Microstructure and properties of thermally sprayed Al-Sn-based alloys for plain bearing applications

Science.gov (United States)

Marrocco, T.; Driver, L. C.; Harris, S. J.; McCartney, D. G.

2006-12-01

Al-Sn plain bearings for automotive applications traditionally comprise a multilayer structure. Conventionally, bearing manufacturing involves casting the Al-Sn alloy and roll-bonding to a steel backing strip. Recently, high-velocity oxyfuel (HVOF) thermal spraying has been used as a novel alternative manufacturing route. The present project extends previous work on ternary Al-Sn-Cu alloys to quaternary systems, which contain specific additions for potentially enhanced properties. Two alloys were studied in detail, namely, Al-20wt.%Sn-1wt.%Cu-2wt.%Ni and Al-20wt.%Sn-1wt.%Cu-7wt.%Si. This article will describe the microstructural evolution of these alloys following HVOF spraying onto steel substrates and subsequent heat treatment. The microstructures of powders and coatings were investigated by scanning electron microscopy, and the phases were identified by x-ray diffraction. Coating microhardnesses were determined under both as-sprayed and heat-treated conditions, and by the differences related to the microstructures that developed. Finally, the wear behavior of the sprayed and heat-treated coatings in hot engine oil was measured using an industry standard test and was compared with that of previous work on a ternary alloy.

Positioning system of a torch used in thermal spray coatings applications

Directory of Open Access Journals (Sweden)

Edgar Absalón Torres-Barahona

2016-07-01

Full Text Available This paper presents the design, construction and performance evaluation of a positioning system used for the deposition of coatings with molten particles, by using a torch CastoDyn Ds 8000 thermal spray with oxyacetylene combustion. The design has been done with parameters obtained in the laboratory of materials of the Universidad Pedagógica y Tecnológica de Colombia, and the information determined from the evaluation of the device, allows to control the main process variables as the projection distance, flow powder, torch speed and rotation speed of the sample holder; this has been seen in coatings made in application tests zirconia / nickel on a carbon steel substrate and analyzed with Scanning Electron Microscopy - SEM.

Electrical properties of pressure quenched silicon by thermal spraying

International Nuclear Information System (INIS)

Tan, S.Y.; Gambino, R.J.; Sampath, S.; Herman, H.

2007-01-01

High velocity thermal spray deposition of polycrystalline silicon film onto single crystal substrates, yields metastable high pressure forms of silicon in nanocrystalline form within the deposit. The phases observed in the deposit include hexagonal diamond-Si, R-8, BC-8 and Si-IX. The peculiar attribute of this transformation is that it occurs only on orientation silicon substrate. The silicon deposits containing the high pressure phases display a substantially higher electrical conductivity. The resistivity profile of the silicon deposit containing shock induced metastable silicon phases identified by X-ray diffraction patterns. The density of the pressure induced polymorphic silicon is higher at deposit/substrate interface. A modified two-layer model is presented to explain the resistivity of the deposit impacted by the pressure induced polymorphic silicon generated by the thermal spraying process. The pressure quenched silicon deposits on the p - silicon substrate, with or without metastable phases, display the barrier potential of about 0.72 eV. The measured hall mobility value of pressure quenched silicon deposits is in the range of polycrystalline silicon. The significance of this work lies in the fact that the versatility of thermal spray may enable applications of these high pressure forms of silicon

Elastic response of thermal spray deposits under indentation tests

International Nuclear Information System (INIS)

Leigh, S.H.; Lin, C.K.; Berndt, C.C.

1997-01-01

The elastic response behavior of thermal spray deposits at Knoop indentations has been investigated using indentation techniques. The ration of hardness to elastic modulus, which is an important prerequisite for the evaluation of indentation fracture toughness, is determined by measuring the elastic recovery of the in-surface dimensions of Knoop indentations. The elastic moduli of thermal spray deposits are in the range of 12%--78% of the comparable bulk materials and reveal the anisotropic behavior of thermal spray deposits. A variety of thermal spray deposits has been examined, including Al 2 O 3 , yttria-stabilized ZrO 2 (YSZ), and NiAl. Statistical tools have been used to evaluate the error estimates of the data

Effect of layer thickness on the properties of nickel thermal sprayed steel

Energy Technology Data Exchange (ETDEWEB)

Nurisna, Zuhri, E-mail: zuhri-nurisna@yahoo.co.id; Triyono,, E-mail: triyonomesin@uns.ac.id; Muhayat, Nurul, E-mail: nurulmuhayat@staff.uns.ac.id; Wijayanta, Agung Tri, E-mail: agungtw@uns.ac.id [Department of Mechanical Engineering, Sebelas Maret University, Jl. Jr. Sutami 36 A, Surakarta (Indonesia)

2016-03-29

Thermal arc spray nickel coating is widely used for decorative and functional applications, by improving corrosion resistance, wear resistance, heat resistence or by modifying other properties of the coated materials. There are several properties have been studied. Layer thickness of nickel thermal sprayed steel may be make harder the substrate surface. In this study, the effect of layer thickness of nickel thermal sprayed steel has been investigated. The rectangular substrate specimens were coated by Ni–5 wt.% Al using wire arc spray method. The thickness of coating layers were in range from 0.4 to 1.0 mm. Different thickness of coating layers were conducted to investigate their effect on hardness and morphology. The coating layer was examined by using microvickers and scanning electron microscope with EDX attachment. Generally, the hardness at the interface increased with increasing thickness of coating layers for all specimens due to higher heat input during spraying process. Morphology analysis result that during spraying process aluminum would react with surrounding oxygen and form aluminum oxide at outer surface of splat. Moreover, porosity was formed in coating layers. However, presence porosity is not related to thickness of coating material. The thicker coating layer resulted highesr of hardness and bond strength.

Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

Science.gov (United States)

Agapakis, John E.; Bolstad, Jon

1993-01-01

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

Advances in Thermal Spray Deposition of Billets for Particle Reinforced Light Metals

International Nuclear Information System (INIS)

Wenzelburger, Martin; Zimmermann, Christian; Gadow, Rainer

2007-01-01

Forming of light-metals in semi-solid state offers some advantages like low process temperatures, improved mould durability, good flow behavior and fine, globular microstructure of the final material. By the introduction of ceramic particles, increased elastic modulus and yield strength as well as wear resistance and creep behavior can be obtained. By semi-solid forging or semi-solid casting, particle reinforced metals (PRM) can be produced with improved matrix microstructure and beneficial forming process parameters compared to conventional MMC manufacturing techniques. The production of this kind of light metal matrix composites requires the supply of dense semi-finished parts with well defined volume fractions of homogeneously distributed particulate reinforcement. A manufacturing method for cylindrical light metal billets is described that applies thermal spraying as a build-up process for simultaneous deposition of matrix and reinforcement phase with cored wires as spraying material. Thermal spraying leads to small grain sizes and prevents dendrite formation. However, long process cycle times lead to billet heating and recrystallization of the matrix microstructure. In order to preserve small grain sizes that enable semi-solid forming, the thermal spraying process was analyzed by in-flight particle analysis and thermography. As a consequence, the deposition process was optimized by adaptation of the thermal spraying parameters and by application of additional cooling, leading to lower billet temperatures and finer PRM billet microstructure

High-power electronics thermal management with intermittent multijet sprays

International Nuclear Information System (INIS)

Panão, Miguel R.O.; Correia, André M.; Moreira, António L.N.

2012-01-01

Thermal management plays a crucial role in the development of high-power electronics devices, e.g. in electric vehicles. The greatest energy demands occur during power peaks, implying dynamic thermal losses within the vehicle’s driving cycle. Therefore, the need for devising intelligent thermal management systems able to efficiently respond to these power peaks has become a technological challenge. Experiments have been performed with methanol in order to quantify the maximum heat flux removed by a multijet spray to keep the 4 cm 2 surface temperature stabilized and below the threshold of 125 °C. A multijet atomization strategy consists in producing a spray through the multiple and simultaneous impact of N j cylindrical jets. Moreover, the spray intermittency is expressed through the duty cycle (DC), which depends on the frequency and duration of injection. Results evidence that: i) a shorter time between consecutive injection cycles enables a better distribution of the mass flow rate, resulting in larger heat transfer coefficient values, as well as higher cooling efficiencies; ii) compared with continuous sprays, the analysis evidences that an intermittent spray allows benefiting more from phase-change convection. Moreover, the mass flux is mainly affecting heat transfer rather than differences induced in the spray structure by using different multijet configurations. - Highlights: ► Intermittent spray cooling (ISC) is advantageous for intelligent thermal management. ► Distributing the mass flow rate through ISC improves heat transfer. ► Multijet sprays with increasing number of jets have higher heat transfer rates. ► ISC with multijet sprays benefit more from phase-change than continuous sprays.

