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R. Bolot
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Proceedings Papers
ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 1049-1054, June 7–9, 2017,
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Tungsten carbide (WC) is a well-known material used to increase the wear resistance of iron-based composite materials that exhibit a favorable wettability with iron alloy particles. In this work, two different additive manufacturing technologies, i.e., cold-spray additive-manufacturing (CSAM) and selective laser melting (SLM), were used to fabricate WC/maraging steel 300 (WC/MS300) composites. An investigation comparing the microstructure and tribological behaviors of the composites was carried out. In addition, the evolution of the reinforcement phase during these two processes was characterized by SEM and EDS methods.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 9-14, May 11–14, 2015,
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The presence of defects such as voids, inter-lamellar porosities or cracks, provides a decrease of the effective thermal conductivity of plasma sprayed coatings as well as a decrease of the corresponding mechanical properties such as the Young’s modulus. In general, effective properties of thermal spray coatings are thus strongly different from that of the bulk material and have thus to be quantified to validate their in service performances. A complementary approach allowing understanding the relationships between the microstructure of a coating and its macro-properties is the use of Finite Element Modeling. The case of composite coatings is still more complicated due to the presence of different materials. In the present study, thermo-mechanical properties of a plasma sprayed composite coating were estimated by numerical modeling based on FEM. The applied method uses directly cross-sectional micrographs without simplification using a one-cell per pixel approach. Characteristics such as the thermal conductivity, the Young’s modulus, the Poisson ratio and the dilatation coefficient were considered. The selected example was an AlSi/polyester coating used as abradable seal in the aerospace industry.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 99-106, May 11–14, 2015,
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Abradable seals are used in aircraft engine compressor and turbine to decrease fuel consumption. Their role is to minimize the clearance between the rotating blades of an engine rotor and the casing to reduce air leakages (compressor) or air-fuel combustion product leakages (turbine). Operating temperatures in turbines (up to 1800°C) can induce a thermal expansion of the blades and give rise to contacts providing damages to the blades or casing. Thus, in case of contact, the blade should remove the abradable seals applied to the casing without being damaged. Besides, the seal must be resistant to the turbine environment. Direct relationships have been observed between plasma spray operating parameters and abradable coating performances. The aim of this study is to determine those relationships for YSZ-Polyester abradable composite coatings. This study is conducted within the frame work of the 7FP European project E-BREAK to reach the environmental objectives of the European Advisory Council for Aviation Research and innovation.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 598-604, May 11–14, 2015,
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Atmospheric Plasma Spray is widely used for tens of years to elaborate protective coatings on parts for several applications. However, our understanding of the APS process can still be improved, requiring a fine modeling of the process in parallel with some corresponding experiments. In the present work, a complete series of models was applied to reinforce our knowledge of the process: the case of an alumina coating was considered. A 3D CFD model was first used to study the internal arc within the torch. Interactions between the external plasma jet and the injected particles were then computed in a second step. At this level, the predicted in-flight particle characteristics were compared with some corresponding measurements recorded with the DPV 2000 diagnostic tool. A third model was then applied to investigate the particle flattening on the substrate/coating material. SEM pictures of coating cross-sections were then captured and a last model was finally applied to estimate the coating effective thermos-mechanical properties based on calculations performed directly on the SEM micrographs. This set of models allows investigating the APS process from the DC arc within the torch to the coating properties.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 432-437, May 21–23, 2014,
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In this work, numerical modeling is used to simulate the effects of laser remelting as a post treatment and as an in-situ component of a hybrid plasma spraying process. Initially, a single-pass 2D model is used to simulate the laser post-treatment process in order to obtain relationships between melting pool depth, relative scanning velocity, and laser power. A 3D finite-element model is then used to study temperature variations during multi-layer deposition of a NiCr alloy by plasma spraying with in-situ laser melting. The effects of phase change are taken into account by defining the enthalpy of the material as a function of temperature. Predicted melting pool depth corresponded well with experimental values.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 1-7, May 13–15, 2013,
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Very low pressure plasma spraying (VLPPS) has been used to manufacture thin, dense, finely-structured ceramic coatings for various applications. This paper presents the results of work in which VLPPS is used to deposit metal. Aluminum was chosen as a demonstrative material, due to its moderate vaporization enthalpy (38.23 KJ·cm -3 ), with the objectives of better understanding the behavior of a solid precursor injected into the plasma jet, leading to the formation of vapors, and controlling the factors affecting coating structure. Nearly dense aluminum coatings were successfully deposited by VLPPS at 100 Pa with an intermediate power (45 kW) plasma torch. Optical emission spectroscopy (OES) was used to observe the behavior of the metal powder injected into the plasma jet, and simplified CFD modeling provided a better understanding of thermophysical mechanisms. The effect of powder size distribution, substrate temperature, and spray distance were studied. Coatings were characterized by SEM observations and Vickers microhardness measurements.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 329-334, May 13–15, 2013,
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The aim of this work is to develop a model that predicts coating thickness based on thermal spray robot trajectories and the thermal history of the workpiece. To test the model, an alumina layer is deposited on a steel substrate by air plasma spraying. Robot path coordinates are stored in a text file and used to compute substrate temperature fields by solving the transient heat conservation equation during torch displacement. The contributions of the impinging plasma jet and molten particle stream are accounted for in the model. The distribution of matter in the particle spray is used to simulate coating formation and determine coating thickness.
