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Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 88-93, May 21–23, 2014,
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In this investigation, high carbon steel wire is deposited on aluminum cylinder bores with different surface profiles by plasma transferred wire arc (PTWA) spraying. The first part of the study deals with feedstock materials, process parameters, droplet formation, and splat morphology. The second part deals with bead profiles, build rates, and the influence of substrate composition, temperature, and surface profile on coating characteristics including microstructure, morphology, composition, and bond strength.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 162-168, May 21–23, 2014,
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This work focuses on the properties of Cu-Ag alloys deposited by cold spraying. Helium was used as the carrier gas, accelerating particles to 823 m/sec, which is in the middle of the deposition window for Cu alloys. To avoid oxygen contamination, the gun was placed in a helium-filled chamber and a closed-loop circulating system was used to minimize helium loss. Deposition parameters were varied during spraying and their effect on hardness, tensile properties, residual stress, and porosity was assessed in as-sprayed and heat-treated samples. Ultimate tensile strengths of 450 MPa and yield strengths of about 420 MPa were obtained for the as-sprayed samples and it was shown that strength and ductility can be tailored by heat treating, reaching elongation values higher than 45%. An increase in deposition rate from 55 to 142 g/min was also achieved without a significant decrease in mechanical properties.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 403-407, May 21–23, 2014,
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This study evaluates the effects of heat treating on the microstructure, phase composition, and friction and wear behavior of plasma sprayed FeAl coatings. Fe-40Al feedstock powder was deposited on mild steel substrates by atmospheric plasma spraying and the coatings were vacuum annealed at 500, 650, 900, and 1000 °C. An examination of coating cross-sections revealed the presence of diffusion layers in the samples treated at 900 and 1000 °C. XRD analysis indicates that annealing at 650°C facilitates the transformation of Fe(Al) solid solution into FeAl intermetallic phase, resulting in an increase in coating hardness. At higher temperatures, however, Al depletion occurs along with a reduction in hardness. Tribological testing showed that both the friction coefficient and the effects of wear increased after heat treatment.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 588-592, May 21–23, 2014,
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Residual stresses arising during high-velocity oxyfuel (HVOF) spraying usually impose a limit on coating thickness. In this work, dry-ice blasting is used in combination with HVOF spraying to produce thick WC-Co coatings characterized by compact microstructure, crystal refinement, high hardness, and excellent sliding wear resistance.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 819-823, May 21–23, 2014,
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In this work, alumina coatings are produced by atmospheric plasma spraying using dry-ice blasting to prepare substrate surfaces. Feedstock powder and coating microstructure are examined and dielectric strength and ac-dc breakdown voltages are measured. The results show that dry-ice blasting improves the dielectric properties of alumina coatings produced by atmospheric plasma spraying.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 22-28, May 13–15, 2013,
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This study assesses the effects of dry ice blasting on the lifetime and durability of thermal barrier coatings (TBCs). Three sets of TBCs consisting of a CoNiCrAlY bond coat and YSZ topcoat were deposited by air plasma spraying, each set with a different dry ice blasting treatment. Different microstructures were obtained in both the bond coat and topcoat depending on blasting conditions. Bond coat oxidation and thermal shock lifetime of the TBC are also shown to vary with the blasting treatment. TBCs where both the bond coat and topcoat are dry-ice blasted proved to be the most durable with the biggest improvement in lifetime. They also exhibited the most regular surface roughness.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 636-641, May 13–15, 2013,
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In the present study, Fe-Al 2 O 3 -FeAl 2 O 4 and FeAl coatings were synthesized in situ by reactive plasma spraying of Al-Fe 2 O 3 composite powder under atmosphere and low-pressure conditions. Coating microstructure and phase composition are examined and coating formation mechanisms are discussed. It was found that FeAl 2 O 4 hercynite phase is always synthesized as an intermediate product under low oxygen partial pressure conditions. In the APS process, such a phase can be retained in the final coating by extremely fast cooling. It can also be continuously reduced to FeAl by deoxidation in an oxygen-free H/H 2 atmosphere.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 666-671, May 13–15, 2013,
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In this work, Fe-40Al coatings are produced by atmospheric plasma spraying using a nanostructured feedstock exhibiting a very low degree of order. The as-sprayed deposits consist of fundamental FeAl phases, Fe3Al phases, and oxides and are found to be ferromagnetic due to the low degree of order and the presence of unmelted nanoparticles retained from the feedstock. The magnetic properties of the coatings are shown to be heterogeneous in the parallel and vertical direction.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 672-676, May 13–15, 2013,
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This study investigates the effect of dry-ice blasting distance on the deposition of CoNiCrAlY coatings obtained by plasma spraying. Dry-ice blasting was used before, during, and after spraying and its effect on coating quality was measured. The results show how blasting distance influences the deposition efficiency as well as the microstructure, porosity, adhesion strength, hardness, and oxide content of plasma-sprayed coatings. The optimal dry-ice blasting distance was proposed as 25 mm.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 609-614, May 21–24, 2012,
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Yttria-stabilized zirconia (YSZ) coatings have been frequently used as a thermal protective layer on the metal or alloy component surfaces. In the present study, ZrO 2 -7%Y 2 O 3 thermal barrier coatings (TBCs) were successfully deposited by DC (direct current) plasma spray process under very low pressure condition (less than 1 mbar) using low-energy plasma guns F4-VB and F100. The experiments were performed to evaluate the thermal shock resistance of the different TBC specimens which were heated to 1373 K at a high-temperature cycling furnace and held for 0.5 h, followed by air cooling under room temperature during 0.2 h. For comparison, the corresponding APS counterparts were also elaborated to carry out the similar experiments. The results indicated that the VLPPS coatings displayed better thermal shock resistance. Moreover, the failure mechanism of the coatings was also elucidated.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 615-621, May 21–24, 2012,
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To implement image-based numerical modeling of the thermal conductivity of coatings, a YSZ coating was considered as a network of two phases, namely the coating material and pores. The variation of the thermal conductivity of the gas trapped within the pores caused by their small size was considered by complying with the Knudsen law. In the present work, the quantification of the Knudsen effect on the effective thermal conductivity of coatings was achieved with the help of image analysis. The thicknesses of the pores were determined by combining the use of the Scion image software with a new in-house algorithm coded in C language. The Knudsen effect was quantified by applying a finite-difference model for both 2D images and a 3D image. In both cases, a decrease of the computed thermal conductivity was found while considering the Knudsen effect. Furthermore, the Knudsen effect was also taken into account in a finite-element model applied on the same images. Despite differences were noticed on the computed thermal conductivities obtained with the two methods, a quite similar decrease was calculated by comparing with data computed with the FDM method.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 646-650, May 21–24, 2012,
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Dry-ice blasting, as an environmental-friendly method, was used to pretreat the substrate to be coated. In the present paper plasma-sprayed CoNiCrAlY splats were examined on the dry-ice blasted substrate. The cleaning effect of dry-ice blasting was demonstrated accompanying the condensation phenomenon, which is also harmful for the formation of ideal disk-like splat. A solution of ensuring the substrate temperature over dew point temperature was proposed for the proper application of dry-ice blasting during droplet flattening.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 651-656, May 21–24, 2012,
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Atmospheric plasma spray is considered as one of the most efficient methods for forming FeAl intermetallic coatings. But the performance of plasma-sprayed FeAl coatings was remarkably limited because of oxidation and phase transformation during the preparation. In the present work, FeAl intermetallic coatings were prepared by atmospheric plasma spray combined with dry-ice blasting. The microstructure, oxidation and porosity of FeAl intermetallic coatings were investigated. In addition, XRD measurements were also employed to illustrate the lattice-scale performance, e.g., dislocation density. The temperatures during plasma spray were also measured using an infrared pyrometer system. The results show that a denser B2-FeAl coating with a lower content of oxide and lower phase transformation can be achieved because of the cryogenic effect and the mechanical effect of dry-ice blasting. Moreover, the microhardness of FeAl coating was nearly increased by 72%, due to the lower porosity and higher dislocation density.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 724-728, May 21–24, 2012,
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In recent years, the production of coatings obtained by LPPS process (Low Pressure Plasma Spraying) was successfully introduced in industrial markets for aerospace, gas turbines, medical and other special applications. The deposition of coatings with superior properties requires an improved understanding of this complex spray process, including the inflight particle temperature and velocity. In this study, DPV- 2000 (Tecnar, St-Bruno, QC, CA) was employed to characterize the LPPS process at different operational pressure ranges from typically 250 mbar to 150 mbar. Measurements of the temperatures and velocities of the in-flight yttria-stabilized zirconia (YSZ) particles were carried out in an argon– hydrogen plasma jet. The YSZ coatings were also deposited in accordance with different operating parameters. The microstructures of the coatings were analyzed by SEM.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 734-739, May 21–24, 2012,
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A previous study indicated that improved adhesions of plasma-sprayed Al 2 O 3 coatings have been achieved by using dry-ice blasting. Therefore, it is important to understand the mechanisms involved. In this study, the surface roughness of different substrates treated by dry-ice blasting was firstly examined. And then the surface wettability was characterized in order to clarify the effect of dry-ice blasting on the substrate surface properties. The effect of dry-ice blasting on Al 2 O 3 splat morphology with different treatment times was investigated. The residual stress of plasma-sprayed Al 2 O 3 coatings using dry-ice blasting was measured and compared with that of coatings deposited with conventional air cooling. Based on these numerous assessment tests, it could be concluded that the cleaning effect of dry-ice blasting on different organic substances adsorbed on the substrates was the most important influence on the adhesion improvement of Al 2 O 3 coatings.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 846-850, May 21–24, 2012,
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With the purpose of elaborating high-quality FeAl coatings, a so-called very low pressure reactive plasma spray technique that combines VLPPS and SHS processes was used in the present study. A dense and homogeneous FeAl coating was thus successfully in situ synthesized by reactive plasma spraying of an Al/Fe 2 O 3 composite powder under 1 mbar. The phase composition and microstructural features of the coating were characterized by XRD and SEM. Results indicated that the B2 ordered FeAl phase was synthesized, and the coating featured a dense and defect-free microstructure. The fracture mechanism of the coating remains mainly a brittle failure but the appearance of some dimples in local zones suggests some unexpected toughness.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 828-834, September 27–29, 2011,
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Very low pressure plasma spraying has been intensively studied in recent years especially the properties of plasma jet. These properties are affected by plasma generating and working conditions. These operating parameters such as arc power, plasma gas flow rate and chamber pressure have influences on specific enthalpy and temperature of plasma jet. In this work, the measurements under very low pressure were performed using enthalpy probe which was previously modified (increase of the internal diameter and depositing TBC coating (Ni/Al and ZrO 2 + Y 2 O 3 ) on the head). Different parameters, for instance, current intensity, hydrogen gas flow rate and detecting distance were changed in order to point out their effect on the characteristics of plasma jet. The specific enthalpy, temperature and quantity of heat in this situation were obtained.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1037-1041, September 27–29, 2011,
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Magnesium coatings were deposited upon aluminum and stainless steel substrates by cold spraying. Three Mg powders with different particle size distributions were used as feedstock. The microstructures of as-sprayed coatings were evaluated by optical microscopy, and scanning electron microscopy. The coating observations show that a main gas temperature has an important effect on the deposition behaviour of particles. Changing the gas temperature from 350°C to 630°C involves an increase of the deposition efficiency from 1.57% to 19.57%. The effects of the particle size distribution and substrate material on the deposition efficiency of particles were also investigated. The results show that the particle size distribution has a significant effect on the deposition efficiency of particles which increases from 19.57% to 59% when the mean particle size decreases from 63 µm to 38 µm under gas temperature of 630°C. However, the deposition efficiency of particles was slightly influenced by the substrate material. In addition to these experimental results, the in-flight particle velocities were simulated by FLUENT software to point out the effects of the gas temperature and particle size distribution.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1042-1045, September 27–29, 2011,
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In this paper, a commercial AZ91D magnesium alloy powder and its mixture with 30 vol.% SiC powder were used to deposit coatings by cold spraying. Two types of converging-diverging nozzles with different cross-sectional shapes were employed. The velocity and temperature of in-flight particles under different operating conditions were simulated using the FLUENT software. The simulated results show that the particle velocity through the rectangular cross-section nozzle is the same with that through the circular one. However, the coating observation shows that the AZ91D coating and its composite could only be deposited using the rectangular cross-section nozzle. The increase of gas temperature has little effect on the coating microstructure, porosity and microhardness. Furthermore, the observation of the composite coating produced under the gas temperature of 600°C shows that the SiC content in the composite is about 23 vol.%. The microhardness of the composite is improved to about 140 HV 0.3 due to the enhancement of SiC particles, compared to that of about 100 HV 0.3 for the AZ91D coating.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1110-1114, September 27–29, 2011,
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Automatic robot trajectory generation for thermal spray applications is considered necessary for advanced automatic manufacturing. Achieving coating uniformity on the free-form surfaces is the principal challenge due to the complexity of their geometries. The purpose of this study is to develop a new function of Thermal Spray Toolkit with user-friendly interface for automatic generation of robot trajectory on the irregular workpieces according to the spray parameters, such as the torch speed, the spray distance, the spray angle, etc. This software toolkit is based on RobotStudio which is an off-line programming and simulation software by ABB company. The results showed that the robot trajectories can be generated rapidly, accurately and automatically on the free-form surfaces by using Thermal Spray Toolkit.
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