Identifying Indicators of Progress in Thermal Spray Research Using Bibliometrics Analysis

Science.gov (United States)

Li, R.-T.; Khor, K. A.; Yu, L.-G.

2016-12-01

We investigated the research publications on thermal spray in the period of 1985-2015 using the data from Web of Science, Scopus and SciVal®. Bibliometrics analysis was employed to elucidate the country and institution distribution in various thermal spray research areas and to characterize the trends of topic change and technology progress. Results show that China, USA, Japan, Germany, India and France were the top countries in thermal spray research, and Xi'an Jiaotong University, Universite de Technologie Belfort-Montbeliard, Shanghai Institute of Ceramics, ETH Zurich, National Research Council of Canada, University of Limoges were among the top institutions that had high scholarly research output during 2005-2015. The terms of the titles, keywords and abstracts of the publications were analyzed by the Latent Dirichlet Allocation model and visually mapped using the VOSviewer software to reveal the progress of thermal spray technology. It is found that thermal barrier coating was consistently the main research area in thermal spray, and high-velocity oxy-fuel spray and cold spray developed rapidly in the last 10 years.

Design Optimization of Liquid Fueled High Velocity Oxy- Fuel Thermal Spraying Technique for Durable Coating for Fossil Power Systems

Energy Technology Data Exchange (ETDEWEB)

Choudhuri, Ahsan [Univ. of Texas, El Paso, TX (United States); Love, Norman [Univ. of Texas, El Paso, TX (United States)

2016-11-04

High-velocity oxy–fuel (HVOF) thermal spraying was developed in 1930 and has been commercially available for twenty-five years. HVOF thermal spraying has several benefits over the more conventional plasma spray technique including a faster deposition rate which leads to quicker turn-around, with more durable coatings and higher bond strength, hardness and wear resistance due to a homogeneous distribution of the sprayed particles. HVOF thermal spraying is frequently used in engineering to deposit cermets, metallic alloys, composites and polymers, to enhance product life and performance. HVOF thermal spraying system is a highly promising technique for applying durable coatings on structural materials for corrosive and high temperature environments in advanced ultra-supercritical coal- fired (AUSC) boilers, steam turbines and gas turbines. HVOF thermal spraying is the preferred method for producing coatings with low porosity and high adhesion. HVOF thermal spray process has been shown to be one of the most efficient techniques to deposit high performance coatings at moderate cost. Variables affecting the deposit formation and coating properties include hardware characteristics such as nozzle geometry and spraying distance and process parameters such as equivalence ratio, gas flow density, and powder feedstock. In the spray process, the powder particles experience very high speeds combined with fast heating to the powder material melting point or above. This high temperature causes evaporation of the powder, dissolution, and phase transformations. Due to the complex nature of the HVOF technique, the control and optimization of the process is difficult. In general, good coating quality with suitable properties and required performance for specific applications is the goal in producing thermal spray coatings. In order to reach this goal, a deeper understanding of the spray process as a whole is needed. Although many researchers studied commercial HVOF thermal spray

Influence of Bondcoat Spray Process on Lifetime of Suspension Plasma-Sprayed Thermal Barrier Coatings

Science.gov (United States)

Gupta, M.; Markocsan, N.; Li, X.-H.; Östergren, L.

2018-01-01

Development of thermal barrier coatings (TBCs) manufactured by suspension plasma spraying (SPS) is of high commercial interest as SPS has been shown capable of producing highly porous columnar microstructures similar to the conventionally used electron beam-physical vapor deposition. However, lifetime of SPS coatings needs to be improved further to be used in commercial applications. The bondcoat microstructure as well as topcoat-bondcoat interface topography affects the TBC lifetime significantly. The objective of this work was to investigate the influence of different bondcoat deposition processes for SPS topcoats. In this work, a NiCoCrAlY bondcoat deposited by high velocity air fuel (HVAF) was compared to commercial vacuum plasma-sprayed NiCoCrAlY and PtAl diffusion bondcoats. All bondcoat variations were prepared with and without grit blasting the bondcoat surface. SPS was used to deposit the topcoats on all samples using the same spray parameters. Lifetime of these samples was examined by thermal cyclic fatigue testing. Isothermal heat treatment was performed to study bondcoat oxidation over time. The effect of bondcoat deposition process and interface topography on lifetime in each case has been discussed. The results show that HVAF could be a suitable process for bondcoat deposition in SPS TBCs.

Wear Resistant Thermal Sprayed Composite Coatings Based on Iron Self-Fluxing Alloy and Recycled Cermet Powders

Directory of Open Access Journals (Sweden)

Heikki SARJAS

2012-03-01

Full Text Available Thermal spray and WC-Co based coatings are widely used in areas subjected to abrasive wear. Commercial  cermet thermal spray powders for HVOF are relatively expensive. Therefore applying these powders in cost-sensitive areas like mining and agriculture are hindered. Nowadays, the use of cheap iron based self-fluxing alloy powders for thermal spray is limited. The aim of this research was to study properties of composite powders based on self-fluxing alloys and recycled cermets and to examine the properties of thermally sprayed (HVOF coatings from composite powders based on iron self-fluxing alloy and recycled cermet powders (Cr3C2-Ni and WC-Co. To estimate the properties of  recycled cermet powders, the sieving analysis, laser granulometry and morphology were conducted. For deposition of coatings High Velocity Oxy-Fuel spray was used. The structure and composition of powders and coatings were estimated by SEM and XRD methods. Abrasive wear performance of coatings was determined and compared with wear resistance of coatings from commercial powders. The wear resistance of thermal sprayed coatings from self-fluxing alloy and recycled cermet powders at abrasion is comparable with wear resistance of coatings from commercial expensive spray powders and may be an alternative in tribological applications in cost-sensitive areas.DOI: http://dx.doi.org/10.5755/j01.ms.18.1.1338

Standard guide for metallographic preparation of thermal sprayed coatings

CERN Document Server

American Society for Testing and Materials. Philadelphia

2003-01-01

1.1 This guide covers recommendations for sectioning, cleaning, mounting, grinding, and polishing to reveal the microstructural features of thermal sprayed coatings (TSCs) and the substrates to which they are applied when examined microscopically. Because of the diversity of available equipment, the wide variety of coating and substrate combinations, and the sensitivity of these specimens to preparation technique, the existence of a series of recommended methods for metallographic preparation of thermal sprayed coating specimens is helpful. Adherence to this guide will provide practitioners with consistent and reproducible results. Additional information concerning standard practices for metallographic preparation can be found in Practice E 3. 1.2 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitatio...

Role of oxides and porosity on high temperature oxidation of liquid fuelled HVOF thermal sprayed Ni50Cr coatings

OpenAIRE

Song, B.; Bai, M.; Voisey, K.T.; Hussain, Tanvir

2017-01-01

High chromium content in Ni50Cr thermally sprayed coatings can generate a dense and protective scale at the surface of coating. Thus, the Ni50Cr coating is widely used in high temperature oxidation and corrosion applications. A commercially available gas atomized Ni50Cr powder was sprayed onto a power plant steel (ASME P92) using a liquid fuelled high velocity oxy-fuel (HVOF) thermal spray with three processing parameters in this study. Microstructure of as-sprayed coatings was examined using...

