International Thermal Spray & Surface Engineering

AUGUST 2010 • VOL 5 • ISSUE 3

INTERNATIONAL THERMAL SPRAY & SURFACE ENGINEERING

THE OFFICIAL NEWSLETTER OF THE ASM THERMAL SPRAY SOCIETY

Auto Applications Benefit from Thermal Spray

JTST Highlights Society News

tss.asminternational.org

i AUGUST 2010 • VOL 5 • ISSUE 3 T S S e

TM iTSSe 1

INTERNATIONAL THERMAL SPRAY & SURFACE ENGINEERING CONTENTS

THE OFFICIAL NEWSLETTER OF THE ASM THERMAL SPRAY SOCIETY

6 Sulzer Metco SUMEBore Technology Editors Robert Gansert William Jarosinski Targets Cylinder Bore Coating Managing Editor Ed Kubel Applications Art Director Barbara L. Brody Production Manager Joanne Miller Publisher Joe Zion

10 Thermal Spray Coatings Enhance National Account Manager High Performance Engine Valves Kelly Thomas, CEM.CMP Materials Park, Ohio tel: 440/338-1733 12 Application Note: e-mail: [email protected] Thermal Spray Society Plasma Spray Ceramic Coatings Offer Executive Committee Solutions to Demanding Automotive Mitchell Dorfman, President Applications Peter Hanneforth, Immediate Past President Charles Kay, Vice President Departments William Lenling, Secretary/Treasurer Randall S. Barnes, Executive Director 2 Message from the TSS President

3 ASM Thermal Spray Society News International Thermal Spray & Surface EngineeringTM is published quarterly by ASM International®, 15 JTST Highlights 9639 Kinsman Road, Materials Park, OH 44073; tel: 440/338-5151; www.asminternational.org. Vol. 5, No. 3. Copyright© 2010 by ASM International®. All rights reserved. About the cover Operator sprays premium performance plasma magnesia/zirconia The acceptance and publication of manuscripts in International Thermal Spray & Surface Engineering ceramic thermal-barrier coating on exhaust pipes, which enables does not imply that the editors or ASM International® high-performance vehicles to run at cooler temperatures. Photo courtesy accept, approve, or endorse the data, opinions, and of Woof Thermal Management Technology, Bradford, West Yorkshire, UK. conclusions of the authors. Although manuscripts published in International Thermal Spray & Surface www.woof-tmt.com. Engineering are intended to have archival significance, author’s data and interpretations are frequently insufficient to be directly translatable to specific design, Editorial Opportunities for iTSSe in 2010 production, testing, or performance applications without independent examination and verification The editorial focus for iTSSe in 2010 reflects established of their applicability and suitability by professionally applications of thermal spray technology such as corrosion qualified personnel. and transportation, as well as new applications representing new opportunities for coatings and surface engineering.

Consider submitting an article for the November issue, which focuses on thermal spray applications in the Energy sector.

To contribute an article, please contact the editors c/o Ed Kubel at [email protected]. To advertise, please contact Kelly Thomas, [email protected].

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 33 i T S Message from the President S e ver the past two years, it has been my pleasure to serve as TSS president. Our overall mission has been the sup- Oport of industry, government, and the research & academia community by helping to expand global markets and applications. This has been achieved through the dissemination of new technology, training and education, and new 2 alliances with other professional and trade associations. Our strategy has been well documented in various JTST and iTSSe commentaries. I’m happy to report that with the strong leadership of our TSS committee chairs and our TSS Board of Directors, we are well on our way in achieving our objectives. Here are a few highlights of TSS accomplish- ments over the past two years: • Expansion and growth of Industrial Advisory Committee (IAC): Over the past two years, we have added representatives from RRC, Siemens, and Cummings to our Industrial Advisory team together with suppliers from Sulzer Metco, Praxair, and H.C. Starck, which will serve to give valuable feedback to the strategic direction the TSS Board takes in the upcoming years. • New, creative ITSC event programming: Market-focused presentations in addition to technology-related presentations, increased networking opportunities, and new training classes. • Expansion of TSS topical events into markets outside of the U.S.: TSS has had successful topical events in Canada EDITORIAL and will have a wear and corrosion topical in South America in November 2011. • Redesign of the iTTSe newsletter and JTST: The newsletter was redesigned to promote new and existing TS applications and markets and industry news, while JTST is focused on the dissemination of advanced science and technology. • Redesign of a faster, more user-friendly TSS Web site: The new home page allows for faster access to TSS products and services, and the site will continue to expand and be the key component for information transfer and membership networking. • Populated the TSS Certification Committee: TSS chair and committee, with ASM support, laid the foundation to implement the Certified Thermal Spray Operator (CTSO) Program and the CTSO Grandfathering Program. The certification program is on track and is scheduled to be fully implemented in 2011, and is fully endorsed by the IAC. • Development of new TSS leaders: Succession planning is important, and over the past few years the TSS leaders have compiled a strong list of volunteers capable of serving as leaders of TSS. • Development of alliances with other professional societies and trade associations: TSS continues to grow relationships and develop reciprocal training, education, and events with NACE and ASME to have greater market outreach and penetration into new industries with the goal of informing designers and engineers about the value and benefits of TS coatings. We are also working with the ITSA executive management team to achieve common goals and objectives. • Recognition of existing leadership through awards and ASM positions: Many TSS members have received prestigious awards over the past few years. In addition, Dr. Mark Smith and Prof. Chris Berndt will become ASM president and vice president, respectively, in October 2010. Both are former TSS Presidents that have had the full support of the TSS. • Development of new award recognition programs: The TSS Awards Committee recommended modifying the TSS President’s Award, which now will be known as the “Thermal Spray Society President’s Award for Meritorious Service,” and established the “TSS Research Award” for mid-level engineers and scientists. • Implementation of TSS Student Board Program: The TSS followed ASM’s lead in developing a program that allows valuable feedback to the TSS board from students entering the thermal spray profession. • Redirection of TSS training to align itself with the TSS Certification Program. The importance of the IAC can not be underestimated because of the need to engage industry for feedback on TSS strategic decisions. Also important in my opinion is the need to establish an Academic and Research Advisory Coun- cil, which can help develop strategy on how to improve and grow TSS research in the U.S. Today, it has become very clear that TS technology is present in Europe and Asia. The universities are the lifeline for TSS growth of people and ideas, so it is critical that we find better ways to promote TSS research in the U.S. Finally, I would like to thank Thom Passek, Randall Barnes, Sarina Pastoric, and other ASM staff; Klaus Middeldorf, Jens Jerzembeck, and Simon Mahlstedt, our German Welding Society partners; Peter Heinrich, my general co-chair for the various ITSC conferences; the TSS executive board; my fellow TSS board members, key advisors, and former past TSS presidents (Mark Smith, Rick Knight, Robert Tucker Jr., and Chris Berndt) for their continued support throughout the two years that I have been president. The future is bright, and I’m confident that incoming TSS president Charlie Kay will continue to move TSS forward in the years ahead.

Mitchell R. Dorfman President, ASM Thermal Spray Society

34 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i T Dorfman and Marple named TSS EVENTS S ASM Fellows S Mitchell R. Dorfman e and Basil R. Marple have been elected to the 2010 3 Class of ASM Fellows.

ASM established the TSS NEWS honor of ASM Fellow in 1969 to recognize mem- Organizers: Mr. Al Kay, President, ASB Industries, Barberton, Ohio; and bers for their distin- Dr. J. Karthikeyan, Director of Research and Development, ASB Industries guished contributions to materials science and engineering The two-day technical program includes presentations on Interna- and to develop a broadly based forum of technical and pro- tional Status, Process Development, Equipment & Supplies, and Ap- fessional leaders to serve as advisors to the Society. plications. Monday, Sept. 27 will feature a Keynote address by Mr. Vic Champagne, Army Research Laboratory, USA, on Cold Spray: From Lab- Mitch is a Sulzer Metco Fellow, Sulzer Metco (US) Inc., oratory Curiosity to Production. A Panel Discussion is scheduled for Westbury, N.Y., and is the current president of the ASM Tuesday, Sept. 28 from 10:40 a.m. – 12:10 p.m. Table-Top Exhibits are Thermal Spray Society. His citation is “for outstanding con- open Monday from 9:30 a.m.- 8:00 p.m. and Tuesday from 7:00 a.m. – tributions to the technology and application of thermal spray noon. materials and coating worldwide, and for outstanding pro- To register, visit http://asmcommunity.asminternational.org/content/ Events/coldspray/. For more information, contact Jessica Bauer at +1 fessional service to technical societies.” (440) 338-5151, ext. 5581, or email: Jessica.bauer@asminternaitonal. Basil is retired Senior Research Officer, Industrial Mate- org rials Institute, National Research Council of Canada. His citation is “for significant contributions to the science and technology of thermal spray, and for providing leadership in disseminating technical information.” He has been a member of the TSS Board since 2006 and is Lead Editor of JTST. The award will be conferred upon Mitch and Basil at the Convocation of Fellows during the ASM Awards Dinner on Symposium Champions Tuesday, October 19, 2010 at MS&T 2010 in Houston, • Dr. Rogerio Lima, National Research Council of Canada (NRC), Canada; email: [email protected] Texas. • Mr. André O’Czerny, Sulzer Metco Inc., USA; email: andre.oczerny@ sulzer.com Nominations Sought for Solve your wear and corrosion problems. Join international experts for two days of education, networking, and exhibits focusing on the latest Thermal Spray Hall of Fame advancements in preventing wear and corrosion including thermal spray The Thermal Spray Hall of Fame, established in 1993 by coatings. the Thermal Spray Society of ASM International, recog- For more information, visit http://asmcommunity.asminternational.org/ content/Events/corrosionwear/. nizes and honors outstanding leaders who have made significant contributions to the science, technology, practice, education, management, and advancement of thermal spray. For a copy of the rules, nomination form and list of previous recipients go to www.asminternational.org/tss and click Networking and then Connections; or contact Sarina Pas- toric at [email protected]. Nominations are due September 30, 2010. ITSC 2010 in Singapore Deemed a Great Success The Thermal Spray community recently came together in May for another International Thermal Spray Conference (ITSC 2010) in Singapore. This year’s event, entitled “Ther- The plenary session at ITSC 2010 saw a packed house. mal Spray: Global Solutions for Future Applications,” was organized by the German Welding Society with the ASM for the exposition. The approximate distribution of atten- Thermal Spray Society and IIW serving as co-sponsors. The dees was 50% from Europe, 20% from the Americas, and event featured four educational classes; a three-day, four 30% from Asia Pacific. A future goal for international events track technical program; Young Scientist presentations; in Asia will be to have greater industry and university par- poster sessions; and an Awards Banquet for Best Paper. ticipation from the Americas and greater participation from Despite the challenging economy, more than 350 persons local industrial leaders from the region. This should be pos- registered for the technical program and nearly 400 persons sible through longer term planning and networking, and a

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 35 i T strong working relationship with local organizers. This indicates a continual a need for training and educa- S A highlight of the event was the excellent turnout tion. This becomes even more important as the world be- S e (about 75 registrants) for the four educational classes: Un- comes “smaller” through global communication, and as derstanding and Improving your Thermal Spray Process; international companies move manufacturing and tech- Thermal Spray Technology; Gas Turbine Metallurgy, nology centers to lower cost regions. 4 Coating, and Repair Technology; and Metallographic One TSS strategic initiative is to implement reciprocal Preparation and Evaluation of Thermal Spray Coatings. training classes in other professional and trade association

JTST Editorial Committee network more than lesser cited journals. References from one ar- JTST achieves its highest Impact Factor yet! ticle in a journal to another article from the same journal are re- According to the recently released 2009 Impact Factors, the Jour- moved, so that Eigenfactor Scores are not influenced by journal nal of Thermal Spray Technology (JTST) has received its highest Im- self-citation. pact Factor ever: a spectacular 1.338! Provided by Dr. Robert Tucker Jr., chair JTST Editorial Committee Impact Factor is a measure of the frequency with which the “average article” in a journal has been cited in a particular year. The TSS NEWS TSS Programming Committee annual Impact Factor is a ratio between citations and recent citable Two upcoming TSS events taking place in 2010 are the TSS Cold items published, calculated by dividing the number of current year Spray Conference in Akron, Ohio, September 27-28, and the citations to the source items published in that journal during the pre- TSS/NACE joint Symposium on Practical Solutions for Wear & Corro- vious two years. sion Problems in São Paulo, Brazil, November 8-10. (See more Because Impact Factor measures the previous two years of pub- specifics about the conferences on p 3). Both conferences have lication, this is the first Impact Factor measured for JTST since it’s strong and active organizers who are creating forums to exchange been published by Springer starting in 2007. One of the reasons ASM information on research and development and new markets in ther- partnered with a commercial publisher (starting in 2007) was to mal spray.

COMMITTEE REPORTS drive increased use, visibility, and impact among academics and re- The Cold Spray Conference is the third such TSS conference searchers worldwide. Beginning in 2007, all articles were published in Akron. This event is a true international meeting for persons inter- online first on SpringerLink prior to print publication, and were also ested in cold spray technology. A unique part of the conference is the available to all users of the 2000+ institutions that had access to diverse technical program specifically geared to advanced cold- JTST through online deals (consortia, multi-site licenses, and site li- spray technology, together with the opportunity to see equipment censes). The number of institutions having exposure to JTST in 2009 demonstrations as part of the conference program. reached 4,556. The Symposium on Practical Solutions for Wear and Corrosion The JTST Impact Factor for the past eight years is shown below. Problems (co-sponsored by TSS and NACE International) is the An Impact Factor of 1.0 is considered a good, healthy number for a first time TSS is hosting an event in Brazil. This event will address basic research journal. major wear and corrosion problems in the automotive, steel, paper, textile, and oil and gas industries. The organizers created 2002 2003 2004 2005 2006 2007 2008 2009 a unique registration sponsorship option for thermal spray com- 0.591 0.726 1.068 0.875 1.278 1.204 1.200 1.338 panies, which allows the companies to sponsor attendees (em- ployees, clients, or colleagues) to attend the conference on a JTST Editor-in-Chief Christian Moreau, FASM, thanked the JTST complimentary basis. Registration sponsorship total more than editorial team (Basil Marple, Kendall Hollis, Seiji Kuroda, and Armelle $60,000 – a great showing for a first time conference. Vardelle), Mary Anne Fleming (ASM staff), and members of the JTST ITSC 2011 will be held September 26-29 in Hamburg, Germany. Editorial Committee, chaired by Robert Tucker, FASM, for their hard The technical program will be organized by the German Welding So- work and contributions that led to this achievement. Dr. Moreau said, ciety (DVS) and other organizations to promote thermal spray tech- “We can be proud of this result as it is a consequence of our efforts nology in new industries such as automated robotic joining and in attracting high quality papers, performing thorough reviews, and marine. Based on the partnership between TSS and DVS, ITSC ro- reducing the time to publish. Our authors and reviewers are clearly tates the venue each year between Europe, Pacific Rim, and North at the heart of this progress too.” America. Each ITSC involves sharing of responsibilities to promote There is more good news in the data published in ISI Web of Sci- worldwide participation in thermal spray technology. The 2011 Call ence in 2009. JTST has the third highest “Article Influence Score” for Papers will be available in the coming months. (0.611) among the 15 journals listed in its category (MATERIALS SCI- ITSC 2012 is planned for Houston, Texas, USA in May. Preliminary ENCE, COATINGS & FILMS), even higher than Surface and Coatings planning of specific symposia and the exposition has begun. Hous- Technol. (0.608) and Thin Solid Film (0.594). ton was selected as a viable location due to the oil, gas, turbine, de- The Article Influence determines the average influence of a jour- fense, and electronics industries in the region. ITSC 2012 looks to nal’s articles over the first five years after publication. It is calcu- highlight thermal spray applications in these industries and build on lated by dividing a journal’s Eigenfactor Score by the number of specific topic areas from ITSC 2011. articles in the journal, normalized as a fraction of all articles in all South Korea has been selected as the location for ITSC 2013. publications. This measure is roughly analogous to the 5-year Jour- Strong presentations from potential countries and organizers were nal Impact Factor in that it is a ratio of a journal’s citation influence presented during ITSC 2010 in Singapore to ITSC event organizers. to the size of the journal’s article contribution over a period of five Each presentation showed the impact of the thermal spray industry years. in that region and the strong support of the respective local commit- The Eigenfactor Score calculation is based on the number of tee. After review and discussion, South Korea was chosen as the lo- times articles from the journal published in the past five years have cation for 2013. The ITSC event committee thanks all individuals been cited in the JCR year, and it also considers which journals have who contributed presentations at ITSC 2010. contributed these citations, so highly cited journals influence the Provided by Charlie Kay, chair, TSS Programming Committee.

36 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i events. To begin implementing this strategy in 2010, ASM Launches New Learning T ASME’s TurboExpo Gas Turbine Metallurgy class (orga- S Management System S nized by Jeff Smith and Doug Nagy) was held at ITSC e 2010, and Dr. Robert Tucker Jr. was the instructor for a Study Thermal Spray Technology class entitled “Thermal Spray and Other Coatings for Gas (6-lesson series) online. Turbines – Selection & Application for OEM and Main- The Online Learning Center offers accessible learning 5 tenance & Repair” at ASME’s TurboExpo event in Glas- around the clock using the new Learning Management gow, Scotland. The value of this strategy is global System (LMS). Persons interested in learning/training outreach of TS technology to new designers and applica- gain access to a variety of learning formats, with a system tors in both non-thermal spray conferences, as well TSS- that is easy to navigate. ASM is positioned to help its focused events to provide application-specific education. members and industry professionals more effectively and The educational focus at ITSC 2010 was aerospace appli- conveniently achieve their career development goals. cations because of the high concentration of the aerospace Benefits include: industry in the Singapore region. • Complete online access to educational offerings 24 hours a day, 7 days a week • Online registration for all education courses, including online, lecture, lab, webinars, and self-study • Single sign-on into ASM site and Online Training Center • Access to online tests, assessments, and examinations • Complete training history with details such as course enrollments, completions, and test results • Automated awarding and self-printing of certificates • Automatic tracking of continuing education unit certificates and extension program diplomas All self-studies and instructor led training (ILT)—both lab and lecture—are live on the LMS. For more information, contact Gerry Peterson at ASM: tel: 440-338-5151, Exhibitors at ITSC 2010. ext. 5654.

asbindustries.com [email protected]

ADVANCED MATERIALS & PROCESSES • MAY 2010 37 i T S Sulzer Metco SUMEBore Technology S e Targets Cylinder Bore Coating Applications

6 Richard McCullough wear demands inherent in the application. Alloying low- Operations Manager, SUMEBore friction materials (e.g., molybdenum) into thermal spray powders specific to the application can result in reducing Sulzer Metco friction losses and thereby improve efficiency and horse- Westbury, N.Y. power. Many of these alloys cannot be plated, and are pro- hibitively expensive to cast as liners. ulzer Metco, Westbury, N.Y., a leader in the sur- A plasma coated cylinder bore offers another benefit face engineering industry for decades, has devel- for customers looking to eliminate the need for liners. As Soped many technological advancements for use in engine block casting technology evolves, many engine a variety of industries. Today, the aerospace and petro- manufacturers are designing lighter, stronger cylinder chemical industries are some examples of industries that blocks made of aluminum alloys. As aluminum has poor benefit from the application of coatings on various com- wear properties, a plasma spray coating can be applied di- ponents to improve aspects of performance in their respec- rectly to the aluminum cylinder bore, which produces the tive applications. desired properties and allows designers to reduce the en- The automotive industry has also benefited from the ap- tire cylinder block length by spacing the cylinders closer plication of surface treatments. Certain critical components together. The significant weight and dimensional reduc- in every passenger car, tions improve the performance and efficiency of the over- truck, motorcycle, and all driving package. racing car have some de- Other benefits of plasma sprayed cylinder bores are re- gree of surface treatment. duced emissions and improved corrosion resistance. Re- Some of these treatments duced emissions result from the special porous surface, include various chemical which allows a reduction in oil consumption/burn-off. The deposition processes, improved corrosion resistance is important to allow the painting, and thermal use of biofuels or fuels having higher sulfur contents. spray coatings, and are Sulzer Metco has various plasma spray devices avail- typically engineered in an able for these applications, the choice of which depends effort to improve a vehi- on the geometry of the component being coated. For ex- cle’s driving dynamics, ample, the most efficient tool for applying coatings to performance, efficiency, most engine block configurations is the Sulzer Metco Ro- and durability. taPlasma®. This is a unique plasma spray device that Sulzer Metco has pi- eliminates the need to rotate the engine block due to ob- oneered the innovation vious physical and production efficiency limitations. and development of ther- Using patented technology, the plasma gun is mounted to mal spray coatings for a rotating device that incorporates the interfacing and seal- automotive drive-train ing technology necessary to provide the cooling water, components for decades. power, plasma gases and powder to the gun. The entire One of the company’s unit is then mounted to the robot and manipulated in and Fig. 1 — Typical setup of a V-8 engine most successful coating out of the cylinder block while the block remains fixed. block in the plasma spray booth. technologies has been the For larger cylinder liner applications—typically in excess application of specifically of 200 mm (8 in.) in diameter—there is the capability of engineered coatings to the cylinder bores of engine using alternate plasma spray technology that operates at blocks. higher power levels and material feed rates, thus increasing production efficiency. Typically, these components, Cylinder Bore Coating Technology not the plasma gun, are rotated. Traditional methods of achieving desirable properties The availability of a nearly infinite number of powder in cylinder bores have been to either plate the bores using compositions and the ability to manipulate the coating a chemical process or to insert liners into the cylinder. The properties with the plasma spray parameters means that plating methods currently in use have issues with failure this process has the capability of being tailored to each in certain service conditions, and cylinder liners add un- cylinder block service requirement. Therefore, it offers necessary weight and length to engine block dimensions. greater variety than traditional methods of surface treat- Coating a cylinder wall provides many benefits that can be ment like plating or lining technologies. Figure 1 illus- tailored to a specific application. For example, a high-rev- trates a V-8 configuration engine block undergoing a spray olution race engine may benefit from the application of a setup exercise in the plasma spray booth. coating tailored specifically to cope with the friction and Sulzer Metco currently has production plasma spray

38 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i T S S e systems in its Wohlen, Switzerland, plant, that are used to With these benefits in 7 apply coatings to various diesel- and gasoline-powered mind, a strategic decision engine blocks (including some Formula 1, Touring car, was made to install a pro- and LeMans racing team engines), various aircraft engine totype and pilot produc- blocks, and some limited-production supercars including tion facility in the U.S. the Bugatti Veyron and the new Aston Martin One-77. The large automotive, The Volkswagen engine plant in Salzgitter, Germany, heavy-duty truck, and has coated in excess of three-million gasoline- and diesel- railway industries in the engine bores on its production line over the past five years U.S. are likely customers with this technology. interested in the benefits Fig. 2 — Portable CMM (FARO® arm) of the plasma process. measuring cylinder bore dimensions of a SUMEBore® Technology The new cell will be 6-cylinder engine block. Increasing environmental awareness globally and the used to develop a new demand for economy and efficiency improvements in the brand identity. SUMEBore technology will now be the automotive industry have pressured engine designers to brand that identifies the plasma process with any perform- be more creative about limiting emissions and reducing ance enhancement (whether it be power, economy, or ef- fuel and oil consumption. With the ability to tailor the ficiency) in cylinder bore applications. The cell will also coating to the application, plasma spray coatings offer a be used to develop high-volume cylinder bore coating ap- favorable solution to increasing the overall efficiency of plications for installation at key OEMs and also to per- the internal combustion engine. If we consider a large form small batch production coating work for high truck fleet for example, the fleet operator could literally value/low volume cylinder bore applications (e.g., save millions of dollars per year in fuel and oil costs with NASCAR). just a 2-3% increase in engine operating efficiency. The SUMEBore production cell was installed at Sulzer

progressivesurface.com

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 39 i T SUMEBore Technology, continued S S e Metco’s Westbury, N.Y., plant to take advantage of its ex- machine (CMM) can measure any conceivable dimension isting thermal spray technology, experience, and business on an engine block or large cylinder liner to generate and facility support functions, which could work with the drawings and inspection reports. 8 various automotive OEMs, NASCAR race teams, and The Westbury SUMEBore installation accommodates commercial trucking and locomotive manufacturers cylinder blocks ranging from single cylinder to V-12 located throughout the U.S. variants weighing up to 500 kg (1,000 lb) and is The SUMEBore installation team also capable of coating individual cylinder liners set specific goals regarding the for any cylinder application up to functionality and appearance approximately 300 mm (12 in.) in of the cell. Wherever diameter. The final layout of the cell possible, the team is shown in Fig. 3. employed lean in Fig. 3. The SUMEBore manufacturing plasma spray booth principles, is shown in Fig. 4. paid strict The booth, robot, attention to the MultiCoat® finer details, plasma control and attained new system and dust collection technologies to are all integrated to ensure safe, increase produc- consistent operation. The climate tivity and maintain control and dust collection systems the highest quality incorporate remote access and alarm standards. notification of critical supply failures via email Figure 2 illustrates new and text message alerts to ensure safe and environ- technology for the cell. The portable coordinate measuring Fig. 3 — SUMEBore cell layout. Don’t be Left out in the Cold. TSS Cold Spray Conference Plan today for this intensive two-day meeting featuring invited talks by cold spray experts from September 27-28, 2010 around the world. Keep current with today’s cold Akron, Ohio spray technology. Along with targeted presentations on applications for specific industries, there are several networking Don’t miss an opportunity to join the growing list opportunities as well as a poster session, Q&A panel of exhibitors and sponsors. For more information, discussion and table top exhibit area planned for please contact Kelly Thomas, National Account information sharing, connecting with colleagues and Manager, [email protected]@asminternational.org just for fun. or 440.338.1733. • Gain basic understanding of the cold spray process • Follow global R&D programs on cold spray technology See you in September in Akron! • Receive first-hand information on industrial Advance your industry and your career. applications • Network with international experts Plan and register today. www.asminternational.org/coldspraywww.asminernational.org/coldspray

Sponsored by: Supported by: Media Sponsor:

Photo courtesy of ASB Industries.

40 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i T S S e

Fig. 4 — SUMEBore plasma spray booth. Fig. 5 — Sulzer Metco Westbury’s SUMEBore production cell. mentally compliant operation. ISO 9001:2000 and AS9100 quality systems) to ensure The completed SUMEBore production cell is shown in the highest levels of quality are maintained. Fig. 5. Approximately 4500 ft2 (~418 m2) of office area The new cell is capable of small batch production coat- has been converted into productive space. The cell in- ing of a large variety of cylinder block configurations and cludes all the necessary coating support functions; a new will provide an ideal template from which new produc- SAP plant to handle all of the business functions neces- tion systems business can be generated to address the sary to ensure a smooth, transparent operation; and new enormous growth of the internal combustion engine mar- quality procedures (incorporated into Westbury’s existing ket in North and South America. iTSSe

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Braze Laser Rapid Prototyping Thermal Spray PM Millforms

www.cartech.com For more information email [email protected]

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 41 i T S Thermal Spray Coatings S e and High Performance Engine Valves 10 Guido Keijzers of high-performance engine valves take advantage of the Del West USA available techniques. The valve stem requires a coating that exhibits good wear Valencia, Calif. characteristics combined with reduced friction and inherent lubricity. A common coating type applied on the stem is oatings having good tribological characteristics are a plasma sprayed molybdenum-based powder (75% Mo) of great importance in the racing industry, and have with a NiCr flux, which has for many years provided a re- Cthe ability to greatly enhance material properties. liable coating solution for high-performance valves. It also Wear resistance and low friction provide the key to endurance has been used widely in piston-ring applications. and high performance. The titanium engine valve is a great Key to creating an optimal coating system is proper pow- example of enhancing its inherently poor material wear char- der morphology and size distribution. For instance, unmelted acteristics by utilizing different coating techniques. particles may not bond sufficiently, thereby creating a pre- Several techniques currently are being used to protect the mature coating failure, which ultimately causes seizing of the titanium valve, such as physi- valve in the valve guide, resulting in an engine failure. cal vapor deposition (PVD), After applying the coating, it is ground to a tightly con- chemical vapor deposition trolled diameter and required surface finish. The final coat- (CVD) and thermal spray. Al- ing surface exhibits a clear amount of porosity that holds though PVD and CVD coat- small amounts of oil, which provides enhanced lubricity ings are initially more during the reciprocating sliding motion of the valve stem expensive due to their required against the valve guide. large capital investments, they Actuation of the valve occurs at the tip of the valve stem. are widely used, have become If not protected by a tool steel insert tip, this surface requires more affordable, and are gain- protection using a thin film or thermal spray coating. Com- ing in popularity for a variety monly used thermal spray coatings are Cr3C2/NiCr or of reasons. Current tighter en- WC/Co. High compressive and impact forces require this Thermal spray coatings are used vironmental regulations have coating to be free of cracks and porosity, with an even dis- on high-performance auto-engine raised the economical thresh- tribution of the carbide particles. Ductility can be controlled valves to increase wear properties old for start-up booths, or re- by modifying the amount of metal (NiCr, or Co) in the and enhance lubricity. quire costly modifications to sprayed powder. existing operations. In addition to these mandatory invest- In the closed position, the valve head provides a seal to ments, government agencies may increase restrictions on the combustion chamber. High-performance engines tend the consumption of hazardous substances (e.g., powders to decelerate rapidly onto the seat ring. Sliding of the valve containing carcinogenic metals). surface onto the seat, impact forces on landing, as well as However, thermal spray coatings are still widely applied, wear by intake contamination (such as dust and sand) or and have particular advantages from production, as well as combustion debris often require a hard surface to protect application standpoints. Thermal spray has been used for the valve head chamfer. Due to the shock loads from clos- many years to apply coatings on titanium valves. Its ease ing and the reduced cross sectional area, this particular sur- of operation and low initial investment has made it a popu- face is prone to fatigue cracking. In certain applications a lar technique. From a technical perspective, thermal spray Stellite (Deloro Stellite) coating is still applied to the seat coatings still are widely popular and used frequently. The chamfer. The need for undercutting the material locally to method offers the ability to choose the optimal spray fill in the area with Stellite, combined with the risk of melt- method and equipment, and a wide variety of powders also ing the base material and resulting solidification cracks, re- is available, which can be relatively easily tailored to the duces the fatigue strength by such a large extent that this specific needs of the application. Therefore, manufacturers technique is no longer preferred on titanium valves. For SEM image of cross high-performance valves, one has to resort to thin film coat- section of a 75% ings at this particular wear surface. Mo-25% NiCr plasma On a global scale, the market for thermal spray is increas- spray coating. ing for a variety of automotive parts. In addition to its use on high-performance valves, thermal spray continues to provide new coating solutions in different applications, such as cylinder bores and transmission parts. iTSSe

For more information: Guido Keijzers, VP of Materials Engi- neering and Development, Del West USA, Valencia, Calif.; tel: 661-295-5700; [email protected].

42 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i T S S e

www.asminternational.org/events

It pays to be a TSS member. Discover the member benefits. Get the value only your professional society can give. “ THE VALUE OF TSS IS Chapters – Network and get involved with your local thermal spray SOMETHING community. Affiliation is free for all members. THAT I USE Conferences and Expositions – Keep current with conferences, expositions, ALMOST technical symposia and networking. Receive member discounts on registration fees. EVERY DAY.” Education – Stay competitive in today’s challenging market. Special member Charles Kay pricing on seminars, webinars, onsite, home-study, and online courses. Vice President Quarterly iTSSe (International Thermal Spray & EngineeringTM) newsletter ASB Industries, Inc. FREE online, full-text access to Metallurgical Transactions A & B, going back to the first issue And, you earn extra ASM Points when Monthly ASM member magazine, you also join TSS. Use them for document Advanced Materials & Processes®, downloads and premium content available at www.asminternational.org. with special Thermal Spray focus issues and ASM eNews, including Go to www.asminternational.org/tss online access. and get the payoff. ASM Career Center – gain access to useful tools to help you take the next step in your professional life.

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 43 i T S Plasma Spray Ceramic Coatings Offer S e Solutions to Demanding Automotive Applications oof Thermal Management Technology, Brad- industry. Woof coatings have been specifically developed 12 ford, West Yorkshire, UK, a customer of Met- to reduce under bonnet temperatures, increase power out- W allisation Ltd. (Dudley, West Midlands, UK), put, and increase the reliability and longevity of ancillary is applying well-proven plasma ceramic coatings technol- components. ogy to high-performance automotive applications to pro- The durable plasma ceramic coating provides a highly vide highly effective thermal barriers in extreme effective thermal barrier on exhausts, turbos, and brake conditions. parts, and enables high-performance vehicles to run at The company provides premium specialist coatings and cooler temperatures. The plasma ceramic coatings work engineering services to industry and end users. The by preventing heat transfer, which means an increase in APPLICATION plasma ceramic coatings power and reduced heat input to other components. A typ- NOTE range has been developed ical drop of 25ºC (45ºF) in under bonnet temperature will for the nuclear industry, but result in decreased intake temperature, which can give up is proving itself to be very to a 5% increase in power and significantly increases an- effective and valuable in cillary reliability. heavy engineering, aero- The Woof plasma ceramic coatings can reduce surface space, and motorsport in- temperatures by up to 160ºC (290 ºF) and can withstand dustries. temperatures of up to 1400ºC (2550ºF). This compares Using Metallisation plas- with typical standard ceramic-containing paint, which ma spray equipment, Woof may only reduce surface temperatures by up to 9%. Thermal Management Tech- The Woof premium performance plasma ceramic coat- nology has extensive expe- ing contains magnesia/zirconia, and offers the best ther- Plasma sprayed magnesia/zirconia ceramic coating on manifold pipes rience in supplying pre- mal barrier coating. The coating is creamy white in color, provides premium thermal barrier mium thermal barrier with a slightly rough surface texture. performance. coatings to the motorsport There is an alternative darker plasma ceramic coating,

www.asminternational.org/CTSO

44 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i T S S e which contains alumina/titania, and has a grey colored appearance. This offers similar reductions in surface temper- 13 ature, although the radiation of heat is slightly greater than with magnesia/zirconia. In all cases, except maybe some extreme situations, this coating gives the performance advantage, but is less prone to aesthetic degradation due to its darker color. This means the coating stays fresh and smart looking, which may be important for concourse cars. The well-known white exhaust coatings became very Dark colored plasma sprayed Woof Thermal Management alumina/titania ceramic coating Technology’s well-proven popular in the 1990s and are applied on many new breed offers premium thermal barrier plasma spray ceramic coatings turbo-charged four-wheel drive world rally cars. The proof performance, but is less prone are seeing wide use in high- of their success is demonstrated by the teams who opted for to aesthetic degradation. performance automotive these coatings, which include key players in the industry applications. such as Subaru and Mitsubishi. within the motorsport industry. To support our commitment These days, the use of ceramic coatings has become to the industry, we sponsored the Lancashire & Districts widespread including Touring Cars, Super Car manufactur- Subaru owners’ club ‘Best in Show’ trophy at the presti- ers and various rallying disciplines, which has led through gious Preston Flag Market car show in April 2010. This al- to private owners using the coatings on track day cars and lowed us to get close to the car owners and provided great fast road cars. Woof Thermal Management Technology cur- networking opportunities.” iTSSe rently supplies Mellors Elliot Motorsport and the works Proton S2000 Team. For more information on Woof Thermal Management Technol- John Holdsworth, managing director at Woof Thermal ogy, please visit www.woof-tmt.com. For more information on Management Technology, says: “It’s a really exciting time metal spraying solutions, or Metallisation Ltd., please contact Stu- for Woof and we are thrilled to be expanding our services art Milton at 01384 252 464, or visit www.metallisation.com.

www.tekna.com [email protected]

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 45 i T S Certified Thermal Spray Operator S e Program Update In response to input from the Thermal Spray Certification Committee (TSCC), the grandfathering program for the Cer- 14 tified Thermal Spray Operator (CTSO) Program is being extended. The program will now end August 31, 2010. Take advantage of this extension and complete an application before the end of summer. During the grandfathering period—open only to those having 15 years of experience— applicants can waive the written tests and access one performance test; all for half price. Check the TSS Web site (http://tss.asminternational.org/portal/site/tss/Certification/Grand- fathering/) to determine whether you qualify for this program. Performance tests will be available later this year. Five performance exams will be fielded: wire arc, air plasma, HVOF, low velocity oxy-fuel flame spray, and cold spray. Other processes will be added as deemed necessary. If you do not qualify for the grandfathering program, note that the beta testing phase is also coming in fall of 2010. You can still save money on this program (see below). More information on the beta testing program will be published, but you will only need 750 to 1,500 hours of thermal spray activity to apply for the program. It includes, like the grandfathering program, one performance test. Additional performance tests will incur additional costs. The most often heard comment is a variation on “What a great idea: we really need a program like this to demonstrate CERTIFICATION our commitment to consistency and reliability and to help increase our market.” The second most commonly heard comment about the Certified Thermal Spray Operator program is “How much does it cost?” There are three steps to the exam process (see table), and depending on whether you opt for the Grandfathering program or the Beta Test program, the pricing is different for each step. In each program, the total price includes one performance exam; additional performance exams incur additional costs.

Recertification: • First 3 years - by points of by full re-examination: $295 • After 6 years – successful completion of Performance Test Part 2 (hands-on) per method – at $350/method • Years 9 and forward – alternate these two programs every three years Note that ASM reserves the right to change these prices at any time. Check the TSS Web site for the latest information.

For more information, visit the certification section of the TSS Web site at http://asmcommunity.asminternational.org/ portal/site/tss/Certification/, or contact Louise Wehrle, Ph.D., CAE at [email protected], or 440-338- 5151, ext. 5894.

46 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i The Journal of Thermal Spray Technology (JTST), the “Remaining Fatigue Life Assessment of T Plasma Sprayed Thermal Barrier Coatings” S official journal of the ASM Thermal Spray Society, S publishes contributions on all aspects – fundamental Philippe Robin, François Gitzhofer, Pierre e and practical – of thermal spray science, including Fauchais, and Maher Boulos processes, feedstock manufacture, Ceramic functional coatings are frequently applied to structural testing, and characterization. As the materials, covering a wide 15 range of thermo-mechanical primary vehicle for thermal spray and electro-chemical appli- JTST HIGHLIGHTS information transfer, its mission is to cations. The main limiting synergize the rapidly advancing feature is their reliability thermal spray industry and related in- when subjected to cyclic dustries by presenting research and transient thermal stresses. development efforts leading to The work described in this advancements in implementable engi- paper is a continuation of neering applications of the earlier research work fo- technology. cused on acoustic emission (AE) monitoring of the Schematic side view of the experi- mental thermal shock test rig (a), thermo-mechanical aging ef- Several articles from the September issue 19(5), as and air cooling tube mounting de- fects in ceramic coatings. selected by JTST editor Christian Moreau, are tails (b) Here, emphasis is placed on highlighted here. the usefulness of combining AE short term monitoring with finite el- ement modeling (FEM) to predict the performance of such coatings In addition to the print publication, JTST is available when subjected to cyclic thermal loads. Experiments were conducted online through www.springerlink.com. For more using yttria stabilized zirconia (YSZ) and alumina (Al2O3) ceramic information, please visit www.asminternational.org/tss. coatings combined with a NiCr-base intermetallic bond coat.

“Thermal Spray Applications in Electronics and Sensors: Past, Present, and Future” Sanjay Sampath The majority of modern thermal spray applications is “passive”

[email protected] www.cgt.gmbh.com asbindustries.com [email protected]

ADVANCED MATERIALS & PROCESSES • AUGUST 2010 47 i T S S e

Impedance spectroscopy of the plasma sprayed silicon measured in two orientations (in plane and through thickness). The results indicate a 10:1 anisotropy with the through thickness showing substantially higher impedance associated with the splat grain structure as shown in the TEM image.

protective coatings, and rarely perform an electronic function. The ability to consolidate dissimilar material multilayers without substrate thermal loading has long been considered a virtue for thick-

JTST HIGHLIGHTS film electronics. However, the complexity of understanding/control- ling materials functions, especially those resulting from rapid solidification and layered assemblage, has stymied expansion into electronics. That situation is changing: enhancements in process/material science are allowing reconsideration for novel electronic/sen- sor devices. This review critically examines past efforts in terms of materials functionality from a device perspective, together with on- www.dewal.com [email protected] going/future concepts addressing the aforementioned deficiencies. The analysis points to intriguing future possibilities for thermal spray technology in the world of thick-film sensors.

“Discrimination between Over-Thickness and Delamination of Thermal Barrier Coat- ings by Apparent Thermal Effusivity Thermographic Technique” F. Cernuschi and S. Marinetti When the delamination extent of thermal barrier coatings (TBC) is over a sufficiently large area to assess the adhesion of coatings, pulse thermography (PT) is an effective technique, but often the distinction between delamination and TBC over-thickness is very difficult to determine. In this work, a recently developed algorithm based on apparent thermal effusivity has been applied to automati- cally distinguish between delamination and over-thickness during the inspection of a serviced gas turbine TBC-coated vane.

Vane section crossing the transition between platform and foil. The TBC over- thickness in correspondence of transition can be clearly observed.

“Study of the Splat Microstructure, Splat-Substrate Interface, and the Effects of Substrate Heating on the Splat Formation for Ni-Cr Particles Plasma Sprayed on to Aluminum Substrates” S. Brossard, P.R. Munroe, A.T. Tran, and M.M. Hyland This study investigates the mechanisms of formation of plasma- sprayed coatings, through the study of splat morphology and the [email protected] splat-substrate interface of NiCr single splats sprayed onto Al substrates, at both micro- and nano-scale levels, using a range of elec-

48 ADVANCED MATERIALS & PROCESSES • AUGUST 2010 i tron microscopy techniques. Each paper is reviewed, T This study provides direct ob- evaluated, and considered S S servation of extensive substrate by itself, on its merits of e melting, together with chemical scientific and engineering inter-mixing with the splat and content, originality, and the formation of metastable in- presentation style. 17 terfacial phases (including both The JTST Volume 18 non-equilibrium phases and Best Paper is “Sensing, metallic glasses). In addition, Control, and In Situ Meas- JTST HIGHLIGHTS FIB cross section made across Prof. Sanjay Sampath, Center for voids and a range of oxide urement of Coating Proper- the rim of a partially melted Thermal Spray Research, Stony phases were observed. The splat (see inset picture) found ties: An Integrated Approach Brook University (center) receives the mechanisms of formation of on Al5052_PH toward Establishing Pro- JTST Volume 18 Best Paper Award these features are discussed. cess-Property Correlations” from TSS president Mitch Dorfman Two aluminum alloys (with and without Mg additions) and three dif- by Sanjay Sampath, Vasude- (left) and Dr. John Marburger III, vice ferent sets of substrate surface conditions (polished, and heat treated van Srinivasan, Alfredo president for research, Stony Brook prior to and during spraying) were used to investigate the variations Valarezo, Anirudha Vaidya, University, (right). Sampath co-au- in splat morphologies induced by the different preparation condi- and Tilo Streibl. thored the paper with Vasudevan tions. It was found that the heating of substrate during spraying sig- The Best Paper Honor- Srinivasan, Alfredo Valarezo, nificantly reduced splashing. able Mention was awarded Anirudha Vaidya, and Tilo Streibl. to Igor Sevostianov and Mark Kachanov for their paper entitled “Elas- “Bactericidal Performance of Flame- tic and Conductive Properties of Plasma-Sprayed Ceramic Coatings in Sprayed Nanostructured Titania-Copper Relation to Their Microstructure: An Overview.” Composite Coatings” Special thanks to the judging committee including Arvind Agarwal, N. George, M. Mahon, and A. McDonald David V. Bucci, Andrew Gouldstone, David Hart, Jan Ilavsky, Bertrand A large concern surrounding Jodoin, George Kim, Jiri Matejicek, Tim McKechnie, James A. Rudd, stainless steel surfaces is the Philip Shipway, Yoshiki Tsunekawa, Anirudha Vaidya, Joel Voyer, Petri ability of bacteria to grow and Vuoristo, and chair Roland D. Seals. attach to them quite easily. One Congratulations are extended to the winning authors from the possible solution to destroy JTST Editorial Committee and the ASM Thermal Spray Society these pathogens is to coat sur- Board of Directors. faces with a biocidal agent. The photocatalytic effect of titanium dioxide (TiO ) is known to 2 Scanning electron microscope have a bactericidal effect. Coat- images of wear scars on flame- ings of TiO were prepared on 2 sprayed nanostructured TiO2 1010 low carbon steel sub- coating strates using an oxyacetylene flame spray torch. TiO2 coatings containing 5 wt% copper (Cu) were fabricated to increase the bactericidal effect of the coating. Solutions of Pseudomonas aeruginosa (PAK) bacteria were placed onto the coating surface for periods of up to 3 h, and the amount of surviving bacteria were counted. In coatings of copper-free flame-sprayed TiO2, the high flame temperatures facilitated the conversion of the anatase phase to the rutile phase, which limited the photocatalytic destruction of the bacterial cells. However, TiO2-copper composite coatings showed a large bactericidal effect, killing approximately 75% of PAK bacterial cells after 3 h. Under the same conditions, the TiO2-copper composite coatings had the same bactericidal capabil- ities as pure copper surfaces, with the composite coatings showing improved bactericidal performance when exposed to light. It was proposed that increased concentrations of reactive oxide species pro- duced due to TiO2 photocatalysis improved the performance of the irradiated TiO2-copper composite coatings. Best Paper Award presented at ITSC 2010 Dr. Roland Seals, chair of the Journal of Thermal Spray Technol- ogy Best Paper Subcommittee, announced the JTST Volume 18 Best Paper Award winners, as chosen by an international committee of expert judges. The awards were presented at the International Ther- mal Spray Conference & Exposition 2010 in Singapore. The Editorial Board of JTST believes it is important to evaluate the quality of engineering and scientific contributions published in JTST, to provide recognition of excellent work and the publication of such work, and to recognize expertise in thermal spray science and engineering and the publication of such work. www.universalthermal.com ADVANCED MATERIALS & PROCESSES • AUGUST 2010 49