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New Energy and Semiconductor Industry

Thermal spray technology has emerged as a valuable tool in the new energy and semiconductor industries, offering various solutions to enhance the performance, durability, and functionality of components.

Thermal Spray Application for New Energy and Semiconductor Industry

1. New Energy Industry

(1) Battery Components

Corrosion Protection:

In new energy applications such as electric vehicles and energy storage systems, batteries play a crucial role. Battery housings and terminals are often exposed to various environmental conditions, including moisture and corrosive substances. Thermal spray coatings, especially those made of corrosion-resistant alloys or ceramics, can be applied to protect these components from corrosion. For example, a ceramic coating on a battery housing can act as a barrier against moisture and corrosive electrolytes, thereby prolonging the lifespan of the battery.

Thermal Management:

Batteries generate heat during charging and discharging processes, and efficient thermal management is essential to maintain their performance and safety. Thermal spray coatings with high thermal conductivity materials can be applied to battery components to improve heat dissipation. This helps in regulating the battery temperature, preventing overheating, and ensuring the stable operation of the battery system.

(2) Solar Panel Components

Anti-Reflective Coatings:

Solar panels rely on efficient absorption of sunlight to generate electricity. Thermal spray can be used to apply anti-reflective coatings on the surface of solar panel cells. These coatings reduce the reflection of sunlight, increasing the amount of light absorbed by the cells and thus enhancing the power generation efficiency of the solar panel. For example, a thin layer of a specific ceramic material applied via thermal spray can significantly lower the reflectance of the solar panel surface.

Weather Resistance:

Solar panels are installed outdoors and are exposed to various weather conditions such as rain, snow, wind, and ultraviolet (UV) radiation. Thermal spray coatings can provide protection against these elements. Coatings made of durable materials like ceramics or certain alloys can prevent the degradation of the solar panel surface due to weathering, maintaining its performance over time.

(3) Wind Turbine Components

Wear Resistance:

Wind turbines operate in harsh environments with high rotational speeds and continuous exposure to wind and dust. Components such as the rotor blades, gearboxes, and bearings experience significant wear. Thermal spray coatings with wear-resistant materials like tungsten carbide or chromium carbide can be applied to these components to improve their wear resistance. This ensures the proper functioning of the wind turbine and reduces the frequency of component replacements, thereby saving costs and maintaining the efficiency of the power generation system.

Corrosion Protection:

Wind turbines are also exposed to corrosive environments, especially in coastal areas or regions with high humidity. Thermal spray coatings, particularly those made of corrosion-resistant alloys or ceramics, can protect the turbine components from corrosion. This helps maintain the integrity of the turbine structure and prolongs its service life.

2. Semiconductor Industry

(1) Wafer Processing

Surface Passivation:

In semiconductor wafer processing, the surface of the wafer needs to be protected from contamination and oxidation. Thermal spray can be used to apply a thin layer of a protective material, such as a ceramic or a special alloy, to the wafer surface. This layer acts as a passivation layer, preventing unwanted chemical reactions and maintaining the purity and integrity of the wafer. For example, a ceramic coating can block the entry of oxygen and other contaminants, ensuring the quality of the semiconductor device being manufactured.

Thermal Diffusion Barrier:

During certain semiconductor manufacturing processes, such as doping, there is a need to control the diffusion of atoms. Thermal spray coatings can serve as a thermal diffusion barrier. For example, a coating made of a specific material can limit the movement of dopant atoms, ensuring the accuracy of the doping process and the quality of the resulting semiconductor device.

(2) Packaging and Encapsulation

Thermal Management:

Semiconductor devices generate heat during operation, and proper thermal management is crucial to ensure their reliability and performance. Thermal spray coatings with high thermal conductivity materials can be applied to the packaging and encapsulation materials of semiconductor devices. This helps in dissipating heat more effectively, preventing overheating and ensuring the stable operation of the device. For example, a coating on the exterior of a semiconductor package can transfer heat away from the device more efficiently, reducing the temperature gradient and improving the overall performance.

Moisture Barrier:

Semiconductor devices are sensitive to moisture, which can cause degradation and malfunction. Thermal spray coatings can be used to apply a moisture barrier layer to the packaging of semiconductor devices. A coating made of a durable material like a ceramic or a special alloy can prevent moisture from entering the device, protecting it from moisture-related issues and ensuring its long-term reliability.