Thermal conductivity of spray-on foam insulations for aerospace applications

Science.gov (United States)

Barrios, Matt; Vanderlaan, Mark; Van Sciver, Steven

2012-06-01

A guarded-hot-plate apparatus [1] has been developed to measure the thermal conductivity of spray-on foam insulations (SOFI) at temperatures ranging from 30 K to 300 K. The foam tested in the present study is NCFI 24-124, a polyisocyanurate foam used on the External Tanks of the Space Shuttle. The foam was tested first in ambient pressure air, then evacuated and tested once more. These thermal conductivities were compared to the thermal conductivity taken from a sample immediately after being subjected to conditions similar to those experienced by the foam while on the launch pad at Kennedy Space Center. To mimic the conditions experienced on the launch pad, an apparatus was built to enclose one side of the foam sample in a warm, humid environment while the other side of the sample contacts a stainless steel surface held at 77 K. The thermal conductivity data obtained is also compared to data found in the literature.

The history and future of thermal sprayed galvanically active metallic anticorrosion coatings used on pipelines and steel structures in the oil and gas industry

Energy Technology Data Exchange (ETDEWEB)

Rodijnen, Fred van [Sulzer Metco, Duisburg (Germany)

2008-07-01

Since its invention by M. U. Schoop in the beginning of the 20th century, thermal spray has been used for corrosion protection applications in naval, on-shore, submerged and atmospheric environments. Thermally sprayed coatings of zinc, zinc alloys, aluminum and aluminum alloys are currently the most popular materials used for active corrosion protection of steel and concrete, which can be applied using either of the widely known thermal spray processes of combustion wire or electric arc wire. In the oil and gas exploration and production industry, corrosion protection applications using these technologies have evolved since the early sixties. Thermal spray technology has successfully been used to protect steel-based materials from corrosion in many different fields of application like platforms and pipelines. The most used material in the oil and gas industry is TSA (Thermally Sprayed Aluminum) coating. TSA coatings, with a lifetime of 25 to 30 years, require no maintenance except for cosmetic reasons when painted. The surface temperature of a TSA can go as high as 480 deg C. Although TS (Thermal Spray) is an older process, the number of applications and the number of m{sup 2} it is applied to is still increasing resulting from its maintenance-free and reliable active corrosion-protection features. (author)

Thermal spray deposition and evaluation of low-Z coatings

International Nuclear Information System (INIS)

Seals, R.D.; Swindeman, C.J.; White, R.L.

1996-01-01

Thermally sprayed low-Z coatings of B 4 C on Al substrates were investigated as candidate materials for first-wall reactor protective surfaces. Comparisons were made to thermally sprayed coatings of B, MgAl 2 O 4 , Al 2 O 3 , and composites. Graded bond layers were applied to mitigate coefficient of thermal expansion mismatch. Microstructures, thermal diffusivity before and after thermal shock loading, steel ball impact resistance, CO 2 pellet cleaning and erosion tolerance, phase content, stoichiometry by Rutherford backscattering spectroscopy, and relative tensile strengths were measured

Thermal Radiation Effects on Thermal Explosion in Polydisperse Fuel Spray-Probabilistic Model

Directory of Open Access Journals (Sweden)

Ophir Navea

2011-06-01

Full Text Available We investigate the effect of thermal radiation on the dynamics of a thermal explosion of polydisperse fuel spray with a complete description of the chemistry via a single-step two-reactant model of general order. The polydisperse spray is modeled using a Probability Density Function (PDF. The thermal radiation energy exchange between the evaporation surface of the fuel droplets and the burning gas is described using the Marshak boundary conditions. An explicit expression of the critical condition for thermal explosion limit is derived analytically and represents a generalization of the critical parameter of the classical Semenov theory. Because we investigated the model in the range where the temperature is very high, the effect of the thermal radiation is significant.

Engineering a new class of thermal spray nano-based microstructures from agglomerated nanostructured particles, suspensions and solutions: an invited review

Science.gov (United States)

Fauchais, P.; Montavon, G.; Lima, R. S.; Marple, B. R.

2011-03-01

From the pioneering works of McPherson in 1973 who identified nanometre-sized features in thermal spray conventional alumina coatings (using sprayed particles in the tens of micrometres size range) to the most recent and most advanced work aimed at manufacturing nanostructured coatings from nanometre-sized feedstock particles, the thermal spray community has been involved with nanometre-sized features and feedstock for more than 30 years. Both the development of feedstock (especially through cryo-milling, and processes able to manufacture coatings structured at the sub-micrometre or nanometre sizes, such as micrometre-sized agglomerates made of nanometre-sized particles for feedstock) and the emergence of thermal spray processes such as suspension and liquid precursor thermal spray techniques have been driven by the need to manufacture coatings with enhanced properties. These techniques result in two different types of coatings: on the one hand, those with a so-called bimodal structure having nanometre-sized zones embedded within micrometre ones, for which the spray process is similar to that of conventional coatings and on the other hand, sub-micrometre or nanostructured coatings achieved by suspension or solution spraying. Compared with suspension spraying, solution precursor spraying uses molecularly mixed precursors as liquids, avoiding a separate processing route for the preparation of powders and enabling the synthesis of a wide range of oxide powders and coatings. Such coatings are intended for use in various applications ranging from improved thermal barrier layers and wear-resistant surfaces to thin solid electrolytes for solid oxide fuel cell systems, among other numerous applications. Meanwhile these processes are more complex to operate since they are more sensitive to parameter variations compared with conventional thermal spray processes. Progress in this area has resulted from the unique combination of modelling activities, the evolution of

Effects of service condition on rolling contact fatigue failure mechanism and lifetime of thermal spray coatings—A review

Science.gov (United States)

Cui, Huawei; Cui, Xiufang; Wang, Haidou; Xing, Zhiguo; Jin, Guo

2015-01-01

The service condition determines the Rolling Contact Fatigue(RCF) failure mechanism and lifetime under ascertain material structure integrity parameter of thermal spray coating. The available literature on the RCF testing of thermal spray coatings under various condition services is considerable; it is generally difficult to synthesize all of the result to obtain a comprehensive understanding of the parameters which has a great effect on a thermal spray coating's resistance of RCF. The effects of service conditions(lubrication states, contact stresses, revolve speed, and slip ratio) on the changing of thermal spray coatings' contact fatigue lifetime is introduced systematically. The effects of different service condition on RCF failure mechanism of thermal spray coating from the change of material structure integrity are also summarized. Moreover, In order to enhance the RCF performance, the parameter optimal design formula of service condition and material structure integrity is proposed based on the effect of service condition on thermal spray coatings' contact fatigue lifetime and RCF failure mechanism. The shortage of available literature and the forecast focus in future researches are discussed based on available research. The explicit result of RCF lifetime law and parameter optimal design formula in term of lubrication states, contact stresses, revolve speed, and slip ratio, is significant to improve the RCF performance on the engineering application.

Computational homogenisation for thermoviscoplasticity: application to thermally sprayed coatings

Science.gov (United States)

Berthelsen, Rolf; Denzer, Ralf; Oppermann, Philip; Menzel, Andreas

2017-11-01

Metal forming processes require wear-resistant tool surfaces in order to ensure a long life cycle of the expensive tools together with a constant high quality of the produced components. Thermal spraying is a relatively widely applied coating technique for the deposit of wear protection coatings. During these coating processes, heterogeneous coatings are deployed at high temperatures followed by quenching where residual stresses occur which strongly influence the performance of the coated tools. The objective of this article is to discuss and apply a thermo-mechanically coupled simulation framework which captures the heterogeneity of the deposited coating material. Therefore, a two-scale finite element framework for the solution of nonlinear thermo-mechanically coupled problems is elaborated and applied to the simulation of thermoviscoplastic material behaviour including nonlinear thermal softening in a geometrically linearised setting. The finite element framework and material model is demonstrated by means of numerical examples.

ZrO2 coatings on stainless steel by aerosol thermal spraying

International Nuclear Information System (INIS)

Di Giampaolo, A.R.; Reveron, H.; Ruiz, H.; Poirier, T.; Lira, J.

