10 - Thermal spray coatings in renewable energy applications

Abstract

Currently, there is an enormous interest on thermal spray to be utilized in most of the renewable energy applications, mainly due to the flexibility, impressive cost–benefit relationship, favorable and tunable coating properties, and the track record as a potential industry-scalable coating technology. The ability to produce dense coatings with low porosity makes thermal spray popular as a corrosion protective coating in biomass incineration boilers, in wind turbine towers, and in geothermal piping systems. Also, on the other hand, the capability to generate enhanced surfaces by making porous and nanostructures makes thermal spray coatings suitable for producing anodes for photocatalytic hydrogen production. The possibility of producing coatings with lower thermal conductivities by inducing pores and cracks makes them a preferred candidate for fabricating thermoelectric devices. Also, these coatings can provide a good protection for hydroturbines from slurry erosion. Currently, thermal plasma spraying processes are being researched to develop a deposition technique that can produce quality silicon films for photovoltaic applications. However, producing these coatings with all the desired properties on an industrial scale in an economic and reliable way is a challenge.