preparation prior to spraying is required for every thermal spraying process, and is virtually the same for each process. Two important steps are as follows:
