Spray Deposition

The gas atomisation equipment in the Powder Group can also be operated in a spray deposition mode and a system has been developed that allows long lengths of foil substrate to be coated on one or both sides with a thin layer of active material.

• Melting under inert atmosphere
• Spraying with inert gas
• Thin layers of metallic coatings sprayed directly from the melt
• Low oxygen, high purity coatings (typically 50-200µm per side)
• Co-deposition of over-sprayed powder
• Reactive alloys can be processed
• Substrate thickness down to 30µm
• Substrate length up to 50m
• Low oxygen content
• High or low porosity coating
• Small batch size
• No cross contamination between runs
• Liquidus temperatures up to 1500°C are processed
• Patented technology.

Applications of spray deposition to date include the direct manufacture of electrodes for high performance nickel metal hydride batteries and the production of supported high surface area base metal catalyst for the chemical industry.