Thermal Spray Technology

  Table with study documents Copyright: © IOT


Portrait photo Zhao © Copyright: IOT


Lidong Zhao



+49 241 80-99941



Lecture and Exam information


The lecture “Thermal Spray Technology” provides a deep insight into this coating technology. The will introduce and explain fundamentals of this coating technology and all important spray processes, such as flame spraying, plasma spraying, arc wire spraying as well as cold gas spraying. In addition, the class will present and explainimportant production processes for different feedstock materials, including mechanical milling, gas and water atomization as well as agglomeration and sintering. Moreover, the leture will cover typical coating systems for various applications, including different wear and corrosion protective coatings in various industrial branches as well as thermal barrier coatings in modern turbine engines. Finally, a guided tour of the institute subsequent to the lectures and tutorials will further deepen the insight into the production and analysis of thermally sprayed coatings.

Summary of the contents of Thermal Spray Technology



1. Basics of thermal spray technology

  • Interaction between gas stream and particles
  • Interaction between particles and substrate
  • Characteristics of thermally sprayed coatings
  • Post-treatment of thermally sprayed coatings

2. Spray processes

  • Flame spraying
  • Plasma spraying
  • Wire arc spraying
  • Cold gas spraying

3. Production of feedstock materials

  • Wire, rod and flexicord
  • Powder production by mechanical milling
  • Powder production by atomization
  • Powder production by agglomerating and sintering
  • Other methods for powder production
  • Characterization of powders

4. Wear protective coatings

  • Metallic coatings
  • Ceramic coatings
  • Composite coatings

5. Coatings for corrosion protection

  • Coatings as sacrificial anode
  • Oxidation and hot gas corrosion resistant coatings
  • Erosion and corrosion resistant coatings

6. Thermal barrier coatings

  • Requirements
  • Materials and processes
  • Coating properties