1998-01-01

Zirconia coatings, with a wide range of thickness (1 to 80 μ) have been obtained by spraying a ZrO 2 sol with an oxyacetylenic flame, on stainless steel substrates. The sol was prepared by mixing Zr-n-propoxide and acetic acid in order to obtain a zirconium oxyacetate precipitate, which was filtrated, washed with 1-propanol, dryed and subjected to an hydrothermal treatment. A new sol-gel based ceramic deposition process , aerosol thermal spraying was developed based on previous thermal spray work. A compressed air spray gun was used to produce a fine aerosol flow which was injected in the flame of the thermal spray torch and deposited on polished and sand blasted substrates. This original technique allows simultaneous spraying, drying and partial sintering of the zirconia nanometric particles. The maximum working temperature necessary to yield a resistant coating is 1000 deg C. This method produced crack-free homogeneous layers of monoclinic ZrO 2 with good adhesion to the substrate and low porosity, as shown by X-ray diffraction and scanning electron microscopy. Oxidation test, carried out by heat treatments in air atmosphere at 800 deg C indicated good protection, mainly for low thickness coatings deposited in polished substrates. This original deposition technique offers several advantages when compared with classical thermal spraying techniques, such as plasma spraying. Copyright (1998) AD-TECH - International Foundation for the Advancement of Technology Ltd

Engineering a new class of thermal spray nano-based microstructures from agglomerated nanostructured particles, suspensions and solutions: an invited review

International Nuclear Information System (INIS)

Fauchais, P; Montavon, G; Lima, R S; Marple, B R

2011-01-01

From the pioneering works of McPherson in 1973 who identified nanometre-sized features in thermal spray conventional alumina coatings (using sprayed particles in the tens of micrometres size range) to the most recent and most advanced work aimed at manufacturing nanostructured coatings from nanometre-sized feedstock particles, the thermal spray community has been involved with nanometre-sized features and feedstock for more than 30 years. Both the development of feedstock (especially through cryo-milling, and processes able to manufacture coatings structured at the sub-micrometre or nanometre sizes, such as micrometre-sized agglomerates made of nanometre-sized particles for feedstock) and the emergence of thermal spray processes such as suspension and liquid precursor thermal spray techniques have been driven by the need to manufacture coatings with enhanced properties. These techniques result in two different types of coatings: on the one hand, those with a so-called bimodal structure having nanometre-sized zones embedded within micrometre ones, for which the spray process is similar to that of conventional coatings and on the other hand, sub-micrometre or nanostructured coatings achieved by suspension or solution spraying. Compared with suspension spraying, solution precursor spraying uses molecularly mixed precursors as liquids, avoiding a separate processing route for the preparation of powders and enabling the synthesis of a wide range of oxide powders and coatings. Such coatings are intended for use in various applications ranging from improved thermal barrier layers and wear-resistant surfaces to thin solid electrolytes for solid oxide fuel cell systems, among other numerous applications. Meanwhile these processes are more complex to operate since they are more sensitive to parameter variations compared with conventional thermal spray processes. Progress in this area has resulted from the unique combination of modelling activities, the evolution of

Optimization and Characterization of High Velocity Oxy-fuel Sprayed Coatings: Techniques, Materials, and Applications

Directory of Open Access Journals (Sweden)

Maria Oksa

2011-09-01

Full Text Available In this work High Velocity Oxy-fuel (HVOF thermal spray techniques, spraying process optimization, and characterization of coatings are reviewed. Different variants of the technology are described and the main differences in spray conditions in terms of particle kinetics and thermal energy are rationalized. Methods and tools for controlling the spray process are presented as well as their use in optimizing the coating process. It will be shown how the differences from the starting powder to the final coating formation affect the coating microstructure and performance. Typical properties of HVOF sprayed coatings and coating performance is described. Also development of testing methods used for the evaluation of coating properties and current status of standardization is presented. Short discussion of typical applications is done.

Mueller matrix polarimetry on plasma sprayed thermal barrier coatings for porosity measurement.

Science.gov (United States)

Luo, David A; Barraza, Enrique T; Kudenov, Michael W

2017-12-10

Yttria-stabilized zirconia (YSZ) is the most widely used material for thermal plasma sprayed thermal barrier coatings (TBCs) used to protect gas turbine engine parts in demanding operation environments. The superior material properties of YSZ coatings are related to their internal porosity level. By quantifying the porosity level, tighter control on the spraying process can be achieved to produce reliable coatings. Currently, destructive measurement methods are widely used to measure the porosity level. In this paper, we describe a novel nondestructive approach that is applicable to classify the porosity level of plasma sprayed YSZ TBCs via Mueller matrix polarimetry. A rotating retarder Mueller matrix polarimeter was used to measure the polarization properties of the plasma sprayed YSZ coatings with different porosity levels. From these measurements, it was determined that a sample's measured depolarization ratio is dependent on the sample's surface roughness and porosity level. To this end, we correlate the depolarization ratio with the samples' surface roughness, as measured by a contact profilometer, as well as the total porosity level, in percentage measured using a micrograph and stereological analysis. With the use of this technique, a full-field and rapid measurement of porosity level can be achieved.

Thermally sprayed prepregs for thixoforging of UD fiber reinforced light metal MMCs

Science.gov (United States)

Silber, Martin; Wenzelburger, Martin; Gadow, Rainer

2007-04-01

Low density and good mechanical properties are the basic requirements for lightweight structures in automotive and aerospace applications. With their high specific strength and strain to failure values, aluminum alloys could be used for such applications. Only the insufficient stiffness and thermal and fatigue strength prevented their usage in high-end applications. One possibility to solve this problem is to reinforce the light metal with unidirectional fibers. The UD fiber allows tailoring of the reinforcement to meet the direction of the component's load. In this study, the production of thermally sprayed prepregs for the manufacturing of continuous fiber reinforced MMC by thixoforging is analysed. The main aim is to optimize the winding procedure, which determines the fiber strand position and tension during the coating process. A method to wind and to coat the continuous fibers with an easy-to-use handling technique for the whole manufacturing process is presented. The prepregs were manufactured by producing arc wire sprayed AlSi6 coatings on fibers bundles. First results of bending experiments showed appropriate mechanical properties.

Review of US Nanocorp - SNL Joint Development of Thermal-Sprayed Thin-Film Cathodes for Thermal Batteries

Energy Technology Data Exchange (ETDEWEB)

GUIDOTTI,RONALD A.; REINHARDT,FREDERICK W.; DAI,JINXIANG; XIAO,T. DANNY; REISNER,DAVID E.

2000-11-14

The use of plasma spray to deposit thin metal-sulfide cathode films is described in this paper. Conventional electroactive stack components in thermal batteries are constructed from pressed-powder parts that are difficult to fabricate in large diameters in thicknesses <0.010. Plasma-sprayed electrodes do not steer from this difficulty, allowing greater energy densities and specific energies to be realized. Various co-spraying agents have been found suitable for improving the mechanical as well as electrochemical properties of plasma-sprayed cathodes for thermal batteries. These electrodes generally show equal or improved performance over conventional pressed-powder electrodes. A number of areas for future growth and development of plasma-spray technology is discussed.

Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings

Directory of Open Access Journals (Sweden)

Nicholas Curry

2014-08-01

Full Text Available Suspension plasma spraying (SPS has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS or electron beam physical vapor deposition (EB-PVD coatings. Additionally, SPS coatings can have lower thermal conductivity than EB-PVD coatings, while also being easier to produce. The combination of similar or improved properties with a potential for lower production costs makes SPS of great interest to the gas turbine industry. This study compares a number of SPS thermal barrier coatings (TBCs with vertical cracks or column-like structures with the reference of segmented APS coatings. The primary focus has been on lifetime testing of these new coating systems. Samples were tested in thermo-cyclic fatigue at temperatures of 1100 °C for 1 h cycles. Additional testing was performed to assess thermal shock performance and erosion resistance. Thermal conductivity was also assessed for samples in their as-sprayed state, and the microstructures were investigated using SEM.

