ISO/TC 107/WG 1 - Thermal spraying

This document specifies a method for determining the thermal conductivity of ceramic top coat (TC) constituting thermal barrier coating (TBC) subjected to heat treatment, in a direction normal to the coating surface, from room temperature up to 1 000 °C.

This document specifies quality requirements for manufacturers of thermal sprayed coatings to ensure quality assurance for activities in the field of production. NOTE It is independent of the availability of a quality management system, e.g. ISO 9001, ISO 14001 and ISO 45001, which concern the concept and organization of the quality management. This document defines the quality requirements that are of importance for the manufacturing route. This document is applicable to thermal spraying including all the pre- and post-treatments of the whole coating process for new parts, for repairs and maintenance (e.g. after service) at the workshop or on site.

This document specifies a method for measuring the in-plane Young’s modulus of thermal barrier coatings (TBCs) formed on substrates, from room temperature up to 1 000 °C.

This document specifies how the symbolic representation of thermally sprayed coatings is indicated on drawings.

This document specifies a method for measuring the reproducible linear thermal expansion coefficient of ceramic top coats (TCs) for thermal barrier coatings (TBCs) up to 1 300 °C.

This document specifies requirements for the protection of iron and steel surfaces against corrosion by applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys. In this document, requirements for the planning of the corrosion protection system and for the constructive design of the component to be protected are specified, where thermal spraying is intended to be the process for the deposition of the metallic corrosion protection. Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and aluminium materials under different environment conditions are provided. Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of zinc, aluminium or their alloys are determined. This document is valid for applying thermal-sprayed zinc and aluminium protection coatings against corrosion in the temperature range between −50 °C to +200 °C, taking into consideration the service conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by ISO 17834 and are not in the scope of this document. Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing, electroplating or selection and deposition of organic coatings/paints are not in the scope of this document. Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063-2.

ISO 14918:2018 specifies procedural instructions for qualification testing of thermal sprayers. It defines requirements, ranges of qualification, test conditions, acceptance requirements and certification for qualification testing of thermal spray performance. ISO 14918:2018 is applicable when the thermal sprayer's qualification is required by this document, the purchaser, by inspection authorities or by other organizations. The thermal spraying processes referred to in this document include those spraying processes which are designated as manual or mechanized. The test for mechanised application includes the use of automatically controlled thermal spraying, e.g. robotics, scan units.

ISO 17836:2017 specifies a test procedure to determine the deposition efficiency for thermal spraying. It provides a reliable comparison method between different spray processes and different feed stock. It is applicable for all thermal spray processes (see ISO 14917) and all wire, rod, cord and powder spray materials. It is applicable when data concerning the deposition efficiency of a spray process in connection with a defined spray material are required.

ISO 2063-2:2017 specifies requirements for corrosion protection of steel structures, components or parts, which are coated by thermal spraying of zinc, aluminium or their alloys. ISO 2063-2:2017 specifies requirements for coating manufacturers of surface preparation, thermal spraying, testing and post treatments, e.g. sealing of the coating. ISO 2063-2:2017 applies to metallic corrosion protection coatings in the case of new fabrication in the workshop, as well as on-site and for repair on-site after assembly. Requirements for coating thickness, minimum adhesive strength and surface conditions, specified in a coating specification, are given. Recommendations are given for suitable process steps and quality assurance measures for new production and maintenance and for supervising of corrosion protection works. ISO 2063-2:2017 covers the application of thermal-sprayed zinc, aluminium and their alloys for protection against corrosion in the temperature range between ?50 °C to +200 °C. Heat-resistant protective coatings of aluminium are covered by ISO 17834 and are not in the scope of ISO 2063-2:2017. ISO 2063-2:2017 specifies requirements for the equipment, the working place and the qualification of the spray and testing personnel. NOTE ISO 2063‑1:2017 is addressed to the designer and to the planning engineer of corrosion protection system.

