Exxonmobil compares tsa applications
Flame sprayed coupon from unkown applicator (provided by Bob Kay/BRCP)
The substrate has insufficient profile for good adhesion. The first pass of flame spray aluminum formed a carbon deposit from the process and was made on top of the cooled, then the second pass deposit. This is a weak point in the coating.
Thermal Arc Sprayed coupon from standard thermal spray equipment (provided by Bob Kay/BRCP)
This application has through porosity, a weak bond at the interface. The arc has not achieved sufficient temperatures, so incomplete melting of the alloy has occurred.
Thermal sprayed TSA coupon from IMC (provided by Bob Webber/BTCP)
IMC TSA process has a better bond at the interface. The TSA has penetrated the anchor tooth profile for superior adhesion. The molten alloy splats have been deposited at such a rapid rate, proper angle, & high temp that 3-4 mils were accomplished at one pass.