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L.L. Zheng
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Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 717-722, May 14–16, 2007,
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This paper investigated the role of particle injection on inflight particle behavior and its coupling effect on plasma plume in an external orthogonally injected air plasma spray system as well as effects of primary, secondary and carrier gases on in-flight particle status through both experiments and simulations. Diagnostic sensors such as In-flight Particle Pyrometer (IPP) and Spray Position Trajectory (SPT) have been used to obtain the plume characteristics and ensemble temperature, while DPV-2000 was used to measure the distributions of individual particle status such as temperature, velocity and size at the maximum particle flux point. Three-dimensional simulations have been carried out for the corresponding experimental conditions to examine the effects of in-flight particle heating on the plasma plume and in-flight characteristics at different spray distances. Both experiment and simulation results show that particle temperature and velocity will initially increase with plume angle and then decrease after reaching a maximum value for different combination of process parameters at the same plume angle. Theoretical analysis shows strong dependence of the plume angle on the velocity ratio of vertical component from the carrier gas to the horizontal one from primary and secondary gas at their respective nozzle exits. This study enables a better understanding of influence of plasma forming and stabilizing parameters on the particle in-flight characteristics.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 1349-1355, May 2–4, 2005,
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Precursor Plasma Spraying (PPS) using Radio Frequency (RF) induction plasma spray is a new process used to synthesize functional materials. RF plasma spray has the advantages of stability, cleanness, high temperature and high chemical reactivity. In this paper, a two-dimensional numerical model has been developed to investigate the induction electromagnetic (EM) field and the thermo-fluid field in a radio frequency inductively coupled plasma (RF-ICP). In flight particle interaction with the plasma jet will be investigated. The traditional micron-size powder particles, e.g. zirconia (PSZ), are injected with carrier gas such as argon. During their interaction with the RF plasma, the powder particles experience acceleration, heating, melting and evaporation and particle heat transfer is considered coupled with the thermo-fluid flow of the RF plasma. A generalized particle model is developed and applied to the precursor plasma spray process operated in a vacuum chamber. The effects of power input, standoff distance and powder size on the RF plasma and particle in flight characteristics are investigated.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 905-911, May 5–8, 2003,
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The melting behavior of in-flight particle and its impact on splat morphology are studied. A group parameter, “melting index”, has been derived to correlate the melting status of inflight particles with particle size, velocity, and temperature which can be measured experimentally. Numerical simulations have been used to determine the unknown parameters in the melting index. The effect of particle size on its melting behavior has been investigated.