Flame spraying of polymer composite feedstocks: influence of ceramic concentration on particle deposition and coating structure

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Doctoral Researcher Eero Helmi, Tampere University; Doctoral Researcher Reza Jafari, reza.jafari@tuni.fi, Tampere University; Prof. Essi Sarlin, essi.sarlin@tuni.fi, Tampere University; Associate Professor HelK koivuluoto, heli.koivuluoto@tuni.fi, Tampere University; 

https://doi.org/10.53192/ITSC2026560

Flame spraying has long been used to deposit thermoplastic coatings against corrosion and wear in industrial infrastructure, and more recently the technology has shown potential in other novel applications in cold conditions. Improving these coatings’ performance and durability is, of course, a prime motivation for all applicable industries, and a common approach for this cause is the inclusion of solid additives into the polymeric matrix. While this approach has been studied for flame sprayed polymers, it has not been widely adopted, and there still exist several questions about the efficient utilization and control of this technology. Moreover, further advancements in thermally sprayed polymer composite coatings could open new possibilities for multifunctionality and significantly expand the technology’s use in a broader range of applications. For these purposes, the study explores how the concentration of ceramic additives influences the conventional flame spraying process when a premixed feedstock is used. Powder mixtures are made by mechanically mixing different amounts of fine silica powder together with significantly larger low-density polyethylene. The powder morphology, its melting behaviour, and the resultant coating buildup are studied using different coating parameters, and an in-depth analysis of the coating morphology and microstructure.

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Erscheinungsdatum

March 2026

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