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M. Brochu
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Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 445-450, September 27–29, 2011,
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The objective of this work is to demonstrate the ability of the Pulsed Gas Dynamic Spraying process (also known as Shockwave Induced Spraying) to produce nanostructured metal matrix composite. Nanocrystalline and microcrystalline (conventional) Al5356+20%B 4 C composite feedstock powders were used. The influence of the coating process as well as the nature of the feedstock material on the microstructure and mechanical properties of the coatings were studied. The new spraying process provides an opportunity to produce hard and dense coatings with good cohesion between deformed particles and good adhesion to the substrate. No phase degradation, low compressive residual stresses and high dry sliding wear resistance were observed which seem to be an advantage compared to the traditional thermal spray coatings.
Proceedings Papers
ITSC 2009, Thermal Spray 2009: Proceedings from the International Thermal Spray Conference, 397-402, May 4–7, 2009,
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A noncryogenic milling process was recently developed to produce equiaxed nanostructured NiCrAlY powders. In this study, the powders are used to deposit metal bond coats, with and without thermal barrier topcoats, via HVOF and low-pressure plasma spraying. TBCs with bond coats derived from non-cryogenically milled nanopowder show a reduction in porosity and TGO growth rate, delayed formation of mixed oxides, and a 50% increase in cycles to failure during thermal cycle testing. The presence of very fine alumina in the powder and bond coats plays a significant role in these improvements.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 604-609, May 14–16, 2007,
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Thermal barrier coatings (TBCs) with nanostructured bond coats have shown significant thermal cycling enhancements over their conventional microstructured counterparts; however, the high cost inherent to the cryomilling processing of the MCrAlY powder limits commercial application. Hence, this study characterizes and evaluates nanostructured bond coats derived from non-cryogenically milled MCrAlY powder with emphasis placed on reduced processing cost and scale-up capability. After extensive development of both a high-energy planetary mill and its operating parameters, fine-grained equiaxed NiCrAlY powder has been produced. XRD and SEM characterization of the milled powder will be presented. Microstructural analyses of the coatings sprayed via the HVOF and cold spray processes will also be carried out, in addition to some preliminary static oxidation test results of the conventional and milled NiCrAlY.