May 29-31, 2008
8:00 AM – 5:00 PM

Location: Thames room Maastricht Expositie & Congres Centrum Maastricht,
The Netherlands

Instructors:
Dr. Christopher C. Berndt, FASM
Professor, Swinburne University of Technology, Hawthorn, Victoria, Australia

Dr. Richard Knight, FASM
Auxiliary Professor, Drexel University Philadelphia, Pennsylvania, USA

Course Overview:
Thermal spray technology and coatings solve critical problems in demanding environments. They provide “solutions” to problems involving repair, wear, high temperature and aqueous corrosion, and thermal protection. Thermal spray can also be used to manufacture net-shapes, advanced sensors and materials for the biomedical and energy/environmental sectors. These and other emerging applications take advantage of the rapid and cost-effective capabilities of thermal spray technology in the OEM and repair industries. Thermal spray processes - twin wire-arc, combustion, high velocity oxy-fuel (HVOF), cold spray and plasma spray, and associated technologies, can deposit virtually any material as a surface coating onto a wide range of other materials. Coating reliability and effectiveness requires that these overlay coatings be selected, engineered and applied correctly. This course provides (i) a thorough grounding and understanding of thermal spray processes, (ii) presents the complex scientific concepts in terms of simple physical models, and (iii) integrates this knowledge to practical applications and accepted thermal spray practices. NO mathematics is used to explain the processes or materials/mechanical engineering. Participants are encouraged to contact the instructor(s) prior to the course so that any particular application or problem can be discussed as a case history.

Learning Objectives
Upon completion of this course, participants should be able to:
• Describe the historical basis for thermal spray technology and the development of equipment and materials as it relates to present-day technology.
• Recognize the terminology, principles and underlying theory of thermal spray technology.
• Compare and contrast thermal spray technologies with respect to competing coating technologies - PVD, CVD, hardfacing, electroplating etc..
• Explain how feedstocks are designed and manufactured and how to select them for different spray processes.
• Identify applicable testing methods and currently accepted industrial practices used for quality control of coatings.

Who Should Enroll?
• Technologists
• Engineers
• Technicians
• Technical marketing personnel
• Graduate students and other professionals entering the thermal spray field or who wish to update their knowledge

Course Outline
1. Surface Science
2. Equipment & Theory
3. Processing & Design
4. Materials
5. Applications
6. Testing & Characterization

Instruction Language: All instruction from this course and all course materials will be in English.

May 30-31, 2008
8:00 AM – 6:30 PM

Location: Seine room Maastricht Expositie & Congres Centrum Maastricht, The Netherlands

Instructors:
Dr. Maher Boulos, TS-HoF
Professor, University of Sherbrooke Sherbrooke, Quebec, Canada

Dr. Pierre Fauchais, FASM, TS HoF
Professor, Université de Limoges Limoges, France

Dr. Joachim Heberlein, FASM, TS-HoF
University of Minnesota Minneapolis, Minnesota

Course Overview
Thermal spray coatings are receiving increased attention as solutions to corrosion, wear and materials compatibility problems. Thermal spray processes using electric arcs, combustion and plasma spray can apply almost any material to the surface of another. These coatings must be correctly engineered and applied to operate as an overlay surface. Education is vital to understanding coating systems and improving thermal spray coating reliability. This 2-day course will review the processing science of a wide range of thermal spray coating processes. The theory of operation and practice of the coatings will be presented, including thermal spray process control, coating application, characterization and testing. Practical coating systems for electric arc, combustion and plasma spray will be reviewed using case studies.

Learning Objectives
Upon completion of this course, participants should be able to:
• Summarize thermal spray processing science, applications and practice.
• Describe how thermal spray processing interacts with the materials it is designed to protect.
• Perform a techno-economic comparison of different technologies.

Who Should Enroll: This course will be of interest to process, application, development and design engineers, researchers and quality-control personnel. It will also be helpful for anyone involved in specifying materials, materials suppliers, sales representatives and technical management.

Course Outline:
1. Introduction and course objectives
2. Overview of Thermal Spray Techniques
3. Flame Spraying Systems
4. Cold Spray
5. Characteristics of the Plasma State
6. Plasma Spraying I - D.C. Plasma Spraying
7. Plasma Spraying II - R.F. Induction Plasma Spraying
8. Wire-Arc Spraying
9. Plasma Transferred Arc
10. Plasma/Particle Interactions
11. Process Diagnostics
12. Powder Production for Thermal Spraying
13. Surface Preparation
14. Deposit Formation and Coating Properties
15. Thermal Spray Process Controls
16. Industrial Applications of Plasma Spray
17. Summary, Conclusions and Discussion.

Instruction Language: All instruction from this course and all course materials will be in English.

May 31, 2008
8:00 AM – 5:00 PM

Location: Danube room Maastricht Expositie & Congres Centrum Maastricht, The Netherlands

Instructor:
Douglas G. Puerta
Director of Metallurgical Engineering IMR Test Labs Lansing, New York

Course Overview
Sound metallographic practices are a prerequisite for the accurate evaluation of gas turbine coatings. Poor preparation can lead to false conclusions about coating integrity and spray booth parameters. This course covers a wide range of topics relating to the metallographic preparation and evaluation of gas turbine coatings. Emphasis is placed on equipment and consumables selection, and how these choices influence the observed structure of a given coating. In addition to an overview of metallographic preparation, we also discuss common issues encountered with various coating families (e.g. hardcoats, ceramic (TBCs), etc.). Methods are covered which can help to ensure that the true coating microstructure has been revealed.

Learning Objectives
Upon completion of this course, participants should be able to:
• Describe the basic elements of metallographic preparation (sectioning, mounting, grinding, and polishing).
• Discuss the relationship between consumables, preparation recipes, and coating structure.
• Determine if features observed within a given coating are inherent or have been induced during metallographic preparation.

Who Should Enroll?
This course is designed for anyone involved in either the processing or evaluation of thermal spray coatings.

Course Outline
1. The use of coatings within a turbine
2. Metallography Overview
3. Sectioning
4. Hot and Cold Mounting
5. Grinding
6. Polishing I – Selection of fine grinding and polishing consumables
7. Polishing II – Recipes and coating families
8. Metallographic Standards
9. Evaluation of Coatings I – Image analysis
10. Evaluation of Coatings II – Electron microscopy
11. Evaluation of Coatings III – Issues specific to the different coating families

Instruction Language: All instruction from this course and all course materials will be in English.