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Powder Flame Spray (PFS)

Powder Flame Spray (PFS) is the first technique of thermal spray (1917). The material (in powder form) is fed continuously towards the gun where it is melted in a flame resultant from the combustion between an oxidizing gas (oxygen O2) and a combustible gas (acetylene C2H2, hydrogen H2 or propane C3H8). The molten particles are projected onto a prepared substrate, where they impact and solidify to form a coating.



Process Advantages:

• Low capital investment.

• Simple to operate.

• Deposition efficiency is very high.

• Portable system.

• A wide range of materials can be easily processed into powder form, thus making them sprayable.


Process Disadvantages:

• Materials with higher melting temperatures than the flame’s (2700ºC) cannot be deposited; or if the material decomposes on heating.

• Due to the relatively low temperature of the flame and low speed of the particle (50-70m/s), the coatings are generally of worse quality, have high porosity (7-12%) and low cohesive and adhesive forces, compared with those coatings obtained by other thermal spraying techniques.



Coatings by flame spray are usually used for restoration of worn parts and for wear and corrosion protection. Ex: Coating of Molybdenum to increase the use life of machine parts, CoCrNiWC coatings is used in applications to resist high temperature wear, hot corrosion and oxidation.


[1] www.eutecticusa.com