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Proceedings Papers
Physical Characteristics of Alumina Coating Using Atmospheric Plasma Spraying (APS) and Low Pressure Plasma Spraying (VPS)
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ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 283-285, May 10–12, 2004,
... Abstract Physical characteristics of Atmospheric Plasma Sprayed (APS) Alumina coating and Low Pressure Plasma Sprayed (VPS) Alumina coating were investigated. High purity Alumina powder was used for thermal spraying in this test. As electrical properties, the volume resistivity, dielectric...
Abstract
View Papertitled, Physical Characteristics of Alumina Coating Using <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS) and Low Pressure <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (VPS)
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for content titled, Physical Characteristics of Alumina Coating Using <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS) and Low Pressure <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (VPS)
Physical characteristics of Atmospheric Plasma Sprayed (APS) Alumina coating and Low Pressure Plasma Sprayed (VPS) Alumina coating were investigated. High purity Alumina powder was used for thermal spraying in this test. As electrical properties, the volume resistivity, dielectric constant, and the dielectric breakdown voltage were measured at R.T. to 873K. And the coefficient of thermal expansion, and the thermal conductivity were measured at also R.T. to 873K, as thermal properties. Mechanical properties, such as the Young’s modulus, the bending strength, and the cross-sectional hardness value were measured at R.T. As a test result, the Alumina coatings using both APS and VPS have similar properties except for the cross-sectional hardness value that was higher when sprayed by VPS.
Proceedings Papers
Homogenization of Coating Properties in Three-Cathode Atmospheric Plasma Spraying by Use of Advanced Diagnostics and Numerical Simulation—Investigations of Suspension Plasma Spraying (SPS)
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ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 452-459, May 11–14, 2015,
... reconstructions of temperature distribution, suspension behavior measurements, and coating analysis. The paper concludes with a discussion of the future directions of their research and the potential impact on the field of thermal spray coatings. atmospheric plasma spraying computed tomography numerical...
Abstract
View Papertitled, Homogenization of Coating Properties in Three-Cathode <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> by Use of Advanced Diagnostics and Numerical Simulation—Investigations of Suspension <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (SPS)
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for content titled, Homogenization of Coating Properties in Three-Cathode <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> by Use of Advanced Diagnostics and Numerical Simulation—Investigations of Suspension <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (SPS)
This paper discusses a research project with the goal of homogenizing the properties of three-cathode plasma sprayed coatings through the use of advanced diagnostics and numerical simulations. The approach included the development of a suspension injection setup, the determination of plasma and suspension behavior through diagnostic methods such as computer tomography and particle image velocimetry, and the analysis of coating formation through computational fluid dynamics and finite element analysis. The results of their investigations are presented, including tomographic reconstructions of temperature distribution, suspension behavior measurements, and coating analysis. The paper concludes with a discussion of the future directions of their research and the potential impact on the field of thermal spray coatings.
Proceedings Papers
Characterization of YSZ SOFC Electrolyte Deposited by Atmospheric Plasma Spraying and Low Pressure Plasma Spraying
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ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 415-420, May 15–18, 2006,
... spraying (LPPS) and atmospheric plasma spraying (APS) with fused-crushed and agglomerated powders to examine the effect of spray method and particle size on the electrical conductivity and gas permeability of YSZ coating. The microstructure of YSZ coating was characterized by scanning electron microscopy...
Abstract
View Papertitled, Characterization of YSZ SOFC Electrolyte Deposited by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> and Low Pressure <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Characterization of YSZ SOFC Electrolyte Deposited by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> and Low Pressure <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
Yttria doped zirconia has been widely employed as electrolyte materials for solid oxide fuel cells (SOFCs). Plasma spraying is a cost-effective process to deposit YSZ electrolyte. In this study, the 8 mol % Y 2 O 3 stabilized ZrO 2 (YSZ) layer was deposited by low pressure plasma spraying (LPPS) and atmospheric plasma spraying (APS) with fused-crushed and agglomerated powders to examine the effect of spray method and particle size on the electrical conductivity and gas permeability of YSZ coating. The microstructure of YSZ coating was characterized by scanning electron microscopy and X-ray diffraction analysis. The results showed that the gas permeability was significantly influenced by powder structure. The gas permeability of YSZ coating deposited by fused-crushed powder is one order lower in magnitude than that by agglomerated powder. Moreover, the gas permeability of YSZ deposited by LPPS is lower than that of APS YSZ. The electrical conductivity of the deposits through thickness direction was measured by potentiostat/galvanostat based on three-electrode assembly approach. The electrical conductivity of YSZ coating deposited by LPPS with fused-crushed powder of small particle size was 0.043 S × cm-1 at 1000°C, which is about 20% higher than that of APS YSZ with the same powder.
Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 52-59, May 5–8, 2025,
... Abstract The commonly used method for preparing EBCs is atmospheric plasma spraying (APS), but it has problems such as easy oxidation of the coating, low spraying power, and low substrate temperature, resulting in the coating having multiple pores, cracks, and insufficient density. The new...
Abstract
View Papertitled, Performance Comparison of <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> and <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> Physical Vapor Deposition for Environmental Barrier Coatings
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for content titled, Performance Comparison of <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> and <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> Physical Vapor Deposition for Environmental Barrier Coatings
The commonly used method for preparing EBCs is atmospheric plasma spraying (APS), but it has problems such as easy oxidation of the coating, low spraying power, and low substrate temperature, resulting in the coating having multiple pores, cracks, and insufficient density. The new plasma spraying physical vapor deposition (PS-PVD) technology can solve these problems. This article compares the microstructure, mechanical properties, and phase composition of EBCs prepared using APS and PS-PVD processes.
Proceedings Papers
Deposition of TiO 2 Coatings: Comparison between High Velocity Suspension Flame Spraying (HVSFS), Atmospheric Plasma Spraying, and HVOF Spraying
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ITSC 2009, Thermal Spray 2009: Proceedings from the International Thermal Spray Conference, 207-212, May 4–7, 2009,
... Abstract In this study, a TiO 2 (anatase) nanopowder suspension was processed by high velocity suspension flame spraying (HVSFS). The resulting coatings were characterized and compared to conventional HVOF and atmospheric plasma sprayed layers. It is shown that the HVSFS operating parameters...
Abstract
View Papertitled, Deposition of TiO 2 Coatings: Comparison between High Velocity Suspension Flame <span class="search-highlight">Spraying</span> (HVSFS), <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>, and HVOF <span class="search-highlight">Spraying</span>
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for content titled, Deposition of TiO 2 Coatings: Comparison between High Velocity Suspension Flame <span class="search-highlight">Spraying</span> (HVSFS), <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>, and HVOF <span class="search-highlight">Spraying</span>
In this study, a TiO 2 (anatase) nanopowder suspension was processed by high velocity suspension flame spraying (HVSFS). The resulting coatings were characterized and compared to conventional HVOF and atmospheric plasma sprayed layers. It is shown that the HVSFS operating parameters can be adjusted to achieve dense titania with a near nanostructure and homogeneous distribution of anatase and rutile phases. These coatings have lower pore interconnectivity and higher wear resistance than the APS and HVOF layers. Alternatively, large unmelted agglomerates of anatase nanoparticles can be embedded in the coating, increasing the porosity and anatase content for enhanced photocatalytic efficiency.
Proceedings Papers
Numerical Simulation of an Electromagnetically Controlled Plasma Jet During Atmospheric Plasma Spraying
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ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 564-567, June 2–4, 2008,
... are derived from the magnetofluiddynamic equations using appropriate simplifications. First calculations confirm the predicted effects. atmospheric plasma spraying magnetofluid dynamic equations numerical simulation plasma flow plasma jet travelling magnetic field International Thermal Spray...
Abstract
View Papertitled, Numerical Simulation of an Electromagnetically Controlled <span class="search-highlight">Plasma</span> Jet During <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Numerical Simulation of an Electromagnetically Controlled <span class="search-highlight">Plasma</span> Jet During <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
We present the results of an investigation of the effects of a travelling magnetic field (TMF) on the plasma flow using a commercial program package. The argon plasma generation in the electric arc and the Lorentz force induced by the TMF are simulated with specific equations, which are derived from the magnetofluiddynamic equations using appropriate simplifications. First calculations confirm the predicted effects.
Proceedings Papers
Relationship between Particle and Plasma Properties and Coating Characteristics of Samaria-Doped Ceria Prepared by Atmospheric Plasma Spraying for Use in Solid Oxide Fuel Cells
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ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1173-1178, September 27–29, 2011,
... ionic conductivity for high cell performance, SDC displays similar ionic conductivities at lower temperatures (600°C – 650°C). The atmospheric plasma spray (APS) process is a promising technique for manufacturing metal-supported SOFCs. In this study, the in-flight characteristics, such as particle...
Abstract
View Papertitled, Relationship between Particle and <span class="search-highlight">Plasma</span> Properties and Coating Characteristics of Samaria-Doped Ceria Prepared by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> for Use in Solid Oxide Fuel Cells
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for content titled, Relationship between Particle and <span class="search-highlight">Plasma</span> Properties and Coating Characteristics of Samaria-Doped Ceria Prepared by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> for Use in Solid Oxide Fuel Cells
Samaria-doped ceria (SDC) has become a promising material for the fabrication of intermediate-temperature, metal-supported solid oxide fuel cells (SOFCs). While typical SOFC materials, such as yttria-stabilized zirconia (YSZ), require high temperatures (> 700°C) to exhibit suitable ionic conductivity for high cell performance, SDC displays similar ionic conductivities at lower temperatures (600°C – 650°C). The atmospheric plasma spray (APS) process is a promising technique for manufacturing metal-supported SOFCs. In this study, the in-flight characteristics, such as particle velocity and surface temperature, of spray-dried SDC agglomerates were analyzed at various plasma spray conditions using the DPV-2000 in-flight particle sensor manufactured by Tecnar Automation. Coatings of SDC were applied on stainless steel substrates using a range of spray conditions, and their resulting microstructures and deposition efficiencies were analyzed. It was found that particle temperature could be related to the specific plasma energy, and that coating porosity was related closely to the measured average particle temperature.
Proceedings Papers
Influence of Plasma Gas Composition on Coating Properties Produced by Atmospheric Plasma Spraying
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ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 1038-1041, March 4–6, 2002,
... Abstract This study investigates the influence of plasma gas composition on deposition efficiency achieved during atmospheric plasma spraying and the properties of the resulting deposits. In the experiments, ternary mixtures of argon, hydrogen, and helium are used in different combinations...
Abstract
View Papertitled, Influence of <span class="search-highlight">Plasma</span> Gas Composition on Coating Properties Produced by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Influence of <span class="search-highlight">Plasma</span> Gas Composition on Coating Properties Produced by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
This study investigates the influence of plasma gas composition on deposition efficiency achieved during atmospheric plasma spraying and the properties of the resulting deposits. In the experiments, ternary mixtures of argon, hydrogen, and helium are used in different combinations and flow rates to spray Al 2 O 3 -TiO 2 and ZrO 2 -Y 2 O 3 powders on test substrates while measuring deposition efficiency. Several coating properties are measured, including porosity, hardness, and bond strength, and correlated with plasma gas ratios. Paper text in German.
Proceedings Papers
Modelling a Plasma Torch for Atmospheric Plasma Spraying (APS): Optimization of Particle Injection Near the Torch Outlet According to the Gas Flow within the Torch
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ITSC 2006, Thermal Spray 2006: Proceedings from the International Thermal Spray Conference, 301-308, May 15–18, 2006,
... on the heat transfer to the injected particles is discussed. atmospheric plasma arc spraying gas flow plasma torches viscosity Thermal Spray 2006: Proceedings from the International Thermal Spray Conference 15 May 2006 18 May 2006, ITSC2006, ITSC 2006, Seattle, Washington, USA DOI: 10.31399...
Abstract
View Papertitled, Modelling a <span class="search-highlight">Plasma</span> Torch for <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS): Optimization of Particle Injection Near the Torch Outlet According to the Gas Flow within the Torch
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for content titled, Modelling a <span class="search-highlight">Plasma</span> Torch for <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS): Optimization of Particle Injection Near the Torch Outlet According to the Gas Flow within the Torch
Understanding the particle injection into the gas flow issuing from an APS torch is necessary to optimize the spraying parameters. In order to solve numerically this task, the distribution of gas velocity and temperature at the torch outlet is required. In this work this is achieved by developing a model which not only delivers the solution for the electrically charged gas flow within the torch, but also includes the thermodynamical condition of minimum entropy production. This additional condition fixes the size of the electric arc inside the torch, whose radius is particularly responsible for the form of the calculated velocity and temperature profiles at the torch nozzle. The velocity and viscosity of the gas flow near the torch outlet mainly control the trajectory of particles injected into the gas flow. For the typical gas mass flow and torch power used in APS, the resulting temperatures at the gas core are slightly above the ionization temperature of the gas species. The radial location of the viscosity maximum corresponding to the ionization temperature is calculated, since this maximum strongly influences the particle trajectory. Finally, the influence of plasma fluctuations on the heat transfer to the injected particles is discussed.
Proceedings Papers
Corrosion Properties of Selected Coatings Produced by Atmospheric Plasma Spraying, HVOF, and Laser Remelt Methods
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ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 85-90, May 13–15, 2013,
... and processes are analyzed by cyclic polarization testing and optical and scanning electron microscopy. Test results are presented and discussed along with the relative merits of each process. atmospheric plasma spraying cobalt base coatings corrosion properties high-velocity oxyfuel spraying laser...
Abstract
View Papertitled, Corrosion Properties of Selected Coatings Produced by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>, HVOF, and Laser Remelt Methods
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for content titled, Corrosion Properties of Selected Coatings Produced by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>, HVOF, and Laser Remelt Methods
This work examines the corrosion behavior of cobalt and nickel base coatings produced by APS and HVOF spraying. Laser fusing and sealing are also assessed for comparison as are the corrosion properties of tungsten carbide, chromium carbide, and chromium oxide. All coatings and processes are analyzed by cyclic polarization testing and optical and scanning electron microscopy. Test results are presented and discussed along with the relative merits of each process.
Proceedings Papers
MCrAlY Bondcoats by High Velocity Atmospheric Plasma Spraying
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ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 570-576, May 13–15, 2013,
... Abstract Atmospheric plasma spray parameters were developed for a three-cathode torch with a high-velocity nozzle and MCrAlY powders of different particle size fractions. The main objectives of the work are to achieve bond coats with low oxygen content and porosity. Other goals are achieving...
Abstract
View Papertitled, MCrAlY Bondcoats by High Velocity <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, MCrAlY Bondcoats by High Velocity <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
Atmospheric plasma spray parameters were developed for a three-cathode torch with a high-velocity nozzle and MCrAlY powders of different particle size fractions. The main objectives of the work are to achieve bond coats with low oxygen content and porosity. Other goals are achieving sufficient surface roughness at high deposition rates and efficiencies. The oxidation behavior of the sprayed coatings was characterized by thermal gravimetric analyses and isothermal heat treatments.
Proceedings Papers
Synthesis of Lanthanum Silicates with Apatite-type Structure by Atmospheric Plasma Spraying
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ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 756-759, May 14–16, 2007,
... spraying (APS) using micro-scale mixtures of La 2 O 3 and SiO 2 powders. Granulometer and scanning electron microscopy analyses have indicated the result of high temperature reaction and rapid solidification in the evolution of multi-scale microstructure. atmospheric plasma spraying lanthanum...
Abstract
View Papertitled, Synthesis of Lanthanum Silicates with Apatite-type Structure by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Synthesis of Lanthanum Silicates with Apatite-type Structure by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
The emergence of lanthanum silicate as an electrolyte is required to accelerate the development of synthesis techniques for intermediate temperature solid oxide fuel cells (ITSOFCs). Apatite-type oxide powders of La 10 (SiO 4 ) 6 O 3 have been elaborated through atmospheric plasma spraying (APS) using micro-scale mixtures of La 2 O 3 and SiO 2 powders. Granulometer and scanning electron microscopy analyses have indicated the result of high temperature reaction and rapid solidification in the evolution of multi-scale microstructure.
Proceedings Papers
Atmospheric Plasma Spraying of Environmental Barrier Coatings – A Parametric Study
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ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 1-13, May 4–6, 2022,
... parameters using a widely used Praxair SG-100 atmospheric plasma spraying torch affect the phase composition, microstructure and mechanical properties of ytterbium disilicate environmental barrier coatings. Ytterbium disilicate coatings were deposited using 5 sets of spray parameters, varying arc current...
Abstract
View Papertitled, <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> of Environmental Barrier Coatings – A Parametric Study
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for content titled, <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> of Environmental Barrier Coatings – A Parametric Study
Environmental barrier coatings (EBCs) are required to protect SiC based composites in high temperature, steam containing combustion environments found in the latest generation of high efficiency gas turbine aeroengines. Ytterbium disilicate has shown promise as an environmental barrier coating, showing excellent phase stability at high temperature and a coefficient of thermal expansion close to that of SiC; however, its performance is dependent on the conditions under which the coating was deposited. In this work, a parametric study was undertaken to demonstrate how processing parameters using a widely used Praxair SG-100 atmospheric plasma spraying torch affect the phase composition, microstructure and mechanical properties of ytterbium disilicate environmental barrier coatings. Ytterbium disilicate coatings were deposited using 5 sets of spray parameters, varying arc current and secondary gas flow. The phases present in these coatings were quantified using X-ray diffraction with Rietveld refinement, and the level of porosity was measured. Using this data, the relationship between processing parameters and phase composition and microstructure was examined. Abradable coatings are used throughout gas turbine engines to increase efficiency in the compression and combustion phases of the turbine. Abradable coatings are soft enough to be worn away by turbine blade tips (without damaging the tip itself), allowing for tighter clearances to be used, limiting leakages and increasing efficiency. Using the optimum process parameter window determined in this work, a low density abradable Yb 2 Si 2 O 7 layer will be deposited in future research.
Proceedings Papers
Importance of Evaluation Procedure of Particle State in Atmospheric Plasma Spraying
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ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 868-875, May 4–6, 2022,
... of the in-flight particle state, with focus on process control applications. The paper demonstrates this on the example of atmospheric plasma spraying (APS) of yttria-stabilized zirconia (YSZ), using a commercially available sensor system Accuraspray for measuring the ensemble particle temperatures and velocities...
Abstract
View Papertitled, Importance of Evaluation Procedure of Particle State in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Importance of Evaluation Procedure of Particle State in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
In-flight particle state has been shown to play a crucial role in determining the properties of thermally sprayed coatings. Therefore, process control strategies have been suggested to keep the in-flight particle state constant in order to decrease the variability of coating quality. Such strategies are already used to some extent in industrial applications, where the particle state is measured before starting the coating of a part to make a go/no-go decision based on whether the values are inside a predefined process window. This paper shows the importance of the evaluation procedure of the in-flight particle state, with focus on process control applications. The paper demonstrates this on the example of atmospheric plasma spraying (APS) of yttria-stabilized zirconia (YSZ), using a commercially available sensor system Accuraspray for measuring the ensemble particle temperatures and velocities as descriptors of the in-flight particle state. It is concluded that the stabilization time of the particle jet might be different from what is practically considered. Moreover, the paper investigates an approach of monitoring the in-flight particle state during a coating run without having to install the sensor system on the robot arm.
Proceedings Papers
High Performance Solid Oxide Fuel Cells (SOFCs) Made by Atmospheric Plasma Spraying (APS)
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ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 98-103, June 2–4, 2008,
... Abstract The potential of atmospheric plasma spraying (APS) technology has been investigated for the manufacture of anode, electrolyte and cathode of a solid oxide fuel cell. As substrates tape-casted or commercial available porous plates both made of a FeCr-alloy were used. The functional...
Abstract
View Papertitled, High Performance Solid Oxide Fuel Cells (SOFCs) Made by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS)
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for content titled, High Performance Solid Oxide Fuel Cells (SOFCs) Made by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> (APS)
The potential of atmospheric plasma spraying (APS) technology has been investigated for the manufacture of anode, electrolyte and cathode of a solid oxide fuel cell. As substrates tape-casted or commercial available porous plates both made of a FeCr-alloy were used. The functional layers were applied by atmospheric plasma spraying, however, it turned out that screen printed LSCF cathodes performed better than thermally sprayed versions. Anode layers with high electrochemical activity could be produced by APS using separate injections of NiO and YSZ powders. The manufacturing of gas-tight electrolyte layers was a key-issue of the present development. With adequate processing conditions and advanced gun technology it was possible to produce highly dense ceramic coatings with a very low amount of micro-cracks and pores. These electrolytes gave high open cell voltages above 1 V corresponding to the low measured leakage rates (<10-3 mbar*l/s) of the rather thin (<50 µm) coatings. Additional layers have been applied to reduce the interdiffusion especially of species from the metallic substrates into the anode. These layers could significantly reduce degradation of the cells. SOFCs with a power density at 800°C well above 0.7 W/cm² could be produced by the developed technology.
Proceedings Papers
Homogenization of Coating Properties in Atmospheric Plasma Spraying – Technical Objectives and First Results of a DFG Funded Research Group
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ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 141-146, June 2–4, 2008,
.... atmospheric plasma spraying coating properties plasma jet plasma torches International Thermal Spray Conference & Exposition E. Lugscheider, editor, p 141-146 httpsdoi.org/10.31399/asm.cp.itsc2008p0141 Copyright © 2008 Verlag für Schweißenund verwandte Verfahren DVS-Verlag GmbH All rights reserved...
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View Papertitled, Homogenization of Coating Properties in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> – Technical Objectives and First Results of a DFG Funded Research Group
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for content titled, Homogenization of Coating Properties in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> – Technical Objectives and First Results of a DFG Funded Research Group
The disadvantage of plasma torches using conventional single cathode techniques is the occurrence of azimuthal and axial instabilities inside the plasma torch. This causes electrical power fluctuations which result in inhomogeneities of the plasma jet enthalpy and with that an uneven plasma particle interaction. Hence, variations in particle properties occur and consequently an uneven coating quality is produced. Using the triple-cathode technique these electrical power fluctuations were successfully reduced, resulting in a stationary plasma flow. Thus this technique appears to offer the potential to homogenize coating properties. Similar results have been shown for plasma torches with triple anode arrangements. The goal of this research group is to homogenize properties of plasma sprayed coatings using of 3-cathode and 3-anode technologies based on numerical simulations. The approach used is to subdivide the complete APS process into the areas plasma torch, free jet as well as coating formation and characteristics. By simulation of the individual areas and combination with experimental results the corresponding process parameters will be obtained for the desired coating properties.
Proceedings Papers
Simulation of PYSZ-Particles Impact and Solidification in Atmospheric Plasma Spraying Coating Process
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ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 548-552, June 2–4, 2008,
.... Simulated splat morphologies are compared with experimentally obtained splats. atmospheric plasma spraying computational fluid dynamics heat transfer partially yttria-stabilized zirconia particle analysis roughness solidification International Thermal Spray Conference & Exposition E...
Abstract
View Papertitled, Simulation of PYSZ-Particles Impact and Solidification in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> Coating Process
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for content titled, Simulation of PYSZ-Particles Impact and Solidification in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> Coating Process
In this work numerical simulation results of the impact and solidification of molten PYSZ-particles on flat and rough substrate surfaces are presented. This investigation deals with the effect of the particle state prior impact, particle diameter and substrate roughness, on splats spreading behaviour and final morphology. The particles have a diameter range between 20 – 60 µm. Particle initial conditions prior to impact: speed, temperature and melting state, are taken from previous simulation modelling approaches of particle accelerating and heating. Simulations of fluid dynamics, heat transfer and solidification during the particle impact were performed using computational fluid dynamics. Tracing of free surfaces determinates volume of fluid method. Heat flux at the particle-substrate interface and temperature dependent liquid phase viscosity of PYSZ are studied and discussed. Simulated splat morphologies are compared with experimentally obtained splats.
Proceedings Papers
Improving Atmospheric Plasma Spraying of Zirconate Thermal Barrier Coatings based on Particle Diagnostics
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ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 561-567, September 27–29, 2011,
... Abstract Lanthanum zirconate (La 2 Zr 2 O 7 ) was proposed as a promising material for thermal barrier coatings. At atmospheric plasma spraying (APS) of La 2 Zr 2 O 7 a considerable amount of La 2 O 3 can evaporate in the plasma flame, resulting in a non-stoichiometric coating. As indicated...
Abstract
View Papertitled, Improving <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> of Zirconate Thermal Barrier Coatings based on Particle Diagnostics
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for content titled, Improving <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> of Zirconate Thermal Barrier Coatings based on Particle Diagnostics
Lanthanum zirconate (La 2 Zr 2 O 7 ) was proposed as a promising material for thermal barrier coatings. At atmospheric plasma spraying (APS) of La 2 Zr 2 O 7 a considerable amount of La 2 O 3 can evaporate in the plasma flame, resulting in a non-stoichiometric coating. As indicated in the phase diagram of the La 2 O 3 -ZrO 2 system, in the composition range of pyrochlore structure, the stoichiometric La 2 Zr 2 O 7 has the highest melting point and other compositions are eutectic. APS experiments were performed with a TriplexPro-200 plasma torch at different power levels to achieve different degrees of evaporation and thus stoichiometry. For comparison, some investigations on Gd 2 Zr 2 O 7 were included which is less prone to evaporation and formation of non-stoichiometry. Particle temperature distributions were measured by the DPV-2000 diagnostic system. In these distributions, characteristic peaks were detected at specific torch input powers indicating evaporation and solidification processes. Based on this, process parameters can be defined to provide stoichiometric coatings intended to show good thermal cycling performance.
Proceedings Papers
Homogenization of Coating Properties in Atmospheric Plasma Spraying – Results and Outlook of a DFG (German Research Foundation)-Funded Research Group
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ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 633-639, September 27–29, 2011,
.... atmospheric plasma spraying computational fluid dynamics computed tomography finite element method particle analysis plasma flow tensile test International Thermal Spray Conference & Exposition 2011 September 27 29, 2011, Congress Center, Hamburg httpsdoi.org/10.31399/asm.cp.itsc2011p0633 Copyright ©...
Abstract
View Papertitled, Homogenization of Coating Properties in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> – Results and Outlook of a DFG (German Research Foundation)-Funded Research Group
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for content titled, Homogenization of Coating Properties in <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span> – Results and Outlook of a DFG (German Research Foundation)-Funded Research Group
The goal of this research group is to homogenize properties of three-cathode plasma sprayed coatings on basis of numerical simulations and advanced diagnostics. Results of the first project phase as well as an outlook to future work are presented. A numerical model for investigation of plasma flow in the free jet, produced by three-cathode torch was developed. Modelling results are verified by plasma diagnostics (Computer Tomography). In order to include particle shrinking effects, coating formation simulation is accomplished by a newly developed model, based on Computational Fluid Dynamics coupled with the Finite Element method, whereat diagnostics carried out in the fields of particle diagnostics. During the next phase of the project, the investigation of the plasma free jet and particle injection by advanced diagnostics and simulation respectively is scheduled. In a subsequent stage the transition from conventional particles to suspensions will be considered. Coating formation simulations are scaled up to dimensions of macroscopic tensile tests. By combining these overarching investigations, appropriate process parameters for homogenized coatings will be obtained.
Proceedings Papers
Reconstitution of Yttria-Stabilised Zirconia Nanopowders to Obtain Coatings by Atmospheric Plasma Spraying
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ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 662-667, September 27–29, 2011,
... Abstract Yttria-stabilised zirconia (YSZ) coatings were deposited on austenitic stainless steel coupons from nanostructured powders using atmospheric plasma spraying (APS). Two suspensions of YSZ nanoparticles were used as starting material: a diluted commercial suspension and a highly...
Abstract
View Papertitled, Reconstitution of Yttria-Stabilised Zirconia Nanopowders to Obtain Coatings by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
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for content titled, Reconstitution of Yttria-Stabilised Zirconia Nanopowders to Obtain Coatings by <span class="search-highlight">Atmospheric</span> <span class="search-highlight">Plasma</span> <span class="search-highlight">Spraying</span>
Yttria-stabilised zirconia (YSZ) coatings were deposited on austenitic stainless steel coupons from nanostructured powders using atmospheric plasma spraying (APS). Two suspensions of YSZ nanoparticles were used as starting material: a diluted commercial suspension and a highly concentrated in-house prepared suspension (obtained by adding an YSZ submicronic powder to the diluted suspension). Both suspensions were reconstituted into sprayable micrometric granules. The reconstitution process was performed by spray drying, followed by a thermal treatment in order to reduce porosity and enhance agglomerate sinterability. The reconstituted powders were characterised by XRD, SEM, granule and pore sizing techniques, and a flowability evaluation. The effect of suspension characteristics on granule morphology and porosity was examined. The reconstituted powders were successfully deposited, yielding well-bonded coatings. The coating microstructure was characterised by XRD and SEM. Mechanical properties and erosion resistance were also determined. Coating microstructure consisted of semi-molten feedstock agglomerates surrounded by fully molten areas that acted as binders. The influence of feed powder characteristics on coating microstructure and properties was also studied.
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