Proceedings Papers
ITSC 2013, Thermal Spray 2013: Proceedings from the International Thermal Spray Conference, 636-641, May 13–15, 2013,
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In the present study, Fe-Al 2 O 3 -FeAl 2 O 4 and FeAl coatings were synthesized in situ by reactive plasma spraying of Al-Fe 2 O 3 composite powder under atmosphere and low-pressure conditions. Coating microstructure and phase composition are examined and coating formation mechanisms are discussed. It was found that FeAl 2 O 4 hercynite phase is always synthesized as an intermediate product under low oxygen partial pressure conditions. In the APS process, such a phase can be retained in the final coating by extremely fast cooling. It can also be continuously reduced to FeAl by deoxidation in an oxygen-free H/H 2 atmosphere.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 609-614, May 21–24, 2012,
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Yttria-stabilized zirconia (YSZ) coatings have been frequently used as a thermal protective layer on the metal or alloy component surfaces. In the present study, ZrO 2 -7%Y 2 O 3 thermal barrier coatings (TBCs) were successfully deposited by DC (direct current) plasma spray process under very low pressure condition (less than 1 mbar) using low-energy plasma guns F4-VB and F100. The experiments were performed to evaluate the thermal shock resistance of the different TBC specimens which were heated to 1373 K at a high-temperature cycling furnace and held for 0.5 h, followed by air cooling under room temperature during 0.2 h. For comparison, the corresponding APS counterparts were also elaborated to carry out the similar experiments. The results indicated that the VLPPS coatings displayed better thermal shock resistance. Moreover, the failure mechanism of the coatings was also elucidated.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 615-621, May 21–24, 2012,
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To implement image-based numerical modeling of the thermal conductivity of coatings, a YSZ coating was considered as a network of two phases, namely the coating material and pores. The variation of the thermal conductivity of the gas trapped within the pores caused by their small size was considered by complying with the Knudsen law. In the present work, the quantification of the Knudsen effect on the effective thermal conductivity of coatings was achieved with the help of image analysis. The thicknesses of the pores were determined by combining the use of the Scion image software with a new in-house algorithm coded in C language. The Knudsen effect was quantified by applying a finite-difference model for both 2D images and a 3D image. In both cases, a decrease of the computed thermal conductivity was found while considering the Knudsen effect. Furthermore, the Knudsen effect was also taken into account in a finite-element model applied on the same images. Despite differences were noticed on the computed thermal conductivities obtained with the two methods, a quite similar decrease was calculated by comparing with data computed with the FDM method.
Proceedings Papers
ITSC2012, Thermal Spray 2012: Proceedings from the International Thermal Spray Conference, 846-850, May 21–24, 2012,
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With the purpose of elaborating high-quality FeAl coatings, a so-called very low pressure reactive plasma spray technique that combines VLPPS and SHS processes was used in the present study. A dense and homogeneous FeAl coating was thus successfully in situ synthesized by reactive plasma spraying of an Al/Fe 2 O 3 composite powder under 1 mbar. The phase composition and microstructural features of the coating were characterized by XRD and SEM. Results indicated that the B2 ordered FeAl phase was synthesized, and the coating featured a dense and defect-free microstructure. The fracture mechanism of the coating remains mainly a brittle failure but the appearance of some dimples in local zones suggests some unexpected toughness.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1037-1041, September 27–29, 2011,
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Magnesium coatings were deposited upon aluminum and stainless steel substrates by cold spraying. Three Mg powders with different particle size distributions were used as feedstock. The microstructures of as-sprayed coatings were evaluated by optical microscopy, and scanning electron microscopy. The coating observations show that a main gas temperature has an important effect on the deposition behaviour of particles. Changing the gas temperature from 350°C to 630°C involves an increase of the deposition efficiency from 1.57% to 19.57%. The effects of the particle size distribution and substrate material on the deposition efficiency of particles were also investigated. The results show that the particle size distribution has a significant effect on the deposition efficiency of particles which increases from 19.57% to 59% when the mean particle size decreases from 63 µm to 38 µm under gas temperature of 630°C. However, the deposition efficiency of particles was slightly influenced by the substrate material. In addition to these experimental results, the in-flight particle velocities were simulated by FLUENT software to point out the effects of the gas temperature and particle size distribution.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1042-1045, September 27–29, 2011,
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In this paper, a commercial AZ91D magnesium alloy powder and its mixture with 30 vol.% SiC powder were used to deposit coatings by cold spraying. Two types of converging-diverging nozzles with different cross-sectional shapes were employed. The velocity and temperature of in-flight particles under different operating conditions were simulated using the FLUENT software. The simulated results show that the particle velocity through the rectangular cross-section nozzle is the same with that through the circular one. However, the coating observation shows that the AZ91D coating and its composite could only be deposited using the rectangular cross-section nozzle. The increase of gas temperature has little effect on the coating microstructure, porosity and microhardness. Furthermore, the observation of the composite coating produced under the gas temperature of 600°C shows that the SiC content in the composite is about 23 vol.%. The microhardness of the composite is improved to about 140 HV 0.3 due to the enhancement of SiC particles, compared to that of about 100 HV 0.3 for the AZ91D coating.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1248-1255, September 27–29, 2011,
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Effective properties of TBCs may be quantified thanks to different measurement techniques. Image-based analysis represents an alternative method for predicting these effective properties. During the last 10 years, 2D modelling was intensively applied to estimate the thermal conductivity from coating cross-sectional images. However, real coatings present a complex 3D architecture so that the use of 2D computations based on cross-sections has to be validated. In the recent decade, 3D imaging approaches were applied for capturing 3D images of thermal spray coatings with relatively high resolution (up to 1 micrometer). Nevertheless, high resolution brings very large computational systems for which finite-element (FE) methods seem to be unsuitable due to high requirements in terms of computer memory (RAM) capacity. In the present study, a three-dimensional finite-difference-based heat transfer model was developed for analyzing the heat transfer mechanisms through a porous structure by saving RAM usage. An artificial 3D coating image, containing 300×300×300 voxels, was generated from microstructural information measured for a real coating cross-sectional image. In particular, this 3D artificial pore network was generated so that calculations performed on its cross-sections present similar results in comparison with those concerning SEM images of real coating cross-sections. Then, the results computed for the 3D image were compared with those obtained from 2D computations performed on cross-sections of the same 3D image, revealing the differences between 2D and 3D image-based analyses. Finally, the results were then compared with those computed by FE packages (OOF2 and ANSYS).
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1267-1273, September 27–29, 2011,
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The development of new plasma spray torches reinforced the use of numerical modelling to help in the design steps. Most of the thermal spray material providers are thus now interested in understanding the arc behaviour inside the torch so that CFD studies focussed on this topic become numerous. Our first calculations performed on the ProPlasma HP gun assuming a laminar hypothesis have shown underestimations of the torch voltage and of the thermal losses in the cooling circuit, and a subsequent overestimation of the thermal efficiency of the torch. In the present study, the setup of different turbulence models was performed and a comparison was made between the results obtained using either the laminar assumption or several turbulence models. The calculations indicate that the results obtained using conventional turbulence models such as k-ε or k-ω type models do not significantly differ from those obtained using a laminar assumption, thus only more sophisticated models can be expected to improve the simulations.
Proceedings Papers
ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1345-1350, September 27–29, 2011,
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As a promising thermal spray technology, the very low pressure plasma spray (VLPPS) process has been significantly used to deposit thin, dense and homogenous ceramic coating materials for special application needs in recent years. In this study, a home-made transferred arc nozzle was mounted on a low power F100 plasma torch for enhancing the plasma jet energy under very low pressure conditions. Thin and dense alumina (Al 2 O 3 ) and yttria-stabilized zirconia (YSZ) ceramic coatings with an average thickness of 30-40 µm were successfully elaborated by VLPPS process below 1 mbar. Optical emission spectroscopy (OES) was used to analyze the properties of the plasma jet with or without powder injection. The microstructures of the coatings were observed by means of scanning electron microscopy (SEM). It was found that the YSZ coatings displayed a bimodal microstructure that was composed of splats formed by melted particles and a little amount of vapor condensation from evaporated particles. However, vapor condensation could not be observed in the Al 2 O 3 coatings formed by lamellar splats only. The Vickers microhardnesses of both coatings were also evaluated.
Proceedings Papers
ITSC 2010, Thermal Spray 2010: Proceedings from the International Thermal Spray Conference, 619-624, May 3–5, 2010,
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The present study is devoted to the modelling of the arc formation in a direct current plasma gun newly commercialized by Saint-Gobain Coating Solutions (Avignon, France). The CFD computations were performed using the FLUENT code and the electromagnetic coupling was taken into account on the basis of a three dimensional model. The main advances compared to previous works performed on the same subject are numerous. First of all, whereas most of earlier models include the arc region only, the CFD domain was here extended to the gas injection region (i.e. upstream part of the gun, including the gas injection sleeve), thus allowing a better description of the effect of the gas injection on the plasma flow. Second, whereas earlier works include the fluid domain only, the present model includes a fluid/solid coupling in the anode. In particular, the thermal and electromagnetic equations are solved not only in the fluid parts but also in the tungsten and copper parts of the anode. This change was found to be important because the internal surface of the anode is no more a boundary of the domain. Thus, its temperature (and electric potential) becomes variable and is thus not necessarily imposed. Finally, the implemented model provides interesting results describing the arc behaviour inside the plasma gun.
Proceedings Papers
ITSC 2010, Thermal Spray 2010: Proceedings from the International Thermal Spray Conference, 636-641, May 3–5, 2010,
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The final target of this study was to achieve a better understanding of the behaviour of thermally sprayed abradable seals such as AlSi/polyester composites. These coatings are used as seals between the static and rotating parts in gas turbine applications. The machinability of the composite coatings during the friction of the blades depends on their mechanical and thermal effective properties. In order to predict these properties from micrographs, numerical studies were performed with different software packages such as OOF developed by NIST and TS2C developed at the UTBM. In 2008, differences were reported concerning prediction of effective thermal conductivity obtained with the two codes. In the present paper, it is shown that a particular attention must be paid to the mathematical formulation of the problem. In particular, results obtained with a finite difference method using a cell centre approach or a nodal formulation, allow explaining the discrepancies previously noticed. A comparison of the predictions of computed effective thermal conductivities is thus proposed for different codes and different meshing methods. This study is part of the NEWAC project, funded by the European Commission within the 6th RTD Framework program (FP6).
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1056-1061, June 2–4, 2008,
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Abradable seals are used in aerospace applications to control the overtip leakages between the blades of an engine rotor and its static parts. To achieve the combination of properties required, these seals have been developed with thermally sprayed coatings and are generally elaborated from a range of two or three phase powder mixtures. In the present study, the thermal conductivity of thermally sprayed AlSi/Polyester abradable coatings produced with Metco 601 NS and Durabrade 1605 powders was measured and investigated using finite element and finite difference methods based on two-dimensional structures obtained from micrographs. The computed values were compared to the experimental results.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1362-1366, June 2–4, 2008,
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Thermal fluxes transferred during HVOF thermal spray have an important influence on the thermal history of the work-piece. Thus, there is an interest in quantifying these fluxes. Today, different studies based on the use of calorimeters were proposed in the literature and CFD calculations may also be used to confirm the measures. In the present study, a new method based on the measurement of the transient increase of the work-piece temperature was used in order to estimate the thermal exchanges between an HVOF jet impinging on different diameter cylinders. The results indicate that fluxes of several MW/m 2 may be transferred depending on the standoff distance, spray parameters and gun.
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