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K. Sonoya
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Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 485-487, May 21–24, 2012,
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The thermal cycle test of Al 2 O 3 sprayed 1%Cr-0.5%Mo steel and 18%Cr-8%Ni steel was performed, and the failure type of thermally sprayed coating on both steels was compared. The results obtained are follows. (1)The thermal cycle fatigue life of thermal sprayed 1%Cr- 0.5%Mo steel was shorter than that of thermal sprayed 18%Cr-8%Ni steel. (2)In the case of thermally sprayed 18%Cr-8%Ni steel that is difficult to oxidize at high temperature, during thermal cycle, a tensile stress occurs in a sprayed coating and a compressive stress occurs in a substrate. Thus the thermal strain occurs at the interface of sprayed coating and substrate. The sprayed coating delaminates when the thermal cycles reach the limit value. (3)In the case of thermal sprayed 1%Cr-0.5%Mo steel that is easy to oxidize at high temperature, during thermally cycle, dense oxide film forms at the interface between the sprayed coating and substrate, and adhesive strength in the interface becomes low. Thus the sprayed coating delaminates under the lower thermal strain.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 203-207, September 27–29, 2011,
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The pin test and stress analysis by FEM were performed for erosion-resistant thermal sprayed coatings, and characteristic of interfacial strength between sprayed coating and substrate was assessed. As a result, the (Kcr) was not affected with specimen size and uniformly converges in spite of the eccentricity of pin.
Proceedings Papers
ITSC 2010, Thermal Spray 2010: Proceedings from the International Thermal Spray Conference, 327-330, May 3–5, 2010,
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The blast erosion-resistance properties of HVOF thermal spray Cr 3 C 2 type coating system and aluminized material were examined to improve erosion-resistance of turbine housings of compressors used in turbochargers for marine diesel engines. As a result, the erosion life of aluminized material is as same as that of the substrate, on the other hand the erosion life of thermal sprayed coating is ten times of that of the substrate. Therefore, erosion life of turbine housing can be extended by the surface treatment procedure. This technology is applicable to actual products.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 104-106, June 2–4, 2008,
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The analytic hierarchy process (AHP) has been widely used as one of decision-making method in economic, social, political and technological field, and for evaluating relative strength of preference quantitatively in decision making process. We think that AHP approach would be useful for analyzing and digitalizing expert’s skills, and for transferring to non-skilled people. In this presentation, we show the AHP approach to analyze a decision to select thermal spraying parameters for achieving high quality wear resistive Al 2 O 3 film by atmospheric plasma spraying (APS). From the result of this study, the process of expert’s subjective thinking could be clear and understood for other person.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 1506-1510, May 2–4, 2005,
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The lamellar microstructure of plasma-sprayed ZrO 2 -8wt.%Y 2 O 3 (8YSZ) coatings was quantitatively characterized by a novel approach. The porous structure of the coating was visualized through infiltrating the tracer into voids in the coating combining with the energy dispersed X-ray line analysis of the tracer in the coating. The quantitative characterization parameters included the mean lamellar interface bonding ratio, mean lamellar thickness and width distribution of lamellar interface gaps. 8YSZ coatings were deposited by plasma spraying under different spray distances to reveal the effect of spray distance on the lamellar microstructure of plasma-sprayed 8YSZ coatings. The results showed that the maximum mean bonding ratio was 32% when the coating was deposited at spray distance from 65 to 80 mm. As spray distance was increased to 100-120 mm, the mean bonding ratio was reduced. The mean lamellar thickness was not significantly influenced by spray distance although it was found that the mean lamellar thickness tended to increase with the increase of spray distance from 80 mm. It was observed that lamellar interface gaps in the coating were mainly in submicrometer order. With the increase of spray distance, the mean width of interface gaps and fraction of wide interface gaps tended to increase.
Proceedings Papers
ITSC 2002, Thermal Spray 2002: Proceedings from the International Thermal Spray Conference, 175-179, March 4–6, 2002,
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Turbine entrance temperatures in the latest high-efficiency jet engines rise to more than 1773 K, which significantly raises the bar for thermal barrier coatings (TBCs). This paper describes a ternary coating system consisting of a vacuum plasma sprayed NiCrAlY bond coat, an atmospheric plasma sprayed ZrO 2 top coat, and a MoSi 2 middle coat. The middle layer inhibits oxidation of the nickel-chromium bond coat, thus extending the service life of the TBC system. Paper includes a German-language abstract.
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 1303-1311, May 28–30, 2001,
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The present investigation compares blast erosion characteristics of coatings that are prepared with abrasion resistant surface treatment materials and various consolidation processes. Furthermore, it elucidates operating mechanisms in blast erosion of various sprayed coatings. The investigation presents the blast erosion test conditions and assessment of test results and discusses the effects of coating materials on abrasion loss and impingement angle on abrasion loss. It includes illustrations on SEM observation and cross-sectional observation of damaged areas. In addition, information on blast erosion resistant characteristics of materials tested and wear mechanism in blast erosion is also provided.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 1249-1253, May 8–11, 2000,
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Trends of turbine blades of advanced aircraft gas turbine engines are to increase output power of the engines, to increase engine efficiency, and to reduce environmental emission, and thus, higher operating temperatures of the engines are required. One of the technologies for increasing the operating temperature is a thermal barrier splayed coating. A research paper claims that molybdenum silicide in a splayed coating has a self-healing capability for cracks formed in the coating by embedding the cracks with silicon dioxide formed from molybdenum silicide at high temperatures. This article discusses the methods for the extension of life of thermal barrier sprayed coatings by incorporating molybdenum silicide. It discusses monitoring method for detecting cracking conditions in heating and cooling cycles by signals of acoustic emission. A possibility of estimating fatigue life by utilizing an X-ray method for measuring residual stress is also considered.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 571-576, March 17–19, 1999,
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This paper focuses on the mechanism responsible for crack expansion and contraction: the behavior of cracks in the ceramic bed of zirconium dioxide membranes formed by plasma spraying, and the thermal stresses caused by differences in thermal expansion factors between the base material and sprayed bed, under a thermally cyclic environment. The test sample was prepared by spraying NiCrAlY on a stainless-steel base material to form a substrate membrane, then covering it with sprayed 8YSZ (zirconium dioxide-type ceramic). To clarify the self-recoverability of fatigue cracks caused during the thermal cycle, membrane cracking and crack expansion/contraction is studied. Paper includes a German-language abstract.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 699-704, March 17–19, 1999,
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In this paper, the influence of the plasma spray parameters on the mechanical properties of Ni-50% Cr coatings is systematically studied using the method of orthogonal regression test planning. The target properties include adhesive strength, micro-hardness, grinding wear, and erosion wear. The three spray parameters used as variables are plasma arc current, Ar flow rate, and spray distance. From the regression formulas, it is concluded that the effects of the spray parameters on the properties largely depend on the individual properties. Paper includes a German-language abstract.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 287-292, May 25–29, 1998,
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The effects of powder types and HVOF spray systems used to produce Cr 3 C 2 -NiCr coating on the relationships between spray parameters and wear performance were investigated based on the effect of fuel gas conditions on abrasive wear and erosion wear. The relationships between spray parameters and wear properties were obtained by orthogonal regression experimental design method. Four types of powders and two HVOF spray systems were used. It is found that with the increase in fuel gas flow or pressure the abrasive wear and erosion of Cr 3 C 2 -NiCr coatings change following a concave curve. The Cr 3 C 2 -NiCr coating with the best wear performance will be deposited under intermediate fuel gas condition. It is experimentally confirmed that by different types of powders and HVOF systems applicable to HVOF spraying of Cr 3 C 2 -NiCr coating, although the optimized fuel gas conditions to deposit coating with the best wear performance will be influenced by types of starting powders.
Proceedings Papers
ITSC1996, Thermal Spray 1996: Proceedings from the National Thermal Spray Conference, 819-825, October 7–11, 1996,
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Low cycle fatigue tests were performed at room temperature (RT) and at 673 K for l%Cr-0.5%Mo steel comparing the specimens coated with chromium carbide by gas spraying and the ordinary uncoated specimens, and the mechanism of fatigue crack formation was investigated. Following observations and conclusions were made: (1) When sprayed with ceramic, the fatigue life suffers reduction at either temperature, but at 673 K, the degradation was so much smaller than that at RT that the fatigue life was actually, though slightly, longer than that at RT. (2) The cracks are initiated in the ceramic layer very early in the whole fatigue life, the crack initiation lifetime becoming the longer, the smaller the strain range. (3) The fatigue failure process can be viewed as comprising following steps: first, early initiation of fatigue crack at the surface of the ceramic coating, rapid propagation through it to the substrate metal, and initiation of crack in the metal, the initial rate of propagation of such a crack being a number of times (perhaps as much as one full order of magnitude) faster than that in uncoated steel.