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P. Marcoux
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Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 482-487, September 27–29, 2011,
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Many processes and systems require hot surfaces. These are usually heated using electrical elements located in their vicinity. However, this solution is subject to intrinsic limitations associated with heating element geometry and physical location. Thermally spraying electrical elements directly on surfaces can overcome these limitations by tailoring the geometry of the heating element to the application. Moreover, the element heat transfer is maximized by eliminating the air gap between the heater and the surface to be heated. This paper is aimed at modeling and characterizing resistive heaters sprayed on metallic substrates. Heaters were fabricated using a plasma-sprayed alumina dielectric insulator and a wire flame sprayed iron-based alloy resistive element. Samples were energized and kept at a constant temperature of 425°C for up to four months. SEM cross-section observations revealed the formation of cracks at very specific locations in the alumina layer after thermal use. Finite element modeling shows that these cracks originate from high local thermal stresses and can be predicted according to the considered geometry. The simulation model was refined using experimental parameters obtained by several techniques such as: emissivity and time-dependent temperature profile (infra-red camera), resistivity (four probe technique), thermal diffusivity (laser flash method) and mechanical properties (micro and nanoindentation). The influence of the alumina thickness and the substrate material on crack formation was evaluated.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 37-42, May 14–16, 2007,
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SiC-reinforced Al-12Si alloy coatings were produced using the Cold Gas Dynamic Spraying deposition process. Feedstock powder mixtures containing 20% and 30% vol. of particulate SiC were used. The composite coatings’ bond strengths and microstructures were evaluated, as well as the porosity and the SiC content. It was found that approximately 45% of the SiC particulate blended with the aluminum alloy was embedded in the coatings. The SiC was homogeneously distributed inside the Al-12Si matrix. Particle velocity measurements revealed that the addition of up to 30% vol. of SiC did not change the Al-12Si particle velocities.
Proceedings Papers
ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 1040-1045, May 10–12, 2004,
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The abrasion and erosion resistance of six different coatings were evaluated in relation to their microstructure. The coatings were produced from six different powders: four containing WC and two containing CrC. Microstructural analysis highlights the relationship between the starting powder morphology and chemistry and the spray conditions in the development of the final coating microstructure. The wear performance of the coatings was evaluated according to the ASTM G-65 standard for the abrasion resistance and a slurry containing 0.66% of 180 μm alumina particles flowing at 20 m/s for wet erosion resistance. The results show that for all tested coatings the abrasion wear resistance is mostly governed by the hardness distribution. For the chrome carbide, coatings having the lowest hardness are the lest abrasion resistant. For the WC containing coatings, carbide debonding and pullout is the main wear mechanisms. The most resistant material being the WC-6Co-8Cr. All the coatings performed better than the D2 tool steel reference sample. The erosion wear resistance is controlled by the local hardness, the matrix properties and the droplet debonding. The most wear-resistant materials are the WC-Co-Cr cermets. The least wear-resistant materials are the clad CrC-20(NiCr) and the WC-Ni cermets.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 809-817, May 5–8, 2003,
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Four-point bend test using acoustic emission (AE) was used to compare coating properties under mechanical solicitation, mainly the toughness and the spalling behaviour. Coatings are made from the same material; the 2005NS (WC-17Co), sprayed with an HVOF gun at various spray parameters. Coatings deposited on thin rectangular substrates were tested with the coating bent in tension and in compression. AE features like the event number, energy per event and cumulative energy were used to assess the damage in the coatings. The results are analyzed in relation with the coating microstructure.