Small Particle Thermal Spray: Technology, Innovation and Advancement

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Director Tech Chin Ma, chin.ma@cwst.com, Curtiss-Wright Surface Technology; Xinqin Ma, xinqing.ma@cwst.com, Curtiss-Wright Corporate; General Manager Peter Ruggerio, peter.ruggerio@cwst.com, Curtiss-Wright Corporate; 

https://doi.org/10.53192/ITSC2026569

It is well-established that the sizes of feedstock significantly affect thermal spray coatings, impacting various microstructural features, properties and performance indicators. This paper seeks to summarize the authors' efforts in developing innovative coating systems utilizing small particle thermal spray (SPTS) technologies, while highlighting the technological innovations and advancements across a range of processes, materials and applications. The feedstock particles, which are small in size, vary from nanometers and submicrons to several microns. In the case studies presented, typical SPTS coatings derived from alloys, carbide composites and ceramics made from these finer particles are evaluated in terms of microstructures and properties compared to traditional TS coatings. The SPTS technologies used for applying these coatings, which demonstrate desirable qualities such as high density, excellent uniformity and superior finish, are thoroughly discussed. Furthermore, advanced SEM, XRD analyses and flame diagnostic tools employed for characterizing and optimizing coating splats, phases, and microstructures, as well as spray parameters, are essential for achieving the intended coating functions and properties. The examples and their potential of these finely structured coatings for specialized applications are examined, particularly within key industry sectors.

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Erscheinungsdatum

March 2026

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