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Poster Session: Arc and Laser Spraying Processes
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Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 1031-1034, June 7–9, 2017,
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Increase of the pressure of air flow from 0.6 to 1.2 MPa provides the growth of its speed from 300 to 600 m/s. The increase of air flow speed reduces the flight time of drop from the arc to the substrate and them against the prepared surface at higher temperatures. Increase of the pressure of air provides reduction the size of drops and oxides between lamellas as well as improves the mechanical characteristics.
Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 1035-1039, June 7–9, 2017,
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An alumina-silicon dioxide composite coating was fabricated by cold spraying on AZ31 magnesium alloy. The microstructure, mechanical properties (microhardness, bonding strength and tribological behaviour) and anticorrosion property of the coating as a function of the ceramic volume were investigated. The results show that the composite coating presents higher bonding strength and microhardness. Addition of silicon dioxide significantly enhances the anti-wear and anti-corrosion performances of AZ31 magnesium alloy.
Proceedings Papers
ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 1019-1024, May 10–12, 2016,
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This study assesses the effect of machine hammer peening (MHP) and carbide grain size fraction on the friction and wear behavior of arc-sprayed WC-W 2 C FeCMnSi coatings. SEM examination shows that post-treatment by MHP compresses the coating, reducing both thickness and porosity, particularly in coatings with ultrafine carbides. The treatments also cause cracking, however, especially in carbide phases. Ball-on-disk tests were carried out on as-sprayed and treated samples to determine sliding wear and friction properties, and dry sand rubber wheel tests were used to evaluate abrasion resistance. SEM and EDX analyses before and after wear testing show how coating microstructure and grain size correlate with the friction and wear test results obtained and the given surface treatments.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1138-1143, June 2–4, 2008,
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To use the manifold possibilities that arc spraying offers to deposit wear resistance layers, the knowledge of the particle formation and their characteristics are necessary. The work is focused on studying the particle trajectories during arc spraying with cored wires. Different cored wires under various spraying parameters are investigated by means of a high speed camera. Particle properties in-flight, such as velocity and temperature are determined. Correlation between particle trajectories and particle characteristics at different spraying conditions are established. At the same time, the particle-laden gas flow is simulated numerically and the computed solutions are used to illustrate the utility of the proposed CFD model and compared with experimental results. The employed mathematical model represents a system of macroscopic conservation laws for the continuous gas phase and for the gas-solid mixture. This formulation makes it possible to circumvent the numerical difficulties associated with the implementation of a (potentially ill-posed) two-fluid model. The discretization in space is performed using a high-resolution finite element scheme based on algebraic flux correction in terms of local characteristic variables. The artificial diffusion operator is constructed on the discrete level and fitted to the local solution behavior using a multidimensional flux limiter of TVD type.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1144-1146, June 2–4, 2008,
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Twin wire arc sprayed Zn, Al and Zn/Al 85/15 coatings were investigated for comparison of their corrosion resistance, electrochemical behavior. The Zn, Al and Zn/Al 85/15 coatings possess prominent electrochemical passivation behavior. Oxide formation mainly onto the coating surfaces were identified with energy-dispersive X-ray analysis and were believed to be responsible for the passivation phenomena observed in the electrochemical polarization. Zn and Al are more negative in electrochemical potential than iron. Zn coatings act as a sacrificial anode and providing cathodic protection. Aluminum shows passive corrosion protection according to stable oxide layer occurs on coating surface. Zn/Al 85/15 coating show two corrosion protection mechanisms together. In this study, steel samples were coated with Zn, Al and Zn/Al 85/15 in optimum conditions by wire arc spraying technique. These coatings were investigated behaviors of polarization and corrosion resistance with electrochemical test.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1147-1152, June 2–4, 2008,
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Zn and Zn/Al coatings were manufactured by using twin wire arc spray (TWEA) system under various gas pressure and current. Microstructure, hardness, surface roughness and adhesion strength of the coatings were investigated by using standard characterization methods. Test results show that increasing atomizing gas pressure increased mechanical properties and surface quality. The process current had an important role on microstructural, mechanical properties and surface quality.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1153-1158, June 2–4, 2008,
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The cavitation erosion result mass loss. Welding is the most common technique used to recover the geometrical profile of the blades. However it is known that tensile residual stress can develop. The search for manufacture process that could reduce or eliminate the residual stress level will contribute for a longer life service. The target in this study to evaluate the potential of ASP thermal spray to recover surfaces. The influence of processing parameters on the cavitation resistance and mechanisms was evaluated for three alloys, AWS309LT1, AWS410NiMo and a Co stainless steel known as Cavitec. Coatings were analyzed by optical and electronic microscopy, microhardness and cavitation tests regarding the effect of air pressure. The results showed that lamellae morphology, oxide volume fraction and cavitation resistance were modified by the ASP parameters. The increase in the pressure modified the oxide fraction from 26 to 37% in AWSI309LT1, 23 to 31% for AWS410NiMo and 16 to 23% for Cavitec. Mass loss varied from 3.5 to 4.8 mg/h for AWSI309LT1, 6.65 to 18.19 mg/h for AWS410NiMo, and 3.4 to 4.0 mg/h for Cavitec; the best performance occurred with Cavitec and was associated with higher pressure of deposition and minor oxide volume fraction.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1159-1163, June 2–4, 2008,
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Many studies have investigated methods to reduce cavitation damage in hydraulic turbines and reduce residual stresses after coating deposition. In this work, a cobalt stainless steel was applied by arc thermal spraying. The influence of air pressure deposition and plasma remelting on the microstructure, oxide volume fraction, porosity, microhardness, and cavitation resistance were studied. Microstructures and properties of the AS895HY cobalt stainless steel coatings were investigated by x-ray diffraction, optical microscopy, scanning electron microscopy, microhardness testing, and ultrasonic cavitation testing (ASTM G32-93). The increase in air pressure, 280 to 550 kPa, modified the oxide fraction from 10.9±1.8% to 24.1±2.8% in the samples. The mass loss results in the cavitation tests were 13.8, 19.2, and 15.0 mg/h for the samples with 280, 410, and 550 kPa, respectively. The remelting of the sprayed coatings eliminated the oxides and porosity. Austenite formation was observed in the two remelted layers with decreases in microhardness; for the first layer, this occurred because of the AWS309L substrate dilution. The PTA remelting reduces the mass loss rate to 0.497 mg/h, with 8.02 hours incubation period. Phase transformations were observed in the remelted coating, but not verified in the arc thermal sprayed coatings.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1164-1170, June 2–4, 2008,
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The deposition of cavitation-resistant materials coatings in turbine blades is an important way to reduce cavitation damage. Fe-Cr-Mn-Si is a cavitation-resistant steel with many deoxidation elements, which can be important for arc thermal spraying materials. The influence of air pressure, arc tension, and chemical composition on the microstructure, area fraction oxide, porosity, microhardness, and cavitation resistance were studied. Microstructures and properties were investigated by XRD, optical and electronic microscopy, microhardness testing, and ultrasonic cavitation testing per ASTM G32-93. Chromium addition promotes an increase in area fraction oxide, and reduces the porosity, changing the microhardness. An increase in air pressure raised the oxide fraction in the SMA_A and 2 alloys. The SMA_A mass loss rates were 31.8, 25.8, and 37.2 mg/h, respectively, for the samples with 280, 410, and 550 kPa of air pressure. For the SMA_3 samples, the increase in the arc voltage reduces the oxide fraction, changing the mass loss rate to 43.8, 32.4, and 29.4 mg/h for 25, 30, and 35 V, respectively. Phase transformations occurred in the arc thermal spray, for all coatings, during cavitation tests. The SEM analysis verified that the mass loss in arc thermal spray coatings occurred because of the oxide fracture and delamination of the splats.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1171-1177, June 2–4, 2008,
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Laser assisted direct metal deposition (or simply DMD) belongs to the family of laser cladding. This is flexible and efficient method for elaboration of diverse coatings including functionally graded, multi-layered, etc. The coatings are characterized by excellent adhesion (metallurgical contact), low porosity and variable thickness up to several millimeters and even centimeters. Actually DMD technology is under intensive development. The most important objective is to increase product quality, process stability and reproducibility along with the simultaneous decrease of risks, failures and defects both on processes and on end-products. The use of the TRUMPF 505 DMD machine with 5 kW CO 2 laser allowed to scale-up the technology to an industrial level. The targeted applications are related to petrol, chemical and plastics industries where wear resistance is improved by deposition of a hard-phase coating; in aeronautics DMD is used for near net shape manufacturing from Inconel alloys.