ISO/TR 14232-2:2017 gives guidelines for selecting the powder chemistry or composition for obtaining an objective coating performance. It provides comparisons of coating performance for wear resistance (Table 1) and corrosion resistance (Table 2) to spray powder chemistry/composition. The wear types shown in Table 1 are abrasive, adhesive, chemical, erosion, fretting, impact, rolling and sliding. The corrosion types shown in Table 2 are acid/alkaline/salt, atmospheric, biochemical, biological, chemical agent, chemicals in food, combustion gas, sea water, fresh water, molten metal, molten salt, non-aqueous solution, soil, steam and miscellaneous. The tables give the coating chemistries and describe the composition of spray powder of metals/alloys, ceramics and cermets. The guidelines have been produced on the basis of academic literature, in particular the Journal of Thermal Spray Technology and the Proceedings of the International Thermal Spray Conference.

ISO 20267:2017 specifies a method for measuring the interfacial toughness of thermal spray ceramic coatings at room temperature based on an indentation method. The interfacial toughness is calculated from the mean length of cracks emanating from the corners of the impression induced by a Vickers hardness tester, and it is intended for use with ceramic coatings with a single layer or multilayers. The test procedures proposed in this document are intended for use in an ambient environment. ISO 20267:2017 is recommended for thermal spray ceramic coatings such as thermal barrier coatings, wear resistant coatings and electrical insulating coatings.

ISO 14232-1:2017 specifies measuring methods for the characterization of powders and their technical supply conditions. It is applicable to powders that are used in thermal spraying on the basis of their physical and chemical properties.

ISO 14916:2017 specifies the procedure to determine the tensile adhesive strength of thermally sprayed coatings under tension in the direction normal to the surface of the coating by applying a tensile test. By using this procedure, comparability of the test results is ensured. The test is intended to determine the tensile adhesive strength between the thermally sprayed coating and the substrate material or between the bond and top coat and/or of the cohesive strength of the related coat of the coating system. In some cases, thermally sprayed coatings might have more than two layers. The method specified in this document applies also to determine the tensile adhesive strength between the interfaces of different layers in a coating system which consists of more than two layers. This test is sufficient to compare coatings manufactured using same or similar feedstock materials and thermal spray processes with each other. The tensile adhesive strength test is not intended to provide absolute values for evaluation of the durability of coatings under operational use. The test is used to assess the influence of substrate preparation, the spraying conditions and the process parameter on the tensile adhesive strength of thermally sprayed coatings. It can also be employed in order to monitor the consistency of the manufacturing and spraying processes. NOTE This tensile test can also be applied to very thin coatings. Moreover, the infiltration of bonding agent into the thermally sprayed coatings containing a required level of porosity can be minimized using an appropriate bonding agent (foil rather than liquid). For further instructions, please refer to 6.5.3. This tensile test is inappropriate for determining the adhesive strength of fused spray coatings deposited using self-fluxing alloys due to their inherent high adhesion strength values.

ISO 14917:2017 defines processes and general terms for thermal spraying. It classifies thermal spraying processes according to type of spray material, to type of operation and to type of energy carrier. It specifies abbreviations for spray processes, sprayed coatings, and manufacturing steps.

ISO 19207:2016 specifies the classification method of adhesive strength for thermal spray coatings at room temperature by using Vickers hardness testing machine. It classifies the adhesive strength, called adhesion index, evaluated from the maximum indentation force without visible cracking, and it is applicable for relative dense metal coatings, ceramic coatings and cermet coatings. It can be used within comparison within each coating system. The indentation method is not recommended for very thin and very porous coatings and also for the coating system with lower cohesion strength than adhesion strength. It is recommended that this test method can be applied for a coating of which porosity is less than approximately 15 %.

ISO 19477:2016 specifies a method for measuring the in-plane Young's modulus, at room temperature, of thermal barrier coatings formed on substrates by thermal spraying.

ISO 18555:2016 specifies the method for determining the thermal conductivities of thermal barrier coatings consisting of metallic bond coats and ceramic top coats, in a direction normal to the coating surface, at room temperature.

ISO 27307:2015 specifies a method for adhesion and cohesion evaluation of thermal sprayed ceramic coating-substrate systems by means of a transverse scratch test. This International Standard is suitable for thermal sprayed ceramic coatings with thickness from 50 μm to over 1 000 μm. It is also suitable for testing ceramic coatings deposited by other spray coating processes, such as cold spray, as well as aerosol deposition.

ISO 13826:2013 specifies a test method of thermal diffusivity of thermally sprayed ceramic coatings using laser technology. This test method is applicable to self-standing thermally sprayed ceramic coatings of thickness between 0,8 mm to 2 mm, deposited by various thermal spray processes and removed from the substrate. Thermal diffusivity values ranging from 10−7 m2/s to 10−4 m2/s are measurable by this test method for temperature range from 300 K to 1500 K.

ISO 14188:2012 specifies test methods applicable to thermal barrier coatings for measuring thermal cycle resistance by using steady cyclical heating and cooling procedures, and for measuring thermal shock resistance using a heating and quenching technique. These measurements are used for the evaluation of durability of thermal barrier coatings to thermal strain. ISO 14188:2012 is applicable for screening thermal barrier coating systems including materials and processing, and not for controlling the thermal spraying processes.

ISO 13123:2011 applies to the test method of cyclic heating to evaluate the thermal-barrier performance and cyclic heat resistance of the thermal-barrier coatings provided for high-temperature components, such as burners, rotor and stator blades, etc. of power-generation gas turbines used in thermal power plants, aircraft engines and rocket engines.

ISO 12670:2011 specifies technical supply conditions for parts with thermally sprayed coatings for the manufacturing or repair of components.

ISO/TR 26946:2011 describes a method for characterizing the porosity of thermally sprayed coatings by metallographical examination. This method is particularly applicable to oxide coatings, such as Al2O3, ZrO2 and TiO2, produced by plasma spray. It also considers the purposes to test the size, shape and density of pores for thermally sprayed coatings.

ISO 12679:2011 includes general guidelines for the workmanlike production of metallic, metal-ceramic, oxide-ceramic and plastic coatings, by means of thermal spraying on metallic and non-metallic parent materials. ISO 12679:2011 provides recommendations for an appropriate and practical spray set-up, faultless manufacturing, monitoring, quality assurance and for non-destructive and destructive tests on the component and accompanying specimen. It describes details about negative effects which can occur. It also gives advice on how to prevent such effects. Permissible coating loads and evaluation categories for quality are not the subject of ISO 12679:2011, as they are dependent on the operating conditions. ISO 12679:2011 can be used for contract purposes.

ISO 14921:2010 specifies the general procedure, when a thermally sprayed coating is applied to enhance the surface properties of a component or to reclaim worn and non-conforming parts. ISO 14921:2010 does not provide definitive methods for specific work due to the variety of the technological, physical and/or chemical requirements and of the component's shape. ISO 14921:2010 specifies the general conditions for the selection of the spraying procedure and materials for this purpose. ISO 14921:2010 does not apply to thermally sprayed zinc and/or aluminium coatings for protection of steel structures against atmospheric corrosion, for which ISO 2063 applies. ISO 14921:2010 also does not apply to coatings of self-fluxing alloys which are subsequently fused. That procedure is covered by ISO 14920.

ISO 12690:2010 specifies the tasks and responsibilities necessary to ensure the quality of a thermal sprayed coating or a coated component, including the coordination of activities related to thermal spraying. Thermal spraying coordination can be carried out by one or a number of persons within the same company or manufacturing department. The responsibilities of the spraying coordinator are specified by the manufacturer.

ISO 14924:2005 specifies the treatment and finishing of thermally sprayed coatings. It is applicable to different types of mechanical post treatment, chemical treatment, and thermal treatment, including chip cutting and other mechanical processes, to sealing, pickling and painting, and fusing, diffusion annealing and hot isostatic pressing.

ISO 17834:2003 is applicable to sprayed metal coatings for protection against corrosion at temperatures up to 1 000 °C (1 273 K). For the protection of iron and steel by sprayed aluminium and zinc coatings against atmospheric corrosion reference should be made to ISO 2063.

ISO 14923:2003 specifies an overview of the characteristics of coatings produced by thermal spraying. It is not possible in ISO 14923:2003 to go into details regarding the different types of coatings and large numbers of coatings due to the fact that all meltable materials can be processed by thermal spraying and that so many and varied thermal spraying processes exist. The tests described are procedures and test criteria in general use for thermally sprayed coatings. Any test methods not mentioned are only used in special cases or under laboratory conditions.

This International Standard specifies requirements for the acceptance inspection of thermal spraying equipment including plasma, arc and flame spraying plants that produce high-quality sprayed coatings.

ISO 2063-1:2017 specifies requirements for the protection of iron and steel surfaces against corrosion by applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys. In ISO 2063-1:2017, requirements for the planning of the corrosion protection system and for the constructive design of the component to be protected are specified, where thermal spraying is intended to be the process for the deposition of the metallic corrosion protection. Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and aluminium materials under different environment conditions are provided. Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of zinc, aluminium or their alloys are determined. ISO 2063-1:2017 is valid for applying thermal-sprayed zinc and aluminium protection coatings against corrosion in the temperature range between ?50 °C to +200 °C, taking into consideration the service conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by ISO 17834 and are not in the scope of ISO 2063-1:2017. Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing, electroplating or selection and deposition of organic coatings/paints are not in the scope of ISO 2063-1:2017. Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063‑2.

ISO 14919:2015 specifies requirements for classification of metal and non-metal wires (solid and cored), rods, cords processed by means of thermal spraying, especially by arc and flame spraying.

ISO 14920:2015 defines the procedure for thermal spraying of self-fluxing alloys that are simultaneously or subsequently fused to create a homogeneous, diffusion bonded coating.

ISO 12671:2012 specifies how the symbolic representation of thermally sprayed coatings has to be indicated on drawings.

ISO 2063:2005 applies to thermal-sprayed metallic coatings for the protection of iron and steel against corrosion by applying zinc or aluminium or their alloys to uncoated surfaces to be protected. This International Standard deals with characteristic properties and gives test methods for coatings obtained by the spraying of zinc and aluminium and their alloys for the general purpose of corrosion protection. It gives firstly the definition, classification and symbols for these coatings in relation to their thickness. It then deals with the preparation of surfaces, application of coatings and their characteristic properties: namely, thickness, appearance and adhesion. Finally ISO 2063:2005 gives test methods for checking these properties.

ISO 17836:2004 defines the procedure for determining the deposition efficiency for a thermal spray process in connection with a spray material and related equipment and auxiliary materials. It is applicable for all thermal spray processes and all wire, rod, cord and powder spray materials. It is essential to apply this International Standard if data concerning the deposition efficiency of a spray process in connection with a defined spray material are required.

This standard specifies requirements so that: ? It is independent of the type of the thermally sprayed structure. ? It defines quality requirements for thermal spraying both in workshops and on site. ? It provides guidance for describing a manufacturer's capability to produce thermally sprayed constructions to meet specified requirements. ? It may also be used as a basis for assessing the manufacturer in respect to his thermal spraying capability. This standard is appropriate when demonstration of a manufacturer's capability to produce thermally sprayed construction, fulfilling specified quality requirements, are specified in one or more of the following: ? a contract between involved parties; ? an application standard; ? a regulatory requirement. The requirements contained within this standard may be adopted in full or may be selectively deleted by the manufacturer if not applicable to the construction concerned. They provide a flexible framework for the control of thermal spraying in the following cases: ? Case 1 To provide specific requirements for thermal spraying in contracts which require the manufacturer to have a quality system in accordance with EN ISO 9001 or EN ISO 9002. ? Case 2 To provide specific requirements for thermal spraying in contracts which require the manufacturer to have a quality system other than EN ISO 9001 or EN ISO 9002. ? Case 3 To provide specific requirements for thermal spraying in contracts which require the manufacturer developing a quality system. ? Case 4 To provide specific requirements for thermal spraying in application standards which uses thermal spraying as part of its requirements or in a contract between relevant parties. It may however be more appropriate for EN ISO 14922-3 or EN ISO 14922-4 to be used in such cases.

This standard specifies requirements so that: ? It is independent of the type of the thermally sprayed structure. ? It defines quality requirements for thermal spraying both in workshops and on site. ? It provides guidance for describing a manufacturer's capability to produce thermally sprayed constructions to meet specified requirements. ? It may also be used as a basis for assessing the manufacturer in respect to his thermal spraying capability. This standard is appropriate when demonstration of a manufacturer's capability to produce thermally sprayed construction, fulfilling specified quality requirements, are specified in one or more of the following: ? a contract between involved parties; ? an application standard; ? a regulatory requirement. The requirements contained within this standard may be adopted in full or may be selectively deleted by the manufacturer if not applicable to the construction concerned. They provide a flexible framework for the control of thermal spraying in the following cases: ? Case 1 To provide specific requirements for thermal spraying in contracts which require the manufacturer to have a quality system other than EN ISO 9001 or EN ISO 9002. ? Case 2 To provide specific requirements for thermal spraying in contracts which require the manufacturer developing a quality system. ? Case 3 To provide specific requirements for thermal spraying in application standards which uses thermal spraying as part of its requirements or in a contract between relevant parties. It may however be more appropriate for EN ISO 14922-4 to be used in such cases.

This standard specifies guidelines to describe thermal spraying quality requirements suitable for application by the manufacturers using the thermal spraying process for coating new parts, for repair and maintenance. They are structured in the way that they can be used for any type of construction to be sprayed. These guidelines relate only to those aspects of the quality of the final construction to be sprayed which may be influenced by thermal spraying and allied processes (pre- and posttreatment, etc.). The guidelines define various approaches to quality requirements for thermal spray works, both in workshops and on sites and to provide guidance for describing the capability of a manufacturer on producing thermally sprayed structures of the specified quality. They also can be used by any interested party as a basis for assessing a manufacturer's thermal spraying quality arrangements. The guidelines are intended as a guide for the preparation of regulatory or contractual requirements and for a manufacturer's management to define the thermal spraying requirements for quality system related to the type of thermally sprayed construction. The guidelines are not structured to be used in isolation as a part of any regulatory contractual or managerial requirement. These guidelines are intended to be used for the following purposes: a) providing interpretation of the requirements in the EN ISO 9000 series of standards, as a guideline for specification and establishment of the part of the quality system related to control of thermal spraying as a "Special Process"; b) providing guidelines to establish specifications and thermal spraying quality requirements, where a quality system according to EN ISO 9001 and EN ISO 9002 is not involved; c) assessment of the thermal spraying quality requirements mentioned in a) and b) above. The application of this standard would typically occur in the following circumstances: ? in contractual situation: specification of thermal spraying requirements for quality systems; ? by manufacturers: establishment and maintenance of thermal spraying quality requirements; ? by committees preparing structural codes or other application standards: specification of thermal spraying requirements; ? by interested parties, e.g. third parties, customers or manufacturers management: assessment of thermal spraying requirements.

This standard specifies requirements so that: ? It is independent of the type of the thermally sprayed structure. ? It defines quality requirements for thermal spraying both in workshops and on site. ? It provides guidance for describing a manufacturer´s capability to produce thermally sprayed constructions to meet specified requirements. ? It may also be used as a basis for assessing the manufacturer in respect to his thermal spraying capability. This standard is appropriate when demonstration of a manufacturer´s capability to produce thermally sprayed construction, fulfilling specified quality requirements, are specified in one or more of the following: ? a contract between involved parties; ? an application standard; ? a regulatory requirement. The requirements contained within this standard may be adopted in full or may be selectively deleted by the manufacturer if not applicable to the construction concerned. They provide a flexible framework for the control of thermal spraying in the following cases: ? Case 1 To provide specific requirements for thermal spraying in contracts which require the manufacturer to have a quality system other than EN ISO 9001 or EN ISO 9002. ? Case 2 To provide specific requirements for thermal spraying in contracts which require the manufacturer developing a quality system. ? Case 3 To provide specific requirements for thermal spraying in application standards which uses thermal spraying as part of its requirements or in a contract between relevant parties.

Specifies characteristic properties and test methods for coatings intended for corrosion protection. This second edition cancels and replaces the first edition (1973). Annex A forms an integral part of this standard. Annex B is for information only.