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Infrared thermography
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Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 455-460, May 21–23, 2014,
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The aim of this study is to determine how various factors, including process parameters and nozzle configurations, affect the shape and size of the spray jet in twin wire arc spraying. In the experiments, steel specimens were sprayed using an iron-based cored wire with a fused tungsten carbide filling. In-flight particle temperature and velocity and fluctuations in voltage and current were measured during spraying. The shape of the thermal spray spot and the 3D footprint of the plume were determined by means of image analysis and tactile surface profiling methods. The results obtained show that spray plume characteristics, and thus particle distribution, are heavily influenced by secondary gas flow, particularly the number, location, and angle of atomization outlet holes in the secondary gas nozzle.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1050-1055, June 2–4, 2008,
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One major shortcoming of thermal barrier coatings applied to gas turbine components is the spallation of the ceramic coating under mechanical stress developing during thermal cycling environments. In order to study the evolution of failure and the expectancy of lifetime under realistic conditions cycling burner rig tests are a well established matter of choice. In the same way the techniques of acoustic emission (AE) testing and infrared (IR) thermography have been widely proofed to provide insight to microscopic crack formation and localization of hidden delaminations, respectively. Both techniques can be utilized to record the evolution of microscopic and macroscopic defects in advance to the apparent failure. Indirectly, this knowledge allows to verify and to improve lifetime models. The aim of this study is to expand the use of AE and IR testing as a rugged in-situ monitoring tools for combustion driven cycling rigs and to provide spatial resolved information on thermal load and failure evolution of the TBC in those tests. For a successful application to an experiment using a gas fired and air cooled burner rig some it is necessary to overcome some limitations which are mainly due to the high level of interfering signals under those experimental conditions.
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 567-572, March 4–6, 2002,
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This paper describes the equipment and procedures used to investigate the effects of the heat load on SOFC surfaces during vacuum plasma spraying. It explains how the authors used a vacuum-sealed IR camera to record thermographic images of the substrate surface as they sprayed different powders and as they varied the dc power, scanning speed, and stand-off distance of the plasma torch. The authors also studied the effect of different cooling methods, including conductive cooling from the backside via a water-cooled aluminum backplate and convective cooling from the front side with a nitrogen gas jet. Using the experimentally obtained data, the authors developed a thermal 3D model of the SOFC plasma spraying process that accounts for torch movements, substrate cooling, and layer growth. An outlook for future work is given expressing an intent to model stress fields within fuel cells during plasma spraying in order to simulate the development of residual stresses. Paper includes a German-language abstract.
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 573-579, March 4–6, 2002,
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This paper discusses the use of IR thermography in the development and control of thermal spraying processes. In the experiments, Al 2 O 3 layers are plasma sprayed on steel, aluminum, and glass substrates while recording surface temperatures. The measurements are then used to establish a correlation between temperature control and internal stress in the layer composite. The work shows that substrate preheating and torch kinematics have a significant effect on residual stress. Paper includes a German-language abstract.
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 779-786, May 28–30, 2001,
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Many thermal spray coating applications require an optimum performance regarding the thermal and mechanical stability of the layer composite. The maximum loads that a composite can sustain, are not only dependent on the intrinsic material properties of the coating, but are also subject to the quality of deposition. The quality of the coating is predominantly influenced by the temperature distribution during the deposition process thereby influencing the residual stress development. Therefore failure of a thermally sprayed coating under mechanical and/or thermal load often could be avoided by an adequate deposition process with well controlled heat and mass transfer, i. e. by avoiding hot-spots on the surface that result in high residual stresses in the composite. With the help of Infrared (IR) thermography an imaging of the lateral and spatial temperature field of a workpiece surface and its evolution in time can be monitored and visualised. In the presented work the atmospheric plasma spraying process serves as an example to demonstrate the suitability of thermographic imaging as a quality control and process optimisation technique for online process monitoring and control in thermal spraying. The results indicate that IR-thermography can be used as a flexible tool for on-line process control of coating manufacturing via thermal spraying, it offers a powerful way to optimise the deposition process.