UNA REVISIÓN DEL SPRAY TÉRMICO COMO TÉCNICA DE DEPOSICIÓN PARA CAPAS DE BARRERAS TÉRMICAS // THE THERMAL SPRAY AS A DEPOSITION TECHNIQUE FOR THERMAL BARRIER COATING: A REVIEW

Directory of Open Access Journals (Sweden)

Eduardo Rondón Briceño

2015-06-01

Full Text Available It is important to know the thermal barrier deposition techniques since materials with low thermal conductivity in the barrier can be obtained from them. The dependence of the thermal conductivity with the temperature can be divided into four regions. In this work, we were interested in the study of used techniques for the manufacture of materials with a desirable low thermal conductivity that will be exposed to high temperatures that is to say, materials found in the III and IV region. In these regions the thermal conductivity can be reduced increasing the porosity of the material. Through the study of the thermal barrier deposition techniques we found that the thermal spray produces a coat with high porosity, being the low velocity flame spray technique the best to produce coat of La2Zr2O7 with a minimal thermal conductivity. The thermal spray technique is low cost and almost any material can be thermally sprayed, so this can be considered a very attractive technique for industrial applications. // RESUMEN Es importante conocer las técnicas de deposición de barreras térmicas ya que de ellas depende la obtención de materiales con baja conductividad térmica en la barrera. La dependencia de la conductividad térmica con la temperatura puede dividirse en cuatro regiones. En este trabajo estuvimos interesados en el estudio de las técnicas que se utilizan para la fabricación de materiales sometidos a muy altas temperaturas y donde se desea que su conductividad térmica sea baja, es decir, materiales que se encuentran en la región III y IV. En estas regiones se puede disminuir la conductividad térmica aumentando la porosidad del material. A través del estudio de las técnicas de deposición de barreras térmica, hemos encontrado que la técnica del spray térmico produce una alta porosidad en el recubrimiento, siendo el método de rociado con baja velocidad el mejor método para producir capas de La2Zr2O7 con mínima conductividad t

Influence of Microstructure on Thermal Properties of Axial Suspension Plasma-Sprayed YSZ Thermal Barrier Coatings

Czech Academy of Sciences Publication Activity Database

Ganvir, A.; Curry, N.; Markocsan, N.; Nylen, P.; Joshi, S.; Vilémová, Monika; Pala, Zdeněk

2016-01-01

Roč. 25, 1-2 (2016), s. 202-212 ISSN 1059-9630. [ITSC 2015: International Thermal Spray Conference and Exposition. Long Beach, California, 11.05.2015-14.05.2015] Institutional support: RVO:61389021 Keywords : axial injection * column ar microstructure * porosity * suspension plasma spraying * thermal conductivity * thermal diffusivity Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.488, year: 2016 http://link.springer.com/article/10.1007%2Fs11666-015-0355-7

Characterization of thermally sprayed coatings for high-temperature wear-protection applications

International Nuclear Information System (INIS)

Li, C.C.

1980-03-01

Under normal high-temperature gas-cooled reactor (HTGR) operating conditions, faying surfaces of metallic components under high contact pressure are prone to friction, wear, and self-welding damage. Component design calls for coatings for the protection of the mating surfaces. Anticipated operating temperatures up to 850 to 950 0 C (1562 to 1742 0 F) and a 40-y design life require coatings with excellent thermal stability and adequate wear and spallation resistance, and they must be compatible with the HTGR coolant helium environment. Plasma and detonation-gun (D-gun) deposited chromium carbide-base and stabilized zirconia coatings are under consideration for wear protection of reactor components such as the thermal barrier, heat exchangers, control rods, and turbomachinery. Programs are under way to address the structural integrity, helium compatibility, and tribological behavior of relevant sprayed coatings. In this paper, the need for protection of critical metallic components and the criteria for selection of coatings are discussed. The technical background to coating development and the experience with the steam cycle HTGR (HTGR-SC) are commented upon. Coating characterization techniques employed at General Atomic Company (GA) are presented, and the progress of the experimental programs is briefly reviewed. In characterizing the coatings for HTGR applications, it is concluded that a systems approach to establish correlation between coating process parameters and coating microstructural and tribological properties for design consideration is required

Processing, structure, property and performance relationships for the thermal spray of the internal surface of aluminum cylinders

Science.gov (United States)

Cook, David James

The increased need for automotive weight reduction has necessitated the use of aluminum for engine blocks. Conventional aluminum alloys cannot survive the constant wear from a piston ring reciprocating on the surface. However, a wear resistant thermal spray coating can be applied on the internal surface of the cylinder bore, which has significant advantages over other available options. Thermal spray is a well-established process for depositing molten, semi-molten, or solid particles onto a substrate to form a protective coating. For this application, the two main challenges were obtaining good wear resistance, and achieving good adhesion. To design a system capable of producing a well-adhered, wear resistant coating for this high volume application it is necessary to identify the overall processing, structure, properties, and performance relationships. The results will demonstrate that very important relationships exist among particle characteristics, substrate conditions, and the properties of the final coating. However, it is the scientific studies to understand some of the process physics in these relationships that allow recognition of the critical processing conditions that need to be controlled to ensure a consistent, reliable thermal spray coating. In this investigation, it will be shown that the critical microstructural aspect of the coating that produced the required tribological properties was the presence of wuestite (FeO). It was found that by using a low carbon steel material with compressed air atomizing gas, it was possible to create an Fe/FeO structure that exhibited excellent tribological properties. This study will also show that traditional thermal spray surface preparation techniques were not ideal for this application, therefore a novel alternative approach was developed. The application of a flux to the aluminum surface prior to thermal spray promotes excellent bond strengths to non-roughened aluminum. Analysis will show that this flux strips

Residual stress determination in thermally sprayed metallic deposits by neutron diffraction

International Nuclear Information System (INIS)

Keller, Thomas; Margadant, Nikolaus; Pirling, Thilo; Riegert-Escribano, Maria J.; Wagner, Werner

2004-01-01

Neutron diffraction was used to obtain spatially resolved strain and stress profiles in thermally sprayed metallic 'NiCrAlY' deposits (chemical composition 67 wt.% Ni, 22 wt.% Cr, 10 wt.% Al, 1 wt.% Y) and the underlying steel substrates. Samples of four different spray techniques were analyzed: atmospheric and water stabilized plasma spraying (APS and WSP), flame spraying (FS) and wire arc spraying (WAS). The results are quantitatively compared with the average in-plane residual stress determined by complementary bending tests and the hole drilling technique. While the stress profiles from the surface to the interface in the deposits are similar for all investigated spray techniques, their absolute values and gradients vary strongly. This is attributed to different quenching stresses from the impinging particles, different thermal histories the deposit/substrate systems undergo during the spraying and subsequent cooling, and also to different coating properties. In the water stabilized plasma sprayed and the wire arc sprayed deposits, a gradient in the stress-free lattice parameter was observed. Crack formation is found to be a dominant mechanism for stress relaxation in the surface plane

The role of nano-particles in the field of thermal spray coating technology

Science.gov (United States)

Siegmann, Stephan; Leparoux, Marc; Rohr, Lukas

2005-06-01

Nano-particles play not only a key role in recent research fields, but also in the public discussions about health and safety in nanotechnology. Nevertheless, the worldwide activities in nano-particles research increased dramatically during the last 5 to 10 years. There are different potential routes for the future production of nano-particles at large scale. The main directions envisaged are mechanical milling, wet chemical reactions or gas phase processes. Each of the processes has its specific advantages and limitations. Mechanical milling and wet chemical reactions are typically time intensive and batch processes, whereas gas phase productions by flames or plasma can be carried out continuously. Materials of interest are mainly oxide ceramics, carbides, nitrides, and pure metals. Nano-ceramics are interesting candidates for coating technologies due to expected higher coating toughness, better thermal shock and wear resistance. Especially embedded nano-carbides and-nitrides offer homogenously distributed hard phases, which enhance coatings hardness. Thermal spraying, a nearly 100 years old and world wide established coating technology, gets new possibilities thanks to optimized, nano-sized and/or nano-structured powders. Latest coating system developments like high velocity flame spraying (HVOF), cold gas deposition or liquid suspension spraying in combination with new powder qualities may open new applications and markets. This article gives an overview on the latest activities in nano-particle research and production in special relation to thermal spray coating technology.

Process-based quality for thermal spray via feedback control

Science.gov (United States)

Dykhuizen, R. C.; Neiser, R. A.

2006-09-01

Quality control of a thermal spray system manufacturing process is difficult due to the many input variables that need to be controlled. Great care must be taken to ensure that the process remains constant to obtain a consistent quality of the parts. Control is greatly complicated by the fact that measurement of particle velocities and temperatures is a noisy stochastic process. This article illustrates the application of quality control concepts to a wire flame spray process. A central feature of the real-time control system is an automatic feedback control scheme that provides fine adjustments to ensure that uncontrolled variations are accommodated. It is shown how the control vectors can be constructed from simple process maps to independently control particle velocity and temperature. This control scheme is shown to perform well in a real production environment. We also demonstrate that slight variations in the feed wire curvature can greatly influence the process. Finally, the geometry of the spray system and sensor must remain constant for the best reproducibility.

Practical Aspects of Suspension Plasma Spray for Thermal Barrier Coatings on Potential Gas Turbine Components

Science.gov (United States)

Ma, X.; Ruggiero, P.

2018-04-01

Suspension plasma spray (SPS) process has attracted extensive efforts and interests to produce fine-structured and functional coatings. In particular, thermal barrier coatings (TBCs) applied by SPS process gain increasing interest due to its potential for superior thermal protection of gas turbine hot sections as compared to conventional TBCs. Unique columnar architectures and nano- and submicrometric grains in the SPS-TBC demonstrated some advantages of thermal shock durability, low thermal conductivity, erosion resistance and strain-tolerant microstructure. This work aimed to look into some practical aspects of SPS processing for TBC applications before it becomes a reliable industry method. The spray capability and applicability of SPS process to achieve uniformity thickness and microstructure on curved substrates were emphasized in designed spray trials to simulate the coating fabrication onto industrial turbine parts with complex configurations. The performances of the SPS-TBCs were tested in erosion, falling ballistic impact and indentational loading tests as to evaluate SPS-TBC performances in simulated turbine service conditions. Finally, a turbine blade was coated and sectioned to verify SPS sprayability in multiple critical sections. The SPS trials and test results demonstrated that SPS process is promising for innovative TBCs, but some challenges need to be addressed and resolved before it becomes an economic and capable industrial process, especially for complex turbine components.

Unit thermal performance of atmospheric spray cooling systems

International Nuclear Information System (INIS)

Porter, R.W.; Jain, M.; Chaturvedi, S.K.

1980-01-01

Thermal performance of an open atmospheric spray pond or canal depends on the direct-contact evaporative cooling of an individual spray unit (spray nozzle or module) and the interference caused by local heating and humidification. Droplet parameters may be combined into a dimensionless group, number of transfer units (NTU) or equivalent, whereas large-scale air-vapor dynamics determine interference through the local wet-bulb temperature. Quantity NTU were implied from field experiments for a floating module used in steam-condenser spray canals. Previous data were available for a fixed-pipe nozzle assembly used in spray ponds. Quantity NTU were also predicted using the Ranz-Marshall correlations with the Sauter-mean diameter used as the characteristic length. Good agreement with experiments was shown for diameters of 1--1.1 cm (module) and 1.9 mm

Applications in the Nuclear Industry for Corrosion-Resistant Amorphous-Metal Thermal-Spray Coatings

International Nuclear Information System (INIS)

Farmer, J; Choi, J

2007-01-01

Amorphous metal and ceramic thermal spray coatings have been developed that can be used to enhance the corrosion resistance of containers for the transportation, aging and disposal of spent nuclear fuel and high-level radioactive wastes. Fe-based amorphous metal formulations with chromium, molybdenum and tungsten have shown the corrosion resistance believed to be necessary for such applications. Rare earth additions enable very low critical cooling rates to be achieved. The boron content of these materials, and their stability at high neutron doses, enable them to serve as high efficiency neutron absorbers for criticality control. Ceramic coatings may provide even greater corrosion resistance for container applications, though the boron-containing amorphous metals are still favored for criticality control applications. These amorphous metal and ceramic materials have been produced as gas atomized powders and applied as near full density, non-porous coatings with the high-velocity oxy-fuel process. This paper summarizes the performance of these coatings as corrosion-resistant barriers, and as neutron absorbers. Relevant corrosion models are also discussed, as well as a cost model to quantify the economic benefits possible with these new materials

The 2016 Thermal Spray Roadmap

Czech Academy of Sciences Publication Activity Database

Vardelle, A.; Moreau, Ch.; Akedo, J.; Ashrafizadeh, H.; Berndt, C. C.; Berghaus-Oberste, J.; Boulos, M.; Brogan, J.; Bourtsalas, A.C.; Dolatabadi, A.; Dorfman, M.; Eden, T.J.; Fauchais, P.; Fisher, G.; Gaertner, F.; Gindrat, M.; Henne, R.; Hyland, M.; Irissou, E.; Jordan, E.H.; Khor, K.A.; Killinger, A.; Lau, Y.C.; Li, C.-J.; Li, L.; Longtin, J.; Markocsan, N.; Masset, P.J.; Matějíček, Jiří; Mauer, G.; McDonald, A.; Mostaghimi, J.; Sampath, S.; Schiller, G.; Shinoda, K.; Smith, M.F.; Syed, A.A.; Themelis, N.J.; Toma, F.-L.; Trelles, J.P.; Vassen, R.; Vuoristo, P.

2016-01-01

Roč. 25, č. 8 (2016), s. 1376-1440 ISSN 1059-9630 Institutional support: RVO:61389021 Keywords : anti-wear and anti-corrosion coatings * biomedical * electronics * energy generation * functional coatings * gas turbines * thermal spray processes Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.488, year: 2016 http://dx.doi.org/10.1007/s11666-016-0473-x

Residual stress determination in thermally sprayed metallic deposits by neutron diffraction

Energy Technology Data Exchange (ETDEWEB)

Keller, Thomas; Margadant, Nikolaus; Pirling, Thilo; Riegert-Escribano, Maria J.; Wagner, Werner

2004-05-25

Neutron diffraction was used to obtain spatially resolved strain and stress profiles in thermally sprayed metallic 'NiCrAlY' deposits (chemical composition 67 wt.% Ni, 22 wt.% Cr, 10 wt.% Al, 1 wt.% Y) and the underlying steel substrates. Samples of four different spray techniques were analyzed: atmospheric and water stabilized plasma spraying (APS and WSP), flame spraying (FS) and wire arc spraying (WAS). The results are quantitatively compared with the average in-plane residual stress determined by complementary bending tests and the hole drilling technique. While the stress profiles from the surface to the interface in the deposits are similar for all investigated spray techniques, their absolute values and gradients vary strongly. This is attributed to different quenching stresses from the impinging particles, different thermal histories the deposit/substrate systems undergo during the spraying and subsequent cooling, and also to different coating properties. In the water stabilized plasma sprayed and the wire arc sprayed deposits, a gradient in the stress-free lattice parameter was observed. Crack formation is found to be a dominant mechanism for stress relaxation in the surface plane.

Study on modernization processes in the coating metal surfaces (plain bearings by thermal spraying

Directory of Open Access Journals (Sweden)

Elena IRIMIE

2011-09-01

Full Text Available Knowledge accumulated within the metal coating through thermal spraying allows the understanding of aspects related to the coat structure phenomena, in this case of the routs that need to be followed in order to create strong and stabile connections between the coats subsided through thermal spraying, between the particles that compose those coats, respectively. However, all this knowledge does not ensure the understanding of some practical situations that are apparently paradoxes, as for instance the absence of tin bronze adherence to ignobly steel holders, the perfect adherence of bronze to the aluminum on the same types of holders, in the context in which both elements, tin and aluminum, respectively are found in equal quantity in the two type of bonze that maintain them in solid solutions (below 10%.The parallel study in the sinter antifriction domain has offered information regarding the optimal correlation between the composition of antifriction material and the required type of application, the optimal pinches level and the way that this morphological characteristic may be influenced. By experimental research it is necessary to determine the conditions under which such coverage can be obtained by thermal spraying of the metal coatings.

Optimal Substrate Preheating Model for Thermal Spray Deposition of Thermosets onto Polymer Matrix Composites

Science.gov (United States)

Ivosevic, M.; Knight, R.; Kalidindi, S. R.; Palmese, G. R.; Tsurikov, A.; Sutter, J. K.

2003-01-01

High velocity oxy-fuel (HVOF) sprayed, functionally graded polyimide/WC-Co composite coatings on polymer matrix composites (PMC's) are being investigated for applications in turbine engine technologies. This requires that the polyimide, used as the matrix material, be fully crosslinked during deposition in order to maximize its engineering properties. The rapid heating and cooling nature of the HVOF spray process and the high heat flux through the coating into the substrate typically do not allow sufficient time at temperature for curing of the thermoset. It was hypothesized that external substrate preheating might enhance the deposition behavior and curing reaction during the thermal spraying of polyimide thermosets. A simple analytical process model for the deposition of thermosetting polyimide onto polymer matrix composites by HVOF thermal spray technology has been developed. The model incorporates various heat transfer mechanisms and enables surface temperature profiles of the coating to be simulated, primarily as a function of substrate preheating temperature. Four cases were modeled: (i) no substrate preheating; (ii) substrates electrically preheated from the rear; (iii) substrates preheated by hot air from the front face; and (iv) substrates electrically preheated from the rear and by hot air from the front.

Electrochemical corrosion behaviour of Mg-Al alloys with thermal spray Al/SiCp composite coatings

International Nuclear Information System (INIS)

Pardo, A.; Feliu Jr, S.; Merino, M. C.; Mohedano, M.; Casajus, P.; Arrabal, R.

2010-01-01

The corrosion protection of Mg-Al alloys by flame thermal spraying of Al/SiCp composite coatings was evaluated by electrochemical impedance spectroscopy in 3.5 wt.% NaCl solution. The volume fraction of SiC particles (SiCp) varied between 5 and 30%. The as-sprayed Al/SiCp composite coatings revealed a high number of micro-channels, largely in the vicinity of the SiC particles, that facilitated the penetration of the electrolyte and the subsequent galvanic corrosion of the magnesium substrates. The application of a cold-pressing post-treatment reduced the degree of porosity of the coatings and improved the bonding at the coating/substrate and Al/SiC interfaces. This resulted in improved corrosion resistance of the coated specimens. The effectiveness of the coatings slightly decreased with the addition of 5-30 vol.% SiCp compared with the un reinforced thermal spray aluminium coatings. (Author) 31 refs.

Research into Thermal Sprayed Coatings with Ultrasonic Methods

Directory of Open Access Journals (Sweden)

Justinas Gargasas

2012-01-01

Full Text Available Research on thermal sprayed coatings with ultrasonic methods is the main object of this thesis. Metal surface coating was applied to modify its mechanical and physical-chemical properties and resistance to external impact and improve aesthetics. Spraying was carried out by scanning the rotating sample of 30 cm/s speed. Surface microstructure, ultrasonic thickness, porosity, micro hardness and surface modulus tests performed. Conclusions were formulated.Article in Lithuanian

Process development for synthesis and plasma spray deposition of LaPO4 and YPO4 for nuclear applications

International Nuclear Information System (INIS)

Chakravarthy, Y.; Sreekumar, K.P.; Jayakumar, S.; Thiyagarajan, T.K.; Ananthapadmanabhan, P.V.; Das, A.K.; Gantayet, L.M.; Krishnan, K.

2009-01-01

Rare earth phosphates are geologically very stable and considered as potential matrix material for nuclear waste disposal and also for many high temperature thermal barrier and corrosion barrier applications involving molten metals. This paper focuses on developmental studies related to synthesis, thermal stability and plasma spray deposition of LaPO 4 and YPO 4 . The rare earth phosphates were synthesized by chemical method from their respective oxide materials using ortho phosphoric acid. The as-precipitated powders were converted to thermal spray grade powder by compaction, sintering and crushing. Thermal stability of these phosphates up to their melting point was determined by arc plasma melting, followed by X-ray diffraction. Results indicate that LaPO 4 and YPO 4 melt congruently without decomposition. Plasma spray deposition was carried out using the in-house 40 kW atmospheric plasma spray system. Adherent coatings could be deposited on various substrates by optimizing the plasma spray parameters. (author)

Applications in the Nuclear Industry for Thermal Spray Amorphous Metal and Ceramic Coatings

Science.gov (United States)

Blink, J.; Farmer, J.; Choi, J.; Saw, C.

2009-06-01

Amorphous metal and ceramic thermal spray coatings have been developed with excellent corrosion resistance and neutron absorption. These coatings, with further development, could be cost-effective options to enhance the corrosion resistance of drip shields and waste packages, and limit nuclear criticality in canisters for the transportation, aging, and disposal of spent nuclear fuel. Iron-based amorphous metal formulations with chromium, molybdenum, and tungsten have shown the corrosion resistance believed to be necessary for such applications. Rare earth additions enable very low critical cooling rates to be achieved. The boron content of these materials and their stability at high neutron doses enable them to serve as high efficiency neutron absorbers for criticality control. Ceramic coatings may provide even greater corrosion resistance for waste package and drip shield applications, although the boron-containing amorphous metals are still favored for criticality control applications. These amorphous metal and ceramic materials have been produced as gas-atomized powders and applied as near full density, nonporous coatings with the high-velocity oxy-fuel process. This article summarizes the performance of these coatings as corrosion-resistant barriers and as neutron absorbers. This article also presents a simple cost model to quantify the economic benefits possible with these new materials.

Validation of HVOF Thermal Spray Coatings as a Replacement for Hard Chrome Plating on Hydraulic/Pneumatic Actuators

Science.gov (United States)

2007-12-01

Projects Agency (DARPA). The program evaluated HVOF, physical vapor deposition (PVD) and laser cladding , and concluded that HVOF was the best overall...components such as titanium flap tracks. 5 2.0 TECHNOLOGY DESCRIPTION 2.1 TECHNOLOGY DEVELOPMENT AND APPLICATION Technology background and...theory of operation: High-velocity oxygen-fuel (HVOF) is a standard commercial thermal spray process in which a powder of the material to be sprayed

Thermal plasma spheroidization and spray deposition of barium titanate powder and characterization of the plasma sprayable powder

Energy Technology Data Exchange (ETDEWEB)

Pakseresht, A.H., E-mail: amirh_pak@yahoo.com [Department of Ceramics, Materials and Energy Research Center, P.O. Box 31787-316, Karaj (Iran, Islamic Republic of); Rahimipour, M.R. [Department of Ceramics, Materials and Energy Research Center, P.O. Box 31787-316, Karaj (Iran, Islamic Republic of); Vaezi, M.R. [Department of Nanotechnology and Advanced Materials, Materials and Energy Research Center, P.O. Box 31787-316, Karaj (Iran, Islamic Republic of); Salehi, M. [Department of Materials Engineering, Isfahan University of Technology, P.O. Box 84156-83111, Isfahan (Iran, Islamic Republic of)

2016-04-15

In this paper, atmospheric plasma spray method was used to produce dense plasma sprayable powder and thick barium titanate film. In this regard, the commercially feedstock powders were granulated and spheroidized by the organic binder and the thermal spray process, respectively. Scanning electron microscopy was used to investigate the microstructure of the produced powders and the final deposits. X-ray diffraction was also implemented to characterize phase of the sprayed powder. The results indicated that spheroidized powder had suitable flowability as well as high density. The micro-hardness of the film produced by the sprayed powders was higher than that of the film deposited by the irregular granules. Additionally, relative permittivity of the films was increased by decreasing the defects from 160 to 293 for film deposited using spheroidized powder. The reduction in the relative permittivity of deposits, in comparison with the bulk material, was due to the existence of common defects in the thermal spray process. - Highlights: • We prepare sprayable BaTiO{sub 3} powder with no or less inside voids for plasma spray application for first time. • The sprayable powder has good flow characteristics and high density. • Powder spheroidization via plasma spray improves the hardness and dielectric properties of the deposited film.

Thermal plasma spheroidization and spray deposition of barium titanate powder and characterization of the plasma sprayable powder

International Nuclear Information System (INIS)

Pakseresht, A.H.; Rahimipour, M.R.; Vaezi, M.R.; Salehi, M.

2016-01-01

In this paper, atmospheric plasma spray method was used to produce dense plasma sprayable powder and thick barium titanate film. In this regard, the commercially feedstock powders were granulated and spheroidized by the organic binder and the thermal spray process, respectively. Scanning electron microscopy was used to investigate the microstructure of the produced powders and the final deposits. X-ray diffraction was also implemented to characterize phase of the sprayed powder. The results indicated that spheroidized powder had suitable flowability as well as high density. The micro-hardness of the film produced by the sprayed powders was higher than that of the film deposited by the irregular granules. Additionally, relative permittivity of the films was increased by decreasing the defects from 160 to 293 for film deposited using spheroidized powder. The reduction in the relative permittivity of deposits, in comparison with the bulk material, was due to the existence of common defects in the thermal spray process. - Highlights: • We prepare sprayable BaTiO_3 powder with no or less inside voids for plasma spray application for first time. • The sprayable powder has good flow characteristics and high density. • Powder spheroidization via plasma spray improves the hardness and dielectric properties of the deposited film.

Applications in the Nuclear Industry for Thermal Spray Amorphous Metal and Ceramic Coatings

OpenAIRE

Blink, J.; Farmer, J.; Choi, J.; Saw, C.

2009-01-01

Amorphous metal and ceramic thermal spray coatings have been developed with excellent corrosion resistance and neutron absorption. These coatings, with further development, could be cost-effective options to enhance the corrosion resistance of drip shields and waste packages, and limit nuclear criticality in canisters for the transportation, aging, and disposal of spent nuclear fuel. Iron-based amorphous metal formulations with chromium, molybdenum, and tungsten have shown the corrosion resis...

Metal-Matrix Hardmetal/Cermet Reinforced Composite Powders for Thermal Spray

Directory of Open Access Journals (Sweden)

Dmitri GOLJANDIN

2012-03-01

Full Text Available Recycling of materials is becoming increasingly important as industry response to public demands, that resources must be preserved and environment protected. To produce materials competitive in cost with primary product, secondary producers have to pursue new technologies and other innovations. For these purposes different recycling technologies for composite materials (oxidation, milling, remelting etc are widely used. The current paper studies hardmetal/cermet powders produced by mechanical milling technology. The following composite materials were studied: Cr3C2-Ni cermets and WC-Co hardmetal. Different disintegrator milling systems for production of powders with determined size and shape were used. Chemical composition of produced powders was analysed.  To estimate the properties of recycled hardmetal/cermet powders, sieving analysis, laser granulometry and angularity study were conducted. To describe the angularity of milled powders, spike parameter–quadric fit (SPQ was used and experiments for determination of SPQ sensitivity and precision to characterize particles angularity were performed. Images used for calculating SPQ were taken by SEM processed with Omnimet Image Analyser 22. The graphs of grindability and angularity were composed. Composite powders based on Fe- and Ni-self-fluxing alloys for thermal spray (plasma and HVOF were produced. Technological properties of powders and properties of thermal sprayed coatings from studied powders were investigated. The properties of spray powders reinforced with recycled hardmetal and cermet particles as alternatives for cost-sensitive applications were demonstrated.DOI: http://dx.doi.org/10.5755/j01.ms.18.1.1348

Application of wear resistant spraying for diesel engine; Diesel kikan eno taimamo yosha no tekiyo

Energy Technology Data Exchange (ETDEWEB)

Kitajima, Y. [Mitsui Engineering and Shipbuliding Co. Ltd., Tokyo (Japan)

1999-03-31

Diesel engines used widely as propelling engines of ships have increasingly been provided with a high output and a high thermal efficiency; their structural members, particularly, the component parts for combustion chambers are therefore used under severe conditions, giving rise to the need of surface treatment and surface reforming of the members. Parts for marine diesel engines are huge, so that the technology applicable to the surface treatment and reforming are limited in point of facility and cost; therefore, most suitable is thermal spraying. This paper primarily discusses, among marine diesel engines, a 2-cycle low-speed engine with a 260-980mm bore used for the main engine of a merchant ship such as a container ship, bulk carrier or a tanker, and a 4-cycle medium-speed engine with a 300-420mm bore used for the main engine of a naval vessel; the paper explains the application status of a thermal spraying technology which is in progress to cope with the high output and high thermal efficiency of the diesel engines, explaining particularly the story of the development and the technological features of the wear resistant thermal spraying, which has been put to practical use, on the cylinder liner and the piston ring of the 4-cycle medium-speed engine. (NEDO)

An electrothermal chemical technology for thermal spray coatings

International Nuclear Information System (INIS)

Wald, S.; Appelbaum, G.; Alimi, R.; Rabani, L.; Zoler, D.; Zhitomirsky, V.; Factor, M.; Roman, I.

1998-01-01

A new spray technology for producing hard-coatings, has been developed at the SOREQ Nuclear Research Center. The concept is based on the extensive experience accumulated at SOREQ in the course of the development of Electrothermal (ET), Electrothermal-Chemical (ETC) and Solid-Propellant Electrothermal-Chemical (SPETC) guns(r). High quality coatings may be obtained by thermal spraying powder particles onto a variety of substrates. Mature state-of-the-art technologies such as plasma spray, high velocity oxy fuel (HVOF) and detonation gun (D-Gun) are widely used for many applications. As each method has its own drawbacks there is a need for a combination of several parameters which cannot be achieved by any existing individual commercial technology. The method presented is oriented toward a high-quality, multi-step, high-throughput, easily programmable continuous coating process and relatively inexpensive technology. The combustion products of a solid or liquid propellant accelerate the powder particles of the coating material. A pulsed-plasma jet, provided by a confined capillary discharge, ignites the propellant and controls the combustion process. The powder particles are accelerated to velocities over 1000 m/s. Due to the very high carrier gas density, high velocity, high throughput and high powder consumption efficiency are obtained. The plasma jet enables control of the gas temperature and consequently influences the powder temperature

Influence of Feedstock Materials and Spray Parameters on Thermal Conductivity of Wire-Arc-Sprayed Coatings

Science.gov (United States)

Yao, H. H.; Zhou, Z.; Wang, G. H.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

2017-03-01

To manufacture a protective coating with high thermal conductivity on drying cylinders in paper production machines, a FeCrB-cored wire was developed, and the spraying parameters for wire-arc spraying were optimized in this study. The conventional engineering materials FeCrAl and FeCrMo coatings were produced as the reference coatings under the same experimental condition. It has been shown that the oxide content in coating influences the thermal conductivity of coating significantly. The FeCrB coating exhibits a relative higher thermal conductivity due to the lower oxide content in comparison with conventional FeCrAl and FeCrMo coatings. Moreover, the oxidation of in-flight particles can be reduced by decreasing the standoff distance contributing to the increase in the thermal conductivity of coating. Total energy consumption of a papermaking machine can be significantly reduced if the coatings applied to dryer section exhibit high thermal conductivity. Therefore, the FeCrB coating developed in this study is a highly promising coating system for drying cylinders regarding the improved thermal conductivity and low operation costs in paper production industry.

Research on the Properties of Thermal Sprayed Ni-Cr-Si-Fe-B Coatings

Directory of Open Access Journals (Sweden)

Raimonda Lukauskaitė

2012-12-01

Full Text Available The article deals with the flame sprayed Ni-Cr-Si-Fe-B coating on aluminum alloy substrates. Before the thermal spraying process, aluminum samples were modified applying chemical, mechanical and thermal processing pre-treatment methods. The main aluminum surface treatment was removing an oxide layer from the surface and improving the exploitation properties of nickel-based coatings. The work involved coating microstructure, porosity, adhesion and microhardness tests. The dependence of the estimated exploitation properties of flame spray coatings on aluminum surface preparation methods and technological parameters of spraying has been established.Article in Lithuanian

Research on the Properties of Thermal Sprayed Ni-Cr-Si-Fe-B Coatings

Directory of Open Access Journals (Sweden)

Raimonda Lukauskaitė

2013-02-01

Full Text Available The article deals with the flame sprayed Ni-Cr-Si-Fe-B coating on aluminum alloy substrates. Before the thermal spraying process, aluminum samples were modified applying chemical, mechanical and thermal processing pre-treatment methods. The main aluminum surface treatment was removing an oxide layer from the surface and improving the exploitation properties of nickel-based coatings. The work involved coating microstructure, porosity, adhesion and microhardness tests. The dependence of the estimated exploitation properties of flame spray coatings on aluminum surface preparation methods and technological parameters of spraying has been established.Article in Lithuanian

Combating Wear of ASTM A36 Steel by Surface Modification Using Thermally Sprayed Cