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Thermal analysis
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Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 637-644, May 4–6, 2022,
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When compared with conventional thermal spraying processes, thermal spraying of suspensions allows to produce coatings with outstanding properties in terms of microstructure, surface topography, and phase compositions, as well as mechanical, electrical or tribological requirements. The use of suspensions as feedstock results in an almost unlimited flexibility in terms of chemical composition of the sprayed coatings. Moreover, thermal spraying of suspensions is a promising technique for processing expensive raw materials. Zn 2 TiO 4 coatings are only one example where the high costs of blended oxide powders as feedstock material hinders the market introduction, whereas outstanding electrical properties and photocatalytic activity of thermally sprayed Zn 2 TiO 4 coatings are of great interest for various industrial applications. In this work, single oxide ZnO and TiO 2 raw materials as well as a Zn 2 TiO 4 feedstock powder were used to develop tailored aqueous suspensions suitable for thermal spraying. To follow the formation of the compositions in the system ZnO-TiO 2 , differential thermal analysis (DTA) and thermal gravimetry (TG) measurements were performed. Preparation routes of stable suspensions with low sedimentation rates, low viscosity and good flowability are discussed. Exemplary microstructures and phase compositions of sprayed coatings are shown. In all sprayed coatings, the Zn 2 TiO 4 phase has been formed during Suspension High Velocity Oxygen Fuel Spraying (S-HVOF). This work demonstrates the potential to develop appropriate cost-efficient suspension feedstocks from single oxide raw materials to obtain Zn 2 TiO 4 coatings.
Proceedings Papers
Laury-Hann Brassart, Anne-Françoise Gourgues-Lorenzon, Jacques Besson, Francesco Delloro, David Haboussa ...
ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 177-188, May 24–28, 2021,
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Industries developing cold-spray processes aim at producing dense and resistant coatings. Controlling microstructure and inter-particular fracture characteristics of sprayed coatings is essential to improve their properties. To do so, post-spraying heat treatment is a promising approach. This work addresses the development of such heat treatments and focuses on the analysis of recovery and recrystallization. Different heat treatment parameters were explored, namely, holding temperature and time, heating rate, and heating method. This approach revealed a competition between recrystallization and other microstructural evolution mechanisms, such as precipitation and porosity coalescence. An optimized heat treatment, allowing microstructural softening and adequate mechanical properties, was sought after. First, differential scanning calorimetry measurements applied to as-sprayed coatings enabled to identify recovery and recrystallization temperature ranges. Then, a variety of heat treatments was applied, involving long-time isothermal holdings as well as shorter cycles. Microstructure analysis and hardness measurements allowed making a first selection of treatment conditions.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 340-345, May 26–29, 2019,
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In this work, CeO 2 -G d2 O 3 co-stabilized ZrO 2 (CGZ) thermal barrier coatings are deposited by solution precursor plasma spraying and the microstructure, phase stability, thermophysical properties, and thermal cycling behaviors of the resulting coatings are investigated and discussed in comparison to conventional 8YSZ coatings.
Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 592-598, May 26–29, 2019,
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Knowledge of thermal interactions between the substrate and deposited particles during cold spraying can shed light on coating formation and bonding mechanisms. In this study, a mathematical model based on the differential quadrature method was used to solve the hyperbolic heat conduction problem to predict the transient thermal evolution associated with the impact of a single particle. In addition, a 2D finite element model was developed to simulate the thermal and dynamic behavior of particle impact. The two models showed good agreement in predicting the maximum temperature at the particle-substrate interface. It was concluded that the proposed mathematical model could be used to predict the transient temperature of metallic and nonmetallic particle-substrate interfaces during cold spray deposition.
Proceedings Papers
ITSC 2018, Thermal Spray 2018: Proceedings from the International Thermal Spray Conference, 105-112, May 7–10, 2018,
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Ba(Mg 1/3 Ta 2/3 )O 3 (BMT), a high melting point refractory oxide, is envisioned as a thermal barrier coating material. In this study, six chemical reagents combinations are investigated as BMT coating precursors: one BMT powder suspension and five Ta 2 O 5 suspensions in nitrate solutions or acetate solutions. A hybrid suspension / sol plasma spray process is designed to axially inject these precursors into a RF thermal plasma torch to synthesize BMT and to deposit nanostructured coatings. X-ray photoelectron spectroscopy (XPS) was used to evaluate the element evaporation during plasma spraying. Thermogravimetric analysis and differential thermal analysis (TG/DTA) are applied to investigate the BMT formation. Parameters such as precursor chemistry and proportion, plasma power, spray distance and substrate preheating are studied with regards to the coating phase structure. The results indicate that the combination of twice the Mg stoichiometric amount with a power of 50 kW shows the best results when using nanocrystalline Ta 2 O 5 as Ta precursor. When choosing nitrates as Ba and Mg precursors, predominant crystalized BMT can be obtained at lower plasma power (45 kW) when compared to acetates (50 kW). BaTa 2 O 6 , Ba 3 Ta 5 O 15 , Ba 4 Ta 2 O 9 , Mg 4 Ta 2 O 9 are the main secondary phases during BMT preparation process. Because of the complicated acetate decomposition, the coating deposition rate from nitrate precursors is higher than that from acetate ones.
Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 1086-1091, June 7–9, 2017,
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Since cold spray is widely considered as an additive manufacturing and damage repair technology, it is crucial to understand the coating build-up process and the temperature evolution. In this work, a 3D numerical model was developed to simulate the transient coating build-up process as well as the heat transfer in cold spray. By coupling the heat transfer with the ALE (Arbitrary Lagrangian–Eulerian) moving mesh and coating thickness model, this 3D model is able to investigate the temperature evolution of a coating which simultaneously grows according to the nozzle trajectory. The nozzle trajectory that represents the heat source and mass flux of particle impact is generated and simulated in the offline programming software RobotStudio. By assigning the results of coating thickness distribution, the simultaneous build-up of coating computational domain is achieved by ALE moving mesh method. The validation of the FEA (finite element analysis) model was carried out by measuring the coating surface temperature via an infrared imaging camera. With the proposed model, it is able to study the actual coating build-up process as well as the heat transfer phenomena, which may provide more insights for the application in additive manufacturing and damage repair.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 867-872, May 11–14, 2015,
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The La 2 Zr 2 O 7 /SrZrO 3 composite with a mol ratio of 1:2 named (La 0.5 Sr 0.5 )ZrO 3.25 (LSZ) was in-situ synthesized by co-precipitation method using ammonia and ammonium oxalate as precipitants. The synthesized LSZ powder showed good phase stability not only from room temperature to 1400°C but also at higher temperature of 1450°C for a long period, as analyzed by thermogravimetry, differential scanning calorimetry and X-ray diffraction, respectively. The bulk LSZ with relative density >95% was prepared by pressureless sintering at 1500°C for 2 h and spark plasma sintering (SPS) at 1300°C for 5 min, respectively. The fracture toughness of the bulk LSZ prepared by both pressureless sintering and SPS were 1.80±0.20 MPa·m 1/2 and 1.95±0.09 MPa·m 1/2 , respectively, which are higher than that of both bulk SrZrO 3 and La 2 Zr 2 O 7 . The coefficients of thermal expansion (CTEs) of the bulk LSZ were 8.4-9.5×10 -6 K -1 in a temperature range of 200-1200°C, which are higher than that of La 2 Zr 2 O 7 but lower than that of SrZrO 3 . The thermal conductivity of the bulk LSZ prepared by pressureless sintering was ~1.1 W·m -1 ·K -1 at 1000°C, which is lower than that of both bulk SrZrO 3 and La 2 Zr 2 O 7 . The LSZ composite is considered as a promising thermal barrier coating material.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 146-156, May 21–23, 2014,
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In this study, Fe-Cr-Al and Fe-Cr-Al-B cored wires were produced and deposited on steel substrates by wire arc spraying. The microstructure, hardness, and high-temperature corrosion behavior of the cored-wire deposits were evaluated in comparison to Fe-Cr and commercial Fe-Cr-Al solid-wire coatings. All coating samples exhibited lamellar microstructures with oxide inclusions, the fewest being in the Fe-Cr-Al-B deposits. Microhardness was measured along coating cross-sections at various distances from the coating-substrate interface. The Fe-Cr coatings were the hardest, followed by the Fe-Cr-Al-B deposits. Thermogravimetric analysis was used to evaluate high-temperature corrosion behavior in a molten salt environment under cyclic conditions, with the Fe-Cr-Al-B cored-wire deposits performing the best.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 603-608, May 21–24, 2012,
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A series of Ni-based cored wires with different boron contents were designed to prepare corrosion-resistant coatings by two-roll wire-arc spraying. These coatings were evaluated for their potential to provide added protection and reduced maintenance for applications in waste-to-energy (WTE) plants. The as-deposited coatings, which primarily are composed of nanocrystalline particles, exhibit uniform and dense layered structures with porosity of about 3%. The investigators selected thermo-gravimetric techniques to evaluate the high-temperature corrosion behavior of the coatings in molten salt environment (Na 2 SO 4 -10 wt% NaCl) at 800°C. The coated surfaces exhibited significantly reduced corrosion rates in comparison to those of the SA 213-T 2 substrate during all tests. These results were due to the formation in the coatings of composite surface oxide films, including Cr 2 O 3 and NiCr 2 O 4 , which serve to prevent the diffusion or penetration of corrosive species. Furthermore, the boron content appears to have a significant influence on the corrosion behavior of the designed coatings: the coating with the best performance had 16 at. % B added. The wire-arc sprayed Ni-based coatings could be an effective and economical treatment to prevent corrosion and extend the lifetime of super-heater tubes in WTE plants.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1126-1129, September 27–29, 2011,
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In this study copper coatings were deposited by cold spraying, under different spraying conditions. Microstructure of the coatings was investigated by optical and scanning electron microscopy. Additionally, differential scanning calorimetry (DSC) and thermal gravimetric analysis were used to examine the quality of the coatings, especially with regards to the extent of the bonded area between the particles. The DCS results indicated exothermic reactions at certain temperatures, which revealed correlations with the spraying conditions and some of the observed microstructural features. In view of these results, it is concluded that thermal analysis can be utilized reliably to assess the quality of coatings, and in particular, to examine the fraction of bonded areas in cold-sprayed deposits.
Proceedings Papers
ITSC 2009, Thermal Spray 2009: Proceedings from the International Thermal Spray Conference, 528-534, May 4–7, 2009,
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Detonation spraying provides the opportunity to produce superabrasive diamond grinding tools under atmospheric conditions. In this study, several methods are used to assess the effects of the spraying process on diamond particles, including SEM analysis, energy dispersive X-ray spectroscopy, differential thermal analysis, thermogravimetric analysis, X-ray diffraction, Raman spectroscopy, and friability and fracture force testing. It was found that under optimized conditions, the thermal and mechanical impact of the detonation can remain low enough to ensure the reliability of the diamonds with no adverse effects.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 411-416, June 2–4, 2008,
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Detonation-gun spray technology is a novel coating deposition process which is capable of achieving very high gas and particle velocities approaching 4-5 times the speed of sound. This process provides the possibility of producing high hardness coatings with significant adherence strength. In the present study, this technique has been used to deposit WC-Co coatings on T22 boiler steel. Investigations on the oxidation performance of detonation-sprayed WC-Co coatings in air and in molten salt Na 2 SO 4 -82Fe 2 (SO 4 ) 3 at 700°C under cyclic conditions have been carried out. The thermogravimetric technique was used to establish the kinetics of corrosion. The uncoated boiler steel suffered a catastrophic corrosion in the form of intense spalling of its oxide scale during air, as well as, molten salt induced oxidation. The WC-Co coated specimens showed lesser overall weight gains in comparison to their uncoated counterparts in both the environments. The oxidation kinetics for the coated specimens followed nearly the parabolic rate law. The overall weight gain has been found to be higher in the case of air oxidation as compared to that in salt environment for all the cases. Scanning electron microscopy/energy-dispersive spectroscopy (SEM/EDS) techniques were used to analyse the corrosion products, which indicated the formation of W and O as main elements in the oxide scales of the coated steel in both the environments.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 767-772, June 2–4, 2008,
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Plasma-sprayed thermal barrier coating (TBC) systems are widely used in gas turbines blades in order to increase turbine entry temperature (TET) with better efficiency. Yttria stabilized zirconia (YSZ) has been usually chosen as the top thermal barrier coating material because of its low thermal conductivity, high thermal expansion coefficient and good corrosion resistance. However as a new candidate commercial TBC material, ceria stabilized zirconia (CSZ) currently looks to be promising. Ceria and ceria based ceramics show an outstanding potential for use at temperatures exceeding 1200 °C. CSZ coatings do not only have high temperature stability, good corrosion resistance and high fracture toughness but also lower thermal conductivity and higher thermal expansion coefficient than YSZ coatings. The sintering and phase transformation characteristics of both ceramic thermal barrier coatings under high temperature conditions are complex phenomena. In this paper, microstructural differences, sintering behaviours (1200 oC, 10h, 25h and 50h) and phase transformations of the plasma sprayed ceria stabilized zirconia (CSZ: ZrO 2 –2.5 wt.%Y 2 O 3 – 25 wt.%CeO 2 ) and conventional yttria stabilized zirconia (YSZ; ZrO 2 –8 wt.%Y 2 O 3 ) coatings and their powder materials have been investigated and compared using thermal analysis techniques, XRD and scanning electron microscope.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 1376-1381, May 2–4, 2005,
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A finite difference model for the thermal analysis of the dynamic stochastic multiple particle deposition process of thermal spray was developed in this paper. Contrary to the traditional layer by layer deposition model, the thermal contribution of individual particles randomly distributed around the spray jet center was taken into account so as to simulate coating formation process. New material was dynamically added onto coating/substrate surface with prescribed gun movement. Latent heat effect was introduced by defining the enthalpy of the material as a function of temperature in order to take into account solidification induced phase change. Real thermal spray process can be simulated with adjustable particle size, spray deposition rate, velocity of gun movement, etc.
Proceedings Papers
ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 866-871, May 10–12, 2004,
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The nanostructured TiO 2 deposits can be synthesized through flame spraying with liquid feedstock based on our previous result. The deposit consisted mainly of anatase TiO 2 with a small fraction of rutile TiO 2 . But the crystalline size of rutile TiO 2 was larger than that of anatase TiO 2 . To clarify the phase formation during the deposition, the nanostructured TiO 2 deposits formed by flame spraying with liquid feedstock were annealed at different temperatures from 200 to 800 °C. The microstructure of the as-deposited and annealed TiO 2 deposits was characterized by transmission electron microscopy (TEM), X-ray diffraction (XRD) and thermal analysis. The transformation of the anatase crystalline to rutile crystalline in the nanostructured TiO 2 was also examined through investigating photocatalytic performance of the TiO 2 coatings to degrade the acetaldehyde under the ultraviolet illumination. XRD analysis showed that the significant transformation of anatase crystalline to rutile crystalline occured at the temperature higher than 600 °C. It was found that the grain size of the rutile phase was larger than that of the anatase phase in the deposits annealed at different temperatures. The deposits annealed at temperature lower than 450 °C presented a good photocatalytic activity. However, although the deposit annealed at temperature of 500 °C contained about 95% anatase crystalline, it became photocatalytically inactive. Despite the anatase contents from 95% to 0% in the deposits annealed at temperatures higher than 500 °C, those deposits presented no significant difference in the photocatalytic activity. On the other hand, thermal analysis suggested that the phase transformation of anatase to rutile occurred at 400 to 500 °C. Based on the experimental findings, a model for the phase formation in flame-sprayed nano-TiO 2 deposit with liquid feedstock and transformation of the nanostructured TiO 2 is proposed.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 1645-1649, May 5–8, 2003,
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Ceramic / plastic composite powder (ceraplas powder) has been produced by Fluidized-bed granulation process (FG process) by varying the binder. Alumina (Al 2 O 3 ) has been used as ceramics and Polyphenylene-sulfide (PPS) has been used as plastics. PPS has high heat and corrosion-resistant performance. Moreover, sprayed composite coatings have been evaluated by the observation of the coating microstructure, the thermal analysis, the corrosion test and the abrasive wear test. It has been recognized that sprayed composite coatings produced by FG powder have high corrosion-resistance and good wear resistance
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 908-911, March 4–6, 2002,
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This paper examines plasma-sprayed alumina and chromia coatings, with and without aluminum phosphate sealing, in order to assess the stability of the as-sprayed layers and phosphate reaction as a function of temperature during the sealing process. Thermogravimetric analysis showed no changes in mass in the alumina layers, an increase of 1.7% in the mass of the chromia layers due to oxidation, and a 14% loss of mass in the sealed layers, which agrees well with the evaporation behavior of a pure seal. Paper includes a German-language abstract.
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 999-1002, May 28–30, 2001,
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Static mechanical properties such as Young's Modulus, Yield Stress and Ultimate Tensile Strength and especially fatigue behavior are important material properties for thermal spray coatings and their industrial application in automotive and aerospace industry. The static and dynamic mechanical properties of Al-Si, Al-Sn, Fe-Cr and Fe-Cr-B based coating materials deposited by APS, TWAS and HVOF were investigated by nanoindentation and in a three point bending test using DMA (Dynamic Mechanical Analysis). This method permits the determination of pure coating material static and dynamic mechanical properties without substrate influence over a wide temperature range. In this investigation all measurements were carried out at room temperature. The DMA method was verified by comparison of Young's modulus to those obtained by nanoindentation.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 1005-1009, May 8–11, 2000,
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The isothermal and cyclic oxidation of freestanding Ni-20Cr-10Al-lY thick coatings has been investigated at 1200°C using TGA, SEM, XRD and XPS techniques. Coatings produced by HVOF are dense and remain crack free after thermal treatments. The protective oxide layer formed did not flake off upon cyclic oxidation as confirmed by SEM analysis. In addition, three oxidation regimes were identified after analyzing TGA data: two below 1000 °C and a third one at approximately 1200°C. The regimes below 1000°C correspond to the selective oxidation of elements on the surface and at the subsurface of the coatings whereas the third regime involves element diffusion from the bulk of the coating to the surface. The oxidation regime became asymptotic at 1200 °C as stable oxides formed. The presence of water vapor affects neither the thickness nor the orientation of oxide crystals formed on the surface as confirmed by the X-ray analysis. The XPS and X-ray results show an inter-diffusion between the coating and substrate with a slight increase in chromium concentration at the interface. Element distribution within the oxide layer was found to follow the order: Al-(oxide)Y-(oxide)/Cr-(oxide)/Ni-(oxide)/NiCrAlY from the outermost oxide layer to the bulk of the coating. These results show that HVOF dense Ni-20Cr-10Al-lY sprayed coatings can be used as anti-oxidant barriers in both isothermal and cyclic oxidation at 1200°C.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 523-530, May 8–11, 2000,
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This investigation was conducted to clarify the effects of process parameters on the formation of the new amorphous coating using Zr-based alloy, which is known as bulk metallic glass forming alloy, by a HVOF (High Velocity Oxygen Fuel) spraying process. Powders used for spraying was prepared by vacuum gas atomization and then crushed by a centrifugal mill. HVOF spraying experiments were carried out using a Tafa JP-5000 spraying gun. DTA (Differential Thermal Analysis) measurements have shown that the amorphous content of the coatings was measured up to about 65% depending on the spraying parameters. The amorphous fraction of the coatings is decreased with increasing the spray distance and the fuel flow rate. Microstructural observations and X-ray diffraction analysis of the spray coated layers reveal that the amorphization behavior during the spraying is attributed to the degree of the solidification of droplets and the oxide (ZrO2) formation in spray coated layers. Therefore, flame temperature and spray distance that can control the carrier gas temperature and undercooling effects of the droplets are the most crucial factors for the evolution of the amorphous phase using this bulk metallic glass forming alloy.
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