Thermal Spray Techniques Commonly Used in the New Energy and Semiconductor Industry

1. Plasma Spray

Plasma spray is a widely used thermal spray technique in both the new energy and semiconductor industries. It creates a high-temperature plasma arc by passing an electric current through a gas (usually argon or a mixture of gases). The plasma arc melts the coating material, which is then sprayed onto the surface of the component in the form of fine droplets. Plasma spray is particularly suitable for applying ceramic coatings, such as those used for anti-reflective coatings on solar panel cells or surface passivation on semiconductor wafers. It offers precise control over coating thickness and quality, making it a preferred choice for applications where high precision is required.

2. Flame Spray

Flame spray is another thermal spray technique utilized in these industries. It uses a fuel gas (such as acetylene or propane) and an oxidizer (usually oxygen) to create a flame that melts the coating material. The melted material is then sprayed onto the surface in the form of droplets. Flame spray is often used for applying coatings with a wide range of materials, including metals, alloys, and some ceramics. It is a relatively simple and cost-effective technique, suitable for on-site repairs or coating large surfaces where high precision is not as crucial. For example, it can be used to coat the exterior of a wind turbine blade or the packaging of a semiconductor device where a quick and easy coating solution is needed.

3. High-Velocity Oxy-Fuel (HVOF) Spray

HVOF spray is a thermal spray technique that combines high velocity and high temperature to deposit coating materials. It uses a mixture of fuel and oxygen to create a high-temperature, high-velocity jet that melts and accelerates the coating material towards the surface to be coated. HVOF spray is known for its ability to produce dense and high-quality coatings, especially with materials like tungsten carbide and chromium carbide. It is highly suitable for applications requiring wear resistance, such as coating the rotor blades of wind turbines or the bearings of gearboxes in wind turbines. The high velocity of the sprayed material results in better adhesion to the surface and a more uniform coating, which contributes to its excellent performance in enhancing wear resistance.

The Application Process of Thermal Spray in the New Energy and Semiconductor Industry

1. Surface Preparation

Before applying any thermal spray coating, the surface of the component must be properly prepared. This typically involves cleaning the surface to remove dirt, grease, rust, and other contaminants. For example, using solvents to clean oily surfaces or mechanical methods like sandblasting to remove rust and roughen the surface. The surface roughening is important as it improves the adhesion of the coating to the surface. In some cases, chemical etching may also be used to further enhance the adhesion, especially for certain types of coatings and materials.

2. Coating Selection

Based on the specific requirements of the component (such as wear resistance, corrosion resistance, or thermal management), the appropriate thermal spray coating material is selected. For example, if the goal is to provide wear resistance for a rotor blade of a wind turbine, a coating material like tungsten carbide may be chosen. If it’s for corrosion protection of a battery housing, a ceramic or corrosion-resistant alloy coating may be selected. The selection also takes into account factors such as the operating environment, temperature range, and the nature of the interaction with other components.

3. Spraying Operation

Once the surface is prepared and the coating material is selected, the thermal spray operation is carried out. The spraying technique (such as plasma spray, flame spray, or HVOF spray) is used according to the requirements of the coating material and the application scenario. During the spraying process, parameters such as spraying distance, angle, velocity, and temperature are carefully controlled to ensure the quality of the coating. For example, in plasma spray, the plasma arc temperature and the spraying distance need to be optimized to obtain a uniform and high-quality coating. The spraying operation may be carried out in a dedicated spraying booth to control the spread of dust and fumes and to ensure a clean and safety-working environment.

Benefits of Thermal Spray in the New Energy and Semiconductor Industry

1. Extended Component Life

By providing wear resistance, corrosion protection, and thermal management functions, thermal spray coatings can significantly extend the service life of components in the new energy and semiconductor industries. This reduces the need for frequent replacements and repairs, saving costs in the long run. For example, a wind turbine with properly applied thermal spray coatings on its rotor blades and gearboxes may last several years longer than one without such coatings.

2. Improved Performance

Thermal spray coatings can enhance the performance of components in several ways. For example, anti-reflective coatings on solar panel cells improve the power generation efficiency of the solar panel. Wear-resistant coatings on wind turbine components ensure the proper functioning of the wind turbine and improve its power generation efficiency. In the semiconductor industry, surface passivation and thermal diffusion barrier coatings ensure the quality of the semiconductor device being manufactured. Thermal management coatings on semiconductor devices prevent overheating and ensure the stable operation of the device.

3. Enhanced Reliability

With the protection provided by thermal spray coatings, components in the new energy and semiconductor industries become more reliable in their operation. This is especially important for critical applications such as energy storage systems and semiconductor manufacturing. The coatings prevent premature failure of components due to wear, corrosion, or overheating, ensuring that the devices function properly for longer periods.
In conclusion, thermal spray technology has become an important tool in the new energy and semiconductor industries, offering numerous benefits such as extended component life, improved performance, and enhanced reliability.

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