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G. Irons
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Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 347-353, May 25–29, 1998,
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The high-velocity air-fuel process (HVAF) is an emerging technology used in the thermal spray industry. The Praxair HVAF process combines air and a liquid fuel (e.g., kerosene, diesel) to generate an energy source with extremely high gas velocities. Analytical studies were conducted to investigate gas and particle dynamics in the Praxair HVAF process for coating with WC-l2Co and stainless steel powders. The mass, momentum, and energy conservation equations were first solved, using the TORCH computer program. Typical output from the model includes temperature and velocity profiles as a function of radial and axial position. The PROCESS gas/particle computer program was then used to calculate from these temperature and velocity profiles the dynamics of particles injected into the gas plume. The primary result of the gas/particle code is a description of the injected particle temperature and velocity as a function of position in the plume. A thorough understanding of the process was obtained using this modeling technique. The results of the modeling were confirmed with process diagnostics. Particle temperature measurements for the WC-Co powder system were obtained with a two-color pyrometer; particle velocity measurements were obtained using particle imaging velocimetry. The coatings produced in the study exhibit superior quality, with high-density, high-hardness, low-oxide content, and high-bond strength.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 529-535, May 25–29, 1998,
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The High-Velocity Combustion Wire Process is a new high-velocity combustion process now being used in the thermal spray industry. This process combines air, oxygen, and a fuel gas to generate a high-temperature, high-velocity plume that is optimum for producing metallic coatings. Analytical studies were conducted to investigate gas and droplet dynamics for the spraying of three different materials: aluminum, stainless steel, and molybdenum. With the relatively low flame temperatures of the process, the feedstock wire is melted by convective heat transfer with no superheating or vaporization of the droplets. When the droplets strike the substrate, their temperature peaks as the high kinetic energy of the droplet is transformed into thermal energy. The conservation equations were solved using the TORCH computer model, yielding the temperature and velocity profiles as a function of location. The PROCESS gas/droplet computer program was then employed to calculate the dynamics of the molten droplets. The results of this modeling was confirmed with process diagnostics. Experimentation included droplet temperature measurements using a two-color pyrometer and droplet velocity measurements using particle imaging velocimetry for the stainless steel material system. The coatings produced in the study exhibit superior quality with high density, high hardness, low oxide content, and high bond strength.
Proceedings Papers
ITSC1996, Thermal Spray 1996: Proceedings from the National Thermal Spray Conference, 39-47, October 7–11, 1996,
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Many thermal spray coatings provide excellent wear and corrosion resistance, while providing die same surface finish offered by chromium plating. In the past, the choice between thermal spraying or plating was usually based on part size, area to be coated, cost and familiarity with one or the other method. Today, the thermal spray processes are showing greater popularity due to: ♦ New thermal spray processes and coatings with better properties ♦ Increased chromium plating costs due to stricter regulations on the process and the disposal of its waste products ♦ The closing of chromium plating facilities Thermal spraying offers an opportunity to select a coating from a wide variety of processes and materials that will meet the specific requirements of each application. While this may cause some difficulty in selecting the optimum coating, the selected thermal spray coating often has superior propolies and/or lower cost compared to chromium plating. The highest quality coatings are sprayed by the HVOF process, many with carbide containing materials. Dense plasma grayed ceramic materials offer good wear resistance plus elevated temperature capability. The most economical replacements for chromium plate are applied by the two-wire arc spray process. This paper examines the properties and costs of eight different dismal sprayed coatings and compares them with electroplated chromium.