Thermal Spray Additive Manufacturing

Thermal spray additive manufacturing (TSAM) uses a high velocity heated gas to propel molten or softened powder / wire material against a substrate, where the particles bond layer-by-layer. As well as being used to create 3D parts, the process can apply functional coatings with enhanced properties such as improved wear or heat resistance.

Key TSAM processes include:

Plasma Spraying: Suitable for both ceramics and metals this process uses high temperature plasma jets that creates dense, high-performance layers
High Velocity Oxygen Fuel (HVOF): Combustion gases are used to achieve high particle velocities that create hard, wear-resistant layers
High Velocity Air Fuel (HVAF): Uses compressed air and fuel, creating lower temperatures which are compensated by higher velocities and less oxidation, resulting in tougher, corrosion-resistant and less porous coatings
Cold Spray (CS): Additive materials are heated to below melting point but delivered to the substrate at supersonic speeds, where mechanical deformation causes the bond, creating dense layers with fewer defects

Blending traditional coating techniques with modern additive manufacturing, TSAM has found applications across industries including aerospace, energy, biomedical and automotive, where it is favoured for the ability to create wear resistant parts, deliver functional surfaces, and provide specialised component repair.

Advantages of TSAM

TSAM provides several advantages for industry, including:

Materials Options: TSAM can create parts from a single material or with composite, graded or multi-layered structures
Improved Properties: Can create functional surfaces and parts with improved corrosion, thermal and wear resistance
Repair: TSAM can be used to repair and upgrade existing parts, saving costs and extending service life
Cost and Environment: TSAM reduces material waste compared to subtractive methods as well as allowing for the recycling and reuse of expensive additive materials, which is better for both costs and the environment

Core Research Programme (CRP) and Joint Industry Projects (JIP)

Core Research

Each year the TWI Core Research Programme (CRP) addresses challenges on behalf of our Industrial Members as well as developing specific technologies and processes. Each of the projects under the CRP is focussed on engineering, materials or manufacturing technologies.

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Joint Industry Projects

TWI also conducts Joint Industry Projects (JIPs) that bring together groups of Industrial Members to share the cost of research activities in areas of mutual industrial interest, gaining exclusive access to the outcomes. These projects cover a broad range of topics.

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Thermal Spray Additive Manufacturing at TWI

TWI provides technical excellence in all aspects of thermal spray additive manufacturing (TSAM), drawing upon years of expertise in additive manufacturing, materials and thermal spray processes.

We can provide feasibility and design support, guidance on every aspect of TSAM adoption, as well as advice on how to maximise the process for the specific industry needs of our Industrial Members, aligned to relevant sector or business requirements.

Our facilities are also equipped to provide one-off manufacturing support and prototyping, allowing our Industrial Members to use our equipment as an extension of their own.

TWI’s TSAM support also includes business case proposals, numerical modelling and topology optimisation, material and process selection, finishing, heat treatments, testing, certification and validation, as well as support with relevant standards.

To find out more about TSAM and how we can support you with its use, please email contactus@twi.co.uk.

For more information please email:

contactus@twi.co.uk