Coating Validation

Microstructure Analysis

Microstructure of coatings produced by thermal spray coating process depends on a number of factors which include :

  • Particle impact conditions
  • Powder/Wire materials
  • Substrate material and its condition
  • Spray parameters
  • Process parameters
  • Spraying technique
  • Spray equipment and its timely maintenance
  • Spraying environment etc.

Slightest variation in any of the above parameters will reflect in the coating microstructure and its operational performance. Microstructure analysis serves as a computational tool that can predict the microstructure of thermal spray coatings as a function of these parameters. Microstructure analysis of coatings primarily indicates :

  • Coating thickness
  • Coating particle distribution and uniformity
  • Porosity level
  • Oxide content
  • Coating interface bonding evaluation

We are determined to provide quality coatings to our customers and have proven this over time through our continual improvement in processes and adoption of new technologies. Taking a step further on this mission, we have now set up an in-house testing facility for microstructure and micro hardness evaluation of thermal spray coatings. The equipment’s used for sample preparation are completely automated and calibrated timely to provide the best results.

We spray test coupons on a regular basis to :

  • Qualify our powder/wire, spray equipment and operators
  • Coating qualification as per customer specification
  • Check coating consistency
  • Continual improvement in coating properties
  • Development of new coating solutions tailored for specific applications
  • Demonstrate our coating quality by spraying samples along with customer component

Micro Hardness Evaluation

Micro hardness evaluation of coatings is done to ascertain the achievement of desired hardness values of coating material. The output of this test can be further used for optimizing spray parameters and for quality control purposes. Same coating material applied with different process and different technique can exhibit varying micro hardness. It is believed that micro hardness evaluation enable quick estimation of coating strength and the quality of spraying because defects such as non-melted particle inclusions and porosity lower micro hardness. Inherent in this usage is the assumption that hardness is a measure of quality. Micro hardness is often used for the first approximation of coating wear resistance, which is by far the most important property in application of Thermal spray technology.

We have in-house test equipment for micro hardness testing and evaluation of coated test coupons. We spray test coupons on a regular basis to:

  • Qualify and accept new batch of powders
  • Coating qualification as per customer specification
  • Check consistency of coating hardness
  • Demonstrate coating hardness to customer during final inspection

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