Thermal Spray Maintenance, Repair and Overhaul Techniques in an Aerospace Environment

THURSDAY, 19 OCTOBER 2017
National Conference Centre, Coventry Road, Solihull, West Midlands, B92 0EJ
Keynote speaker – Marcel van Wonderen
(Master Engineer – Process Equipment and Materials Development)

Thermal Spray is a very challenging, interesting and demanding industry.
Aerospace has been responsible for challenging the Thermal Spray Industry to provide continuous improvement in performance and value.
Specifically, the gas turbine engine provides the Thermal Spray process with more coating opportunities than almost any other single application.
Many wider industries have benefitted from this engineering collaboration and this meeting will provide a forum to discuss Thermal Spraying as a technology in any environment.
Marcel will take us through glimpses of gas turbine history, design of gas turbines, the MRO (Maintenance Repair and Overhaul) business, the different repair techniques used in this aero sector and of course, the wider issues facing Thermal Spraying. Also there will be an opportunity to catch a glimpse of future developments in MRO.

Marcel van Wonderen has been involved in this industry at KLM Engineering and Maintenance for 31 years.

Surface Coatings Engineer Cost Savings

THURSDAY 23 MARCH 2017
TWI Granta Centre, Granta Park, Great Abingdon, Cambridge, CB21 6AL

Since it’s invention in the early part of 20th Century, Thermal Spraying has been associated with not only process improvement, but also cost saving. The subsequent development of complementary Surface Engineering processes has followed in a similar direction.
Whether that cost saving was associated with the reclamation of sprayed worn automotive shafts during war years or hard facing applications to give surface enhancement to cheaper substrate materials, Surface Engineering has played a large part in reducing costs in a wide variety of industry sectors.

This conference not only looks at areas where Surface Engineering has reduced costs for various industries, but also examines methods employed to reduce costs within the industry itself.

Whatever the prevailing market conditions, cost saving both in and surrounding the Coatings industry, is critical to its survival.

We are grateful to all contributors to this conference, who will approach the subject of cost saving from their own individual perspectives.

Quality Assurance in Surface Engineering

Wednesday, 26th November 2014 commencing 9.30 for 10.00 am 

Gloucester Rugby Club, Kingsholm Stadium
Kingsholm Road, Kingsholm, Gloucester, GL1 3AX

It is a well-documented challenge to employ effectively the more traditional methods of NDT when inspecting and qualifying surface coatings.

This has resulted in the development of a vast array of process control techniques, which allow the surface engineer to verify stability of the coating process.

For each process variable, a technique has been developed to minimise deviations and measure true values.

This conference is designed to explore some of the methods employed in today’s surface engineering industry to control variables such as manipulation, application temperature and surface preparation, which therefore result in the creation of a more robust process.

For anyone having an interest in the variables that surround surface technology, this conference will update the attendee on the current “state of the art” as well as providing an insight into new developments in process control methods.

Design for Surface Engineering

Thursday, 13th June 2013 commencing 9.30 for 10.00 am

TWI Technology Centre (Yorkshire) Ltd
Wallis Way, Catcliffe, Rotherham S60 5TZ

Surface Engineering solutions for a wide variety of applications have invariably been added at the end of the design process. This reactive design process can often incur high costs as any problems have to be corrected at a late stage in the iterative design process or when the product is in use. Now, as surface engineering becomes vital to the success of the UK’s manufacturing and engineering sector, there is a greater need to incorporate surface engineering into the design process. This will enable the predictive design of important products to be achieved with the minimum of waste and utilising more sustainable materials using environmentally friendly processes. The predictive design process with quality designed-in leads to early problem identification and provides solutions when the costs are low.

When designing for process excellence, it is important to understand and control variability in the early stages of the design process. This will lead to robust design solutions with predictable product performance and with quantifiable and minimum risk. The variability, stability and sensitivity of the surface engineering process itself also need to be fully understood.

In order to achieve predictive design the product performance needs to be modelled and simulated. Robust databases of coating characteristics and properties that can be used by designers with confidence need to be established. Reliable techniques for measurement and characterisation also need to be developed.

This conference highlights the move to predictive design in the surface engineering sector and will be of interest to designers, specifiers, practitioners and end users of surface engineering. The event is jointly sponsored by The Thermal Spraying and Surface Engineering Association and the Materials Knowledge Transfer Network.

Surface Engineering in Nuclear Power

Wednesday, 7 December 2011 

TWI Technology Centre (Yorkshire) Ltd, Wallis Way, Catcliffe, Rotherham, S60 5TZ

There is a resurgence in interest in investing in new nuclear capability both locally in the UK and globally in recognition that nuclear power generation sources can deliver power on a reliable and consistent basis whilst, at the same time, avoiding the production of CO₂ emissions. Indeed, a recent study by the Royal Academy of Engineering has concluded that these issues will ensure that some combination of Nuclear and Carbon Capture and Storage-equipped Fossil-Fuel generation will play a leading role in the future UK “energy mix”.

The opportunities for Surface Engineering or Particulate Engineering in nuclear power plant will be greatly influenced by health, safety and environmental issues, highlighting the view that enhancement of safety, rather than of power generation efficiency, will be the major driving force in the next round of new nuclear build. It is widely recognised that ensuring safety in all aspects of the Nuclear Power cycle is always going to be a critical issue in gaining public acceptance for new nuclear build, but, because of the recent Japanese earthquake and tsunami and its after-effects, the issue is in even greater focus.

In particular the replacement of cobalt is a major issue because of its half-life and the high gamma radiation produced by Co⁶⁰ and its impact upon refit and maintenance schedules. Surface Engineering technologies are being evaluated for possible cobalt replacement in a number of areas. Surface Engineering solutions for the replacement of cobalt must take into account extended maintenance intervals and also the ability to repair some components at overhauls.

Waste management also carries major safety concerns and there will be opportunities for Surface Engineering in the handling, transportation and storage of nuclear waste. Management of irradiated fuel will initially involve storage in water-filled ponds. The current strategy is that much of the AGR will be stored in this way for many decades. The remainder of the AGR fuel and all of the Magnox fuel is scheduled to be reprocessed to recover uranium and plutonium as fissile material for new fuel. The waste arising from the reprocessing of UK fuels, after separation, the “high level” fission product waste will be immobilised in cement or glass matrices and placed in sealed containers for long-term storage.

This conference highlights the contribution of Surface Engineering in the nuclear power industry.

The event is jointly sponsored by The Thermal Spraying and Surface Engineering Association and the Materials Knowledge Transfer Network.

The Contribution of Surface Engineering to Sustainable Energy

Wednesday, 8 December 2010

National Physical Laboratory, Hampton Road, Teddington, Middlesex, TW11 0LW

Sustainability in the energy sector encompasses both power generation and usage.

Ensuring sustainable generation over the next 20 years will be driven by three major issues:

• Reliability of power supply – this will dictate that conventional, fossil-fuel generation will continue to play a major role.
• Reduction in greenhouse gas emissions – this will not only drive developments in generation from renewable sources (e.g. wind, wave, tidal, solar, geothermal power), but also developments to improve the efficiency of conventional power plants, to fit future plant with Carbon Capture and Storage (CCS) capability and increasingly to adopt biomass or waste co-firing.
• Security of fuel supply, to reduce reliance on gas imports – this will drive the increased usage, in gas turbines, of Syngas, derived from biomass and other hydrocarbon sources.

These developments will introduce more arduous operating environments for many items of power plant, in terms particularly of corrosion, erosion or operating temperature. Surface Engineering, comprising a wide range of technologies that modify the surfaces of materials and components to confer surface properties that are different from the bulk properties and thereby improve performance or service life, is predicted to be a particularly cost-effective means of addressing these needs.

Also, several of the renewable generation technologies and the devices being developed to enhance efficiency of energy usage will rely critically on Surface Engineering for their operation.

This conference highlights the contribution of surface engineering in sustainable energy technologies including biofuels, wind turbines, low-carbon energy technologies, fossil-fuel power generation and high efficiency electroluminescent devices.

The event is jointly sponsored by The Thermal Spraying and Surface Engineering Association and the Materials Knowledge Transfer Network.

Recent Developments in Surface Engineering Technology

Tuesday, 24th November 2009

 BOC Gases, The Fabrication Technology Centre, Lower Walsall Street, Wolverhampton, WV1 2EP

Surface Engineering utilises a wide range of technologies to modify the surfaces of materials and components and thereby improve performance, service life, aesthetic appearance or economics of production. The processes involved, frequently known as surface treatments, confer surface properties that are different from the bulk properties.

The choice of a surface treatment, to achieve appropriate wear, corrosion and fatigue resistance and desired thermal, optical, magnetic and electrical properties, is crucial to functionality. Although the surface treatment is often a coating of one or more different materials, thermal or mechanical treatment of the substrate surface material can also be highly beneficial.

Surface coatings are also often used where it is impractical or uneconomical to manufacture components from a bulk material simply to utilise surface properties. The coated product conserves scarce material resources, performs better than the original and is often cheaper to produce.

The increasing technical and economic importance of surface engineering and rising environmental pressures continue to result in developments in surface engineering technology. This seminar intends to present advances in surface engineering processes from those such as physical vapour deposition, used to produce very thin coatings, to thermal spraying, which produces relatively thick layers. Recent developments in multi-layer coatings will also be presented. The properties and industrial potential of novel surface coatings will be highlighted.

Managing Environmental Impact

Wednesday, 15th October 2008 commencing 9.30 for 10.00 am
Himley Hall, Dudley, West Midlands, DY3 4DF

Thermal spraying and surface engineering requires the management of a wide range of factors with potential for impact on the environment. For example, thermal spraying may produce particulate emissions from abrasive blast substrate preparation and molten metal deposition, solvent emissions from degreasing and painting and gas evolution from spraying processes.

In this conference, several aspects of managing particulate emissions in the thermal spray industry will be considered including developments in filtration, real time monitoring of particulate emissions and reducing particulate emissions. The environmental impact of thermal spray gases will also be discussed.

An important development with potential consequences throughout surface engineering came into force in June 2007. REACH, the Registration, Evaluation, Authorisation and Restriction of Chemicals Regulations will start to bite June 2008 and may result in some substances being withdrawn from the European market. The withdrawal of chemicals or alloys will arise either due to regulatory action or commercial considerations, as the cost of substances rise.

REACH has the potential to impact downstream users of substances whether they are used on their own (like acids or solvents) in preparations (like paints, NDT developers, or alloys) or in articles (such as components, assemblies or whole products). A presentation from Rolls Royce will clarify the business risks, and pinpoint the actions you need to take now for business continuity.

The old criteria of formulating a paint to give optimum balance of performance and cost must now be closely matched with the impact that the paint will have on the environment. A presentation will highlight factors that must be now considered including sustainability of raw materials, toxicology profiles of the raw materials and finished products, together with the health and safety implications of manufacture, application, waste disposal and removal of coatings at the end of their lifetime.

A review of recent progress in relevant waste management legislation including the Landfill Directive and Hazardous Waste Regulations will also be presented.

Surface Engineering for Medical Applications

Wednesday, 18th June 2008 commencing 9.30 for 10.00 am
TWI Technology Centre (Yorkshire) Ltd, Wallis Way, Catcliffe, Rotherham, S60 5TZ

The medical industry is increasingly employing surface engineering to improve the properties and performance of medical and dental implants and other medical products. The range of coatings and surface techniques employed includes anodising, PVD, CVD and thermal spraying to produce coatings for a variety of applications such as wear resistance, encouraging bone growth (osseointegration), corrosion protection, identification and protection of medical devices.

The aim of this conference is to highlight the range of surface engineering and coating technologies that can be employed in the medical sector and bring together industrialists and academics from both the medical and surface engineering sectors to facilitate greater awareness of surface engineering for medical applications.

The conference will include presentations on the use of coatings and surface engineering in medicine, surface engineering for reducing wear in orthopaedic implants, thermal spraying for orthopaedic applications, PVD, plasma electrolytic oxidation and cold spraying.

There will also be a presentation on the Yorkshire Surface Engineering Group and the support available for companies through this regionally funded programme.

The day also includes a tour of TWI Yorkshire incorporating TWI’s new cold spraying facility.

Surface Engineering Solutions

Wednesday, 31st October 2007 commencing 9.30 for 10.00 am
Beaumanor Hall, Woodhouse Eaves, Loughborough

Surface Engineering embraces processes that modify the surfaces of components to improve service performance and life, aesthetic appearance or economics of production. The processes, often known as surface treatments, confer surface properties that are different from the bulk properties.

The choice of a surface treatment, to achieve appropriate wear, corrosion and fatigue resistance and desired thermal, optical, magnetic and electrical properties, is crucial to functionality. Although the surface treatment is often a coating of a different material, thermal or mechanical treatment of the substrate material can also be highly beneficial.

Surface coatings are also often used where it is impractical or uneconomical to manufacture components from a bulk material simply to utilise surface properties. The coated product conserves scarce material resources, performs better than the original and may well be cheaper to produce.

The increasing technical and economic importance of surface engineering and increasing environmental pressures continues to result in the development of novel surface coatings and processes. This seminar intends to present developments in the properties and applications of surface coatings, from ultra thin deposits produced by physical vapour deposition to relatively thick layers achieved by thermal spraying. Process developments, including advances in shot peening and thermal spraying, will be highlighted. Recent advances and the industrial potential of emerging processes such as cold spray will also be considered.

Thermal Spraying – Training, Qualifications & Standards

Wednesday, 7 March 2007 commencing 9.30 for 10.00 am
BOC Gases, The Fabrication Technology Centre, Lower Walsall Street, Wolverhampton, WV1 2EP

The development of the Industrial Coatings Applicator Training Scheme (ICATS) by the Institute of Corrosion has resulted in a structured scheme for the training, certification and registration of industrial surface preparation and coating operatives and this is currently being extended to include thermal spraying for corrosion protection. Many major authorities intend to make ICATS a mandatory requirement for companies submitting tenders for corrosion protection contracts.

For engineering coatings, “NADCAP” offers a worldwide accreditation programme for special processes and products and these are used mainly in the aerospace industry.

The TSSEA has announced its intention to undertake Approval Testing of Thermal Spraying Operators to BS EN ISO 14918 as a service to members. This standard clearly defines the level of skills and knowledge required to obtain approval in flame, arc, plasma, and HVOF spraying of metals, alloys, metal carbides and ceramics.

The TSSEA continues to hold the secretariat for the BSI committee STI-40 and thereby is responsible for input from the UK into committee CEN/TC240, which develops European standards for all aspects of surface spraying. Additionally, if international collaboration occurs, a joint European/International standard may result, which would appear in the UK as a BS EN ISO standard. Therefore, TSSEA has an important role in developing and reviewing thermal spraying standards for widespread use.

This seminar intends to present new developments and to highlight updates in training, qualifications and standards for thermal spraying industry.

Surface Engineering and Joining in the Automotive Industry

Wednesday, 6th December 2006
Heritage Motor Centre, Gaydon, Warwickshire CV35 0BJ

The automotive industry today is driven by the need to reduce fuel consumption and emissions whilst improving safety and reliability standards, and to reduce manufacturing and servicing costs. As manufacturers strive to achieve these targets then surface engineering and joining technologies become increasingly more important.

Materials such as aluminium & alloys, magnesium & alloys, metal matrix composites and polymers are lightweight and can be very cost effective but their surface properties sometimes leave a lot to be desired. However, these surfaces can be engineered with a functional coating specifically designed to meet the in-service demands. These materials also need to be joined to produce high strength structures.

This seminar intends to offer: –

• An update on new and novel surface engineering and joining techniques and processes
• Potential robust solutions for lightweight and other components
• Lessons learnt from motorsport and aerospace
• Minimum use of strategic materials to improve sustainability

The seminar will promote: –

• Lively discussion
• New ideas
• New materials
• New processes

Supported by the Automotive Applications Division Board and the Surface Engineering Division Board of the Institute of Materials, Minerals and Mining.

Environmental Impact of Coatings

Wednesday, 5th July 2006
Beaumanor Hall, Woodhouse Eaves, Loughborough, LE12 8TX
Commencing 9.30 for 10.00 am

Environmental, health and safety regulations are placing increasingly stringent demands on plating process operations and waste treatments. In particular, hard chrome plating used for engineering coatings, produces large volumes of carcinogenic hexavalent chromium solution that can be thrown into the air as a fine mist during the plating process. Nickel plating is also under considerable scrutiny because all nickel salts are now considered to be dangerous to human health.

Hard chrome plating is a simple technology, which is seen as relatively inexpensive, and therefore, is difficult to replace. However, alternatives are decreasing in price whilst the cost of chrome plating is rising. Many modern coatings can now be used instead of hard chrome, and often with better results. Already, thermal spray coatings are replacing hard chrome plating on hydraulic rams in earth moving equipment, aircraft landing gear and gas turbine journals.

Some coatings, rather than the processes that produce them, are also considered as potentially hazardous. For example, nickel is associated with allergic contact dermatitis and consequently, its use is subject to increasing restrictions. Air pollution control for businesses operating medium to large-scale thermal spraying and associated processes is governed in the UK by process guidance notes (PG6/35), which detail emission limits, monitoring and sampling requirements representative of ‘Best Available Techniques’. These regulations have now been in force since April 2004 and industrial experience of implementing the requirements is accumulating.

The aim of this conference is to highlight potential hazards associated with coatings and coating processes, to identify how some of these can be effectively managed and to present alternative coating systems that minimise environmental impact.

Developments in Thermal Spray Engineering

Wednesday, 15th March 2006
The Old Rectory, Rear of St Mary’s Church, Handsworth, Sheffield, S13 9BZ
Commencing 9.30 for 10.00 am

Thermal spraying remains an important technique for the repair and maintenance of engineering components. The technique is also accepted for production of original equipment applications including gas path clearance control in gas turbine engines, surface modification of rolls for steel production processes and as functional coatings on original equipment printing presses. However, increasingly thermal spraying is being specified for the production of a diverse range of newly designed engineering parts.

Thermal spraying as a group of processes including flame, arc, plasma, high velocity oxy-fuel and cold spraying, continues to be refined and developed and new feed materials are being introduced. Higher deposition rates, denser coatings and novel coating materials all serve to increase the range of viable applications.

For products with simple shape such as tubes or high volume parts of more complex geometry, thermal spaying lends itself to automation. Recently, a fully automated, computerised thermal spray facility been commissioned for the spraying of corrosion protection onto pipes for the oil and gas industry. As well as reducing manpower requirements, automation reduces operator fatigue and exposure to the process, producing a more uniform coating in a shorter time and utilising the coating material more efficiently.

Developments in Corrosion Protection

Wednesday, 2 November 2005
Beaumanor Hall, Woodhouse Eaves, Loughborough
Commencing 9.30 for 10.00 am

It is now 20 years since 35,000 sq meters of the steel decking of the Humber Bridge were sprayed with a coating of Zinc (minimum thickness of 75 microns) and preparations are now being made for the planned renewal of the surfacing. This will include the removal of the existing protection and the respraying of a replacement Zinc coating.

Coincidentally, the first important application for offshore structures, the spraying of the tethers and risers of the Conoco platform with Aluminium, took place at much the same time and subsequent inspections have confirmed the success of this system for the protection of steelwork when submerged in salt water. Subsequently, other large off shore structures have been protected by sprayed aluminium coatings in the splash zone and above.

More recently, the Tsing Ma bridge at Hong Kong linking the mainland to Lantau island where the new airport has been built, had 55,000 sq meters of decking sprayed with a 170 micron thick coating of Zinc. (for more details see the latest edition of “Coatings”). Such sprayed coatings are normally applied by the combustion or electric arc processes.

These major enterprises reinforce the confidence of constructors of large structures, often operating under severe conditions, in thermally sprayed sacrificial coatings for protection.

In the entirely different area of engineering components problems of aqueous corrosion are frequently accompanied with other factors requiring consideration, such as wear, elevated temperatures and attack by aggressive chemicals and gases. In these cases much harder, denser coatings of more exotic materials are required, typically ceramics, cermets and superalloys and these materials need to be applied by the High Velocity Oxygen Fuel (HVOF) or Plasma processes. In some cases the latter is frequently applied in the controlled conditions of a vacuum chamber. Other surfacing technologies such as vapour deposition are also of growing use for extreme conditions.

At this conference, expert speakers will review developments in some of the above areas.

The keynote speaker will be Roger Hudson of Corus who will review the use of thermally sprayed coatings in corrosion control of steel structures. Roger will also introduce “ICATS” an Institute of Corrosion scheme for certification of surface preparation and protective coating operatives.

This conference is organised by the Thermal Spraying and Surface Engineering Association and is supported by the Institute of Corrosion.

Alternatives to Hard Chrome Plating

Wednesday, 20 April 2005
Himley Hall, Dudley

Environmental, health and safety regulations are placing increasingly stringent demands on chrome plating process operations and waste treatments. In consumer industries chrome is mostly known as the shiny, decorative plating used on car trim, steel office furniture and motorcycle exhausts. Decorative applications use very little chrome (often just a few microns thick) and are not a particularly serious problem. However, hard chrome plating, the process for thicker engineering coatings (more typically several tens of microns thick) produces large volumes of carcinogenic hexavalent chromium solution that can be thrown into the air as a fine mist during the plating process.

Hard chrome plating is not easy to replace, since it is a very simple technology that is widely available, very versatile and, to date, has been seen as relatively inexpensive. However, many modern coatings can now be used instead of chrome plating, and usually with better results (higher reliability, greater hardness, less wear). Furthermore, modern coating alternatives are dropping in price while the cost of chrome plating is rising. Already, thermal spray coatings are replacing hard chrome plating on aircraft landing gear, gas turbine journals and the hydraulic rams of earth moving equipment.

The aim of this conference is to help determine which hard chrome plating alternative is right for an application and the technologies covered will include:

• Thermal spraying
• Nickel plating
• Trivalent chromium
• Electrospark deposition
• Heat treatments and plasma nitriding
• PVD
• CVD
• Plasma electrolytic oxidation

Surface Engineering for the Transport Industry

Thursday 9 December 2004
Warwick University

The transport industry and surface engineering have been synonymous for hundreds of years from the days of leather coated wooden brake blocks and iron clad wheels for horse-driven carriages, through the heat treatment of shafts and gears to the sophisticated low friction carbon coatings used in today’s modern transmission systems.

But as the transport industry strives to reduce fuel consumption, reduce emissions, reduce cost, meet end-of-life vehicle regulations and sustainability targets; then surface engineering will become more and more important, especially on light weight and low cost materials.

This seminar will address some of these issues by discussing the latest surface engineering technologies used in the transport industry. Talks will include:

• new low friction coatings for light weight cylinder blocks and cylinder liners
• coating developments for automotive engine bearings
• ceramic coatings for light metal alloys
• EB-PVD thermal barrier coatings – application and development
• Keronite and composite complementary technologies for advanced material solution
• piston ring coatings
• high performance PVD coatings for the transport industry

The seminar will be introduced by Mr Nick Barter, Chairman of Foresight Vehicle and is being organised by the Thermal Spraying and Surface Engineering Association. Also supporting the seminar are the Institute of Materials, Minerals and Mining; the Institution of Mechanical Engineers and Foresight Vehicle.here. Edit or remove this text inline or in the module Content settings. You can also style every aspect of this content in the module Design settings and even apply custom CSS to this text in the module Advanced settings.

Health and Safety and Environmental issues as applied to the Thermal Spraying Industry.

Held on 29th April 2004
at BOC, Technical Centre, Lower Walsall Street, Wolverhampton

On this occasion the theme will be Health and Safety and Environmental issues as applied to the Thermal Spraying Industry. This very important topic will be largely based on the Code of Practice which the TSSEA published in October 2001 which is entitled “The Safe Operation of Thermal Spraying Equipment”. Covering all issues of safety requirements in this industry, this comprehensive document includes installation, operation and maintenance of all thermal spraying processes whether installed in soundproof enclosures or with local extraction systems typical of site operations. This document is recognised as an authoritative study on the different hazards and how best to combat them. Members of the association may freely download copies using their log in details and non members may obtain copies for a nominal price of £50.00 Non members attending the conference will be supplied at a 50% discount.

Expert speakers from the Gas supply companies will deal with the issues of compressed gases used for combustion and inert gases typically used in the Plasma process or for cooling purposes. The major spraying equipment suppliers and Health and Safety experts will also be represented. Explanations will be given for Risk Assessments and Zoning of hazardous areas where special electrical equipment must be used. Noise, dust and fume will also be covered.

All who operate or are in any way concerned with thermal spraying equipment will find this conference to be very valuable in explaining the requirements for safe practices in this industry and how best to achieve them.

Surface Engineering Coatings in the National Utilities

To be held on 6th November 2003
at Himley Hall, Himley, Dudley

These industries have needs for surface coatings of many varieties applied by such methods as Thermal spraying, Vapour Deposition, Welding and Plating, to name a few. Each of these technologies have variations on their common
theme providing a multitude of coating characteristics which find applications in all engineering industries. These variations have been introduced by research and development in the search for ever more flexibility and quality and hardly a year goes by without the introduction of more advanced methods. Changes in existing coatings occur much more frequently.

For example, in recent years the Thermal spraying industry has seen conventional flame spraying overtaken first by electric arc, then Plasma in turn im-proved by High Velocity systems and lately the introduction of Cold spray. These changes do not replace the old systems, but introduce more scope for applications, previously untried, and, perhaps more importantly, a better un-derstanding of expected performance in service.

The expert speakers listed here will not only cover the typical coatings pres-ently being applied by the contracting industry and users, but also a view of future trends being established by leading research and development organisations in the U.K.

The association is convinced that such events as this conference, held on a regular basis, are essential to provide engineers up to date information on the ever changing technologies in surface engineering.

Programme 6th November 2003

Full details of timing and presentation titles will be issued on the day.

Speakers will include:-

Ceramic Coatings for Industry

To be held on 16th July 2003
at The Beaumanor Hall, Woodhouse, Near Loughborough
Leicestershire

As usual we will have a team of expert speakers which will include:

Mr K Harrison. Sulzer Metco Limited
Mr K Lawson Cranfield University
Mr S Bomford Plasma and Thermal Coatings
Mr M Cole BOC Gases Europe
Mr M Wilson Pamarco Limited (+ 2 or 3 more)

The Versatility of thermally sprayed coatings
in the Engineering Industry

To be held on 25th April 2003
at the offices of The Welding Institute Ltd
Aurora Court, Barton Road, Riverside Park Middlesborough

Co Sponsored by The Welding Institute Limited

Options for coatings.

There are now many surfacing technologies for either repair or improvement coatings for components or structures available to engineers.

The versatility of the thermal spraying processes is unique in that there is a wid range of materials for coating to choose from (any material which has a melting point) and there is no limit to the size or quantity of components which may be treated using automated equipment. Using hand operated preparation equipment and lightweight spraying guns no steel structure is too large to be treated. For one off repair applications, cylindrical components may be held in conventional machine tools, rotated and the spraying gun traversed so that an even coating may be applied.

For batch or production quantities special purpose machines for component handling, combined with programmed robotic gun manipulators, are now commonplace, enabling coatings to be applied with the highest possible level of quality control. Although spraying may be regarded essentially as a “line of sight process” there are instances where customised spraying devices are available to treat small internal diameters where the component need not be moved during treatment. A classic example of this is described in one of the presentations at this conference.

Different coating characteristics may be achieved not only by the choice of material, but also by varying the operating parameters. Normal wear resistant coatings are achieved by applying materials such as Tungsten Carbide, using optimum parameters to ensure the ‘best’ coating characteristics, such as maximum inter particle cohesion and density. However abradable coatings used in the aerospace industry need to combine a degree of erosion resistance with minimum resistance to the cutting action of a fast rotating component when an interference occurs. This is achieved with specially engineered coating materials and carefully prepared operating parameters.

In addition to providing coatings for mechanical components, thermal spraying is also used for the protection of iron and steel structures against corrosion. Coatings of zinc, aluminium or their alloys are commonly used to protect such structures as bridges and offshore platforms, where the most arduous and aggressive conditions are experienced. Such protection is afforded by the sacrificial action of these materials besides
conferring barrier protection.

The programme today provides yet another variation in the use of sprayed coatings of Zinc, this time on concrete structures. In this case a coating of Zinc is sprayed on to the exterior of the concrete structure e.g bridges, to provide a secondary anode for an impressed current to be conveyed to protect the reinforcing bars.

Programme 29th April 2003

Full details of timing and presentation titles will be issued on the day.

Speakers will include:-

Taking Coatings to the Limit – Vacuum and Low Pressure Coatings

To be held on 10 July 2002 at “The Beaumanor Hall Conference Centre”, Woodhouse, Loughborough, Leicestershire

Over the past 30 years or more, developments in most engineering technologies has been directed at improving efficiency and quality whilst the markets for these processes have naturally increased keeping pace with industrial growth.

However the history of development in surface engineering is not only about the improvements in the equipment used to provide surface coatings but also the consequential growth in the functions which these coatings are to perform. Thus the increase in market potential for surface coatings has grown phenomenally and continues to do so.

As an example in the early fifties thermally sprayed coatings (metal spraying using combustion gases) were used by adventurous maintenance engineers to replace lost metal for interference fits or other such applications where there was no intended motion between the coating and the mating component. Improvement in coating adhesion levels by the use of special bonding materials, such as Molybdenum, provided the first leap forward and running surfaces, such as plain bearings, were then included. This led to salvage of mis-machined parts where for the first time engineering components were sprayed in batches as opposed to the one off repair applications.

Designers began to recognise the potential for increase in performance by applying coatings of materials which could not be used economically for component manufacture. e.g. stainless steel coatings on to mild steel in areas where corrosion resistance was combined with wear problems.

The subsequent introduction of Plasma spraying in the early sixties saw the introduction of coatings on gas turbine engines making more use of the increasing variety of materials for thermal barrier applications and resistance to erosion by fast moving aggressive gases.

To day the automotive industry is using coatings in mass production to provide resistance to wear in lightwight engine cylinder bores, piston rings and gear box components.

The move to produce coatings applied under controlled conditions ( Vacuum or low pressure chambers) resulted in even higher quality coatings using only inert gases increasing the application to include such critical parts as bio medical implants.

Other surfacing technologies such as vapour deposition, weld surfacing and electroplating have seen similar advances resulting in expansion in their markets as the latest technologies and materials make possible the use of surface coatings operating in the most hostile environments. Presentations at this conference will highlight this continuous development in – “Taking coatings to the limit” .

Details of titles and timing of presentations will be available shortly and will be handed out on the day.

Speakers will include:-

Surface Engineering Coatings in the Paper, Pulp and Printing Industries

25th April 2002 at the Village Hotel,
Waterford Business Park, Bury, Greater Manchester.
Co sponsored by the Paper Industry Technical Association.

Amongst the applications for surface coatings used by these industries, different kinds of rolls feature very importantly. Here, it is essential that a good surface finish is maintained on the rolls in order that the quality of the product is maintained whatever the function.

Steam heated dryer cylinders and rolls are surface coated by thermal spraying and these may be treated in house by the applicator or, as in the case of the famous Yankee Drier Drums, which are typically 5 metres or more in diameter, have to be treated in situ.

Large Calender rolls which may be used in the final stages of production of special paper are required to have a high surface finish and are sprayed with hard wear resistant coatings such as Tungsten Carbide. After diamond wheel grinding and in some cases polishing, WC coatings may be finished to 2 micro inches (0,05 microns) or better.

In the print industry, Anilox rolls are sprayed with a ceramic material and laser engraved to produce a surface profile which will deliver a controlled amount of ink to the paper being printed.

Such rolls, and many other applications will be described by the speakers during the conference, illustrating how worn or scarred components may be salvaged to provide the surface texture required. Such repair operations not only save money by extending component life but also conserve natural resources and energy required in producing replacement components.

Other surfacing technologies such as Welding are also used extensively where coating strength and resistance to shock loading are required and applications using this technology are also covered in this conference.

Surface Engineering in the Transport Industry

Wednesday 5th December
Heritage Motor Centre,
Gaydon,
Warwickshire.

The use of surface engineering to improve component performance has been the subject of much of the development in recent years,.particularly that of thermal spraying in the Aerospace and Automotive industries. As a result large production quantities of parts are now being treated using specially developed equipment and programmed coatings using robots in conjunction with automated production plant are now commonplace.

This will be extended in the future by the use of coatings to enable the designer to extend the capabilities of his product. As an example, thermal barrier coatings enable higher operating temperatures which improve the efficiency of gas turbine and other engines in the transport industry.

Surface coatings have moved on from the early useage for repair and salvage, followed by surface improvement resisting severe wear and attack by aggressive environments. They have now moved on to become an important addition to manufacturing technologies available to enable product design to further the capabilities of engines and other machines.

Engineers, not only those in the transport industry but from all areas of industrial activity, will benefit from learning how surface coatings are now being used and assess how they may be used profitably in other industries in todays competitive global manufacturing industry.

Selection and Evaluation

Held on 12h July 2000 at the Beaumanor Hall, Woodhouse Eaves, Near Loughborough.

The AGM was attended by 20 members and the agenda included the approval of the annual accounts, committee membership and other routine matters.

Mr Keith Harrison offered to continue in the office of chairman for a further year and this was approved unanimously by the attendees. Kieth reported that 1999 had been an eventful year, particularly referring to the setting up of a Health and Safety Committee to establish a Code of Practice for the safe operation, installation and maintenance of thermal spraying equipment. This work is progressing well and the chairwoman, Dr. Jane Blunt (Physics Department, University of Cambridge) reposts that a final draft will be ready within 2-3 months. It is interesting to note that a number of participants identify that the  controls associated with Healt and Safety measures also have a beneficial effect on coating quality and cost savings.

“Coatings”, the official publication of the TSSEA, is now published and controlled directly by the association and is establishing a good reputation for its contents. “Coatings” is distributed to some 4,000 subsribers to the IoM publication “Materials World”. This circulation, together with our own database, makes this a popular attractionfor advertisers. (Rates may be obtained from the Secretary).

The total number of members remains much the same since January 1998. Inevitably, for various reasons, we lose some but the number of new members is maintaining the overall size of the organisation. The number of universities have extended to 7 in the UK and this bodes well for the future development of thermal spraying and other surface engineeing processes.

The conference, held on the same day was attended by 35 delegates and the exhibition attracted much interest. The speakers for the conference on Selection and Evaluation included:

Coatings for Protection

Held on 5th April 2000 at the Ardencote Hotel and Country Club, Lye Green Road, Claverdon, Warwickshire.

The TSSEA held the second in the series of Seminars on the theme “Challenge the Experts” on April 5th 2000 where the topic was Coatings for Protection.

The speakers included:

The speakers described the range of coatings to provide protection against corrosion, oxidation and erosion at temperatues up to 1000°C. The materials included:conventional paint systems for ambient temperatures; multicoat systems of aluminium/ceramic having a smooth glassy finish additionally conferring anti-fouling properties at temperatures in the 500/600°C range; high temperature thermal barrier systems for operation at temperatures over 1000°C.

Coatings for Protection

Held on 5th April 2000 at the Ardencote Hotel and Country Club, Lye Green Road, Claverdon, Warwickshire

The TSSEA held the second in the series of Seminars on the theme “Challenge the Experts” on April 5th 2000 where the topic was Coatings for Protection.

The speakers included:

The speakers described the range of coatings to provide protection against corrosion, oxidation and erosion at temperatues up to 1000°C. The materials included:conventional paint systems for ambient temperatures; multicoat systems of aluminium/ceramic having a smooth glassy finish additionally conferring anti-fouling properties at temperatures in the 500/600°C range; high temperature thermal barrier systems for operation at temperatures over 1000°C.

Selection and Evaluation

Held on 12h July 2000 at the Beaumanor Hall, Woodhouse Eaves, Near Loughborough.

The AGM was attended by 20 members and the agenda included the approval of the annual accounts, committee membership and other routine matters.

Mr Keith Harrison offered to continue in the office of chairman for a further year and this was approved unanimously by the attendees. Kieth reported that 1999 had been an eventful year, particularly referring to the setting up of a Health and Safety Committee to establish a Code of Practice for the safe operation, installation and maintenance of thermal spraying equipment. This work is progressing well and the chairwoman, Dr. Jane Blunt (Physics Department, University of Cambridge) reposts that a final draft will be ready within 2-3 months. It is interesting to note that a number of participants identify that the  controls associated with Healt and Safety measures also have a beneficial effect on coating quality and cost savings.

“Coatings”, the official publication of the TSSEA, is now published and controlled directly by the association and is establishing a good reputation for its contents. “Coatings” is distributed to some 4,000 subscribers to the IoM publication “Materials World”. This circulation, together with our own database, makes this a popular attraction for advertisers. (Rates may be obtained from the Secretary).

The total number of members remains much the same since January 1998. Inevitably, for various reasons, we lose some but the number of new members is maintaining the overall size of the organisation. The number of universities have extended to 7 in the UK and this bodes well for the future development of thermal spraying and other surface engineering processes.

The conference, held on the same day was attended by 35 delegates and the exhibition attracted much interest. The speakers for the conference on Selection and Evaluation included: