Electrical & Electronics
Thermal spraying has a wide and diverse range of applications in the electrical and electronics industries.
In terms of conductive coatings, it can spray materials such as copper and aluminum onto substrates to improve the electrical conductivity of components and reduce the loss during electrical energy transmission. Moreover, it can also be used to repair components whose electrical conductivity has decreased due to wear and corrosion.
For dielectric coatings, by means of plasma spraying or powder flame spraying of ceramic materials, high-quality coatings can be formed to achieve electrical isolation. It can also meet the requirements of electronic devices for miniaturization in terms of thin and uniform coatings.
Electromagnetic shielding coatings can effectively shield electromagnetic signals. The parameters such as thickness, composition, and porosity can be customized according to the needs of different devices to prevent electromagnetic interference.
In the field of sensors and microelectromechanical systems (MEMS), functional coatings can be deposited to improve the sensitivity and stability of sensors and expand their applications. During the manufacturing of MEMS components, thin films or coatings with properties such as wear resistance and corrosion resistance can be deposited to enhance their performance and reliability.
Regarding battery components, thermal spraying can form conductive and corrosion-resistant coatings on the surface of current collectors to improve their performance and thus enhance the overall performance of the battery. It can also prepare protective coatings on the surface of electrodes to reduce corrosion and oxidation, prolonging the stability and cycle life of the electrodes.
Application of thermal spraying technology in the electronics and electrical industry
Plasma Spraying
Preparation of Insulating Coatings:
Plasma spraying can spray ceramic materials such as alumina and zirconia onto the surfaces of electronic components to form high-quality insulating coatings. For example, on components like high-voltage switches and insulators, it can effectively prevent electrical breakdown, ensure the safe and stable operation of equipment in a high-voltage environment, and improve the reliability and service life of the equipment.
Manufacture of Functional Ceramic Coatings:
It is used to prepare functional ceramic coatings such as piezoelectric ceramics and ferroelectric ceramics, which can be applied to electronic components like sensors and actuators, realizing the mutual conversion between mechanical energy and electrical energy, expanding the functions and application ranges of electronic components, and meeting the high-performance requirements of electronic equipment.
Repair of Semiconductor Equipment Components:
During the semiconductor manufacturing process, some equipment components, such as quartz tubes and graphite electrodes, are prone to damage due to the influence of high temperature, chemical corrosion, etc. Plasma spraying can use powders similar to the materials of these components for repair, restore the dimensional accuracy and performance of the components, reduce the maintenance costs and downtime of the equipment, and ensure the continuity of semiconductor production.
High-Velocity Oxygen-Fuel (HVOF) Spraying
Preparation of Wear-Resistant Coatings:
The High-Velocity Oxygen-Fuel spraying technology can spray hard alloy materials such as tungsten carbide and chromium carbide onto the surfaces of wear-resistant components of electrical and electronic equipment, such as the rotating shafts of motors, gears, and the shafts of printer drums, to form high-hardness and dense wear-resistant coatings, significantly improving the wear resistance and service life of the components and reducing equipment failures and maintenance times caused by wear.
Formation of Conductive and Thermally Conductive Coatings:
Using metal or alloy powders such as copper and aluminum as spraying materials, the High-Velocity Oxygen-Fuel spraying can prepare coatings with good electrical conductivity and thermal conductivity. They can be applied to the heat dissipation parts of electronic equipment, such as the heat sinks of computer CPUs and the heat dissipation bases of power amplifiers, effectively improving the heat dissipation efficiency, preventing the performance decline and service life reduction of the equipment due to overheating. They can also be used in electrical connection parts to reduce contact resistance and improve electrical conductivity.
Preparation of Anti-Corrosion Coatings:
For electrical and electronic equipment working in harsh environments, such as outdoor distribution boxes and communication base stations, the High-Velocity Oxygen-Fuel spraying can prepare metal coatings or cermet coatings with good corrosion resistance, such as zinc-aluminum alloy coatings and nickel-chromium alloy coatings, providing long-term anti-corrosion protection for the equipment, resisting the erosion of corrosive media such as water vapor, salt, and acid rain in the external environment, and extending the service life of the equipment.
Arc Spraying
Protection and Repair of Metal Components:
Arc spraying can quickly form a layer of anti-corrosion and wear-resistant metal coatings, such as zinc-coated and aluminum-coated coatings, on the surfaces of metal shells, brackets, bridges and other components of electrical and electronic equipment, improving the corrosion resistance and wear resistance of the components and preventing equipment damage caused by corrosion and wear. Meanwhile, for some metal components damaged accidentally or worn out due to long-term use, arc spraying can conduct on-site repairs, restore the dimensions and performance of the components, and reduce the replacement costs and downtime of the equipment.
Preparation of Grounding Electrode Coatings:
In an electrical system, the performance of the grounding electrode is crucial to the safe operation of the equipment. Arc spraying can prepare a layer of metal coatings with excellent electrical conductivity and corrosion resistance, such as copper coatings and copper-clad steel coatings, on the surface of the grounding electrode, improving the electrical conductivity and corrosion resistance of the grounding electrode, reducing the grounding resistance, ensuring that the electrical equipment can quickly introduce current into the earth in case of a failure, and guaranteeing the safety of personnel and equipment.
Preparation of Electromagnetic Shielding Coatings:
By arc spraying metal or alloy materials such as iron, nickel, and cobalt, electromagnetic shielding coatings can be formed on the shells or internal compartments of electronic equipment, effectively blocking the entry of external electromagnetic interference signals and preventing the leakage of internal electromagnetic signals of the equipment, ensuring the normal operation and information security of the electronic equipment. It is applicable to places with high requirements for electromagnetic compatibility, such as communication equipment and computer rooms.
Flame Spraying
Preparation of Anti-Corrosion Coatings:
Flame spraying can use various metals, alloys and polymer materials to prepare anti-corrosion coatings. For example, epoxy powder coatings and zinc coatings can be sprayed on the surfaces of the shells and circuit boards of electronic equipment to provide effective anti-corrosion protection for the equipment, prevent the equipment from being corroded by the external environment, and extend the service life of the equipment. It is especially suitable for some electrical and electronic equipment with relatively low anti-corrosion requirements and relatively good working environments.
Repair of Electronic Components:
For some surface-damaged electronic components, such as resistors and capacitors, flame spraying can use powders similar to the materials of the components for local repair, restore the performance of the components, and reduce maintenance costs. In addition, flame spraying can also be used to repair the plastic shells and insulating parts of electronic equipment, improving the overall performance and reliability of the equipment.
Preparation of Decorative Coatings:
In some electrical and electronic products, such as audio equipment and lamps, flame spraying can be used to prepare decorative coatings, such as colored metal coatings and imitation gold coatings, improving the appearance quality and market competitiveness of the products and meeting consumers’ demands for product personalization and aesthetics.