Fusing Process: Frame Spray vs Plasma Spray

[tobjung]

Dear forum

I wonder if anyone ever tried both Frame spray and Plasma spray of self-fluxing alloy such as WCCo-NiCrBSi (Metco14E or 31C) and then fuse afterwards. 
From my point of view, no matter the spraying process is, the coating needs to be fused anyway. So, there shouldn't be any difference between HVOF, Plasma spray and Frame spray
as long as we fuse it afterwards.

The thing is I'm not pretty sure if my understanding is correct or not since there are some manufacturers use plasma spray coating for these self fluxing alloys and fuse it.

If anyone have suggestion/experience about this topic ?

Any suggestion is appreciated.

Best regards

Toby

[Vadim Verlotski]

Hi Toby,
You are absolutely right, coatings based on NiCrBSi powders can be applied with flame spraying, plasma spraying, HVOF, and detonation spraying. Since flame spraying is the cheapest method, most people use this method. However, I have successfully used plasma sprayed NiCrBSi coatings and the quality of these coatings was better than flame sprayed.
Regards
Vadim

[Gordon]

Hi Toby,

Agree with Vadim, plasma and particularly HVOF can produce better quality fused coatings. The as-sprayed coatings contain less oxide and are denser so fuse better as fluxes have less work to do. The big but is cost and simplicity, flame spray and fuse is very old and proven.