Rod spray Vs plasma spray
03-26-2012, 05:09 PM,
Rod spray Vs plasma spray
Dear All,

I had a question relating to oxide ceramic coatings;

How different are oxide ceramic coatings achieved from rod spray systems using say a Al2 O3 or a chrome oxide as compared to the same obtained using a plasma spray ( APS)

A comparison between say the porosity, bond strength and wear resistance capacities between same coatings achieved by these two different methodologies would be highly appreciable.


03-26-2012, 05:46 PM,
RE: Rod spray Vs plasma spray
Dear Shantanu,
Nothing beats Plasma spray coatings for ceramics
03-30-2012, 01:44 PM,
RE: Rod spray Vs plasma spray
Hai Shantanu,

Plasma Spray process produces better ceramic coatings than rod spray process.

1) The porosity of ceramic coatings devloped by rod spray will be in the range of 10 t0 20% and with plasma spray, it is 5 to 10%

2) Bond strength of ceramic coatings developed by rod spray will be in the range of 15 MPa and with plasma spray, bond strength 15 to 25 MPa

Detonation spray process also will produce ceramic coatings (Al2O3, Al2O3 + TiO2) and these coatings exhibit very dense coatings (Porosity is less than 2%) with very high bond strength values (in the range of 70MPa).

Thanking you,



03-30-2012, 02:43 PM,
RE: Rod spray Vs plasma spray
Hi Shantanu

I was not going to respond as the question is a bit like comparing apples and oranges and I don't have first hand experience with rod ceramic spraying, but to balance things out a bit and talk more specifically about Rockide C chromium oxide based ceramic coating:

Around 1980 Metco developed Metco 136CP for plasma spraying. This I believe was an attempt to compete with Rockide C coatings. Below is a quote from Metco 136CP technical bulletin:

Quote:Metco 136CP provides one of the most durable plasma chromium oxide coatings in the industry. Metco 136CP has a coating thickness capability of over 0.100" (2.5mm), making it superior to coatings of Rockide C, where a thick ceramic coating is required, while having an equivalent wear resistance.

So a blanket statement "plasma coatings are best" does have a few holes in it. Rockide C coatings are still very hard to beat for applications requiring thick, tough and wear resistant ceramic coatings.


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