Machines used by the basic industries of Russia (metallurgy, oil-gas processing
and power engineering) are characterized by high metal consumption, which in
turn lead to high energy consumption. Their service lives increase and their worn
parts are restored by means of low-cost materials for restoration. The processes
of Thermal Spraying (TS) are more effective than alternative methods in
restoration and increase in service life. Such methods include electroplating,
chemical and thermal processing. The results of research and experience have
proven this. At the same time, the load on the environment is reduced in
comparison with the alternatives by decreasing emissions.
Based on OEM publications and our own experience, we analysed the
efficiency of TS processes. Plasma spraying was excluded from consideration
since it has no real alternative for refractory oxide coatings which are mainly
used for gas turbines and jet engines. By the criteria of the coating’s quality,
performance and cost arc of spraying, flame spraying, HVOF/HVAF, cold
spraying and detonation spraying were compared. Commonly used materials for
TS, such as metals and carbides in metal bond (cermet), were examined as
This paper shows that a combination of activated arc spraying and HVAF for
producing wear and corrosion-resistant coating is a rational variant with respect
to a wide variety of parts for the aforementioned industries.
Examples of resource-saving in metallurgy, oil–gas processing and power
engineering are shown based on our own TS experience in material, equipment
and technology development.
Keywords: resource saving, thermal spraying, HVAF, HVOF, arc spraying,
metallurgy, power engineering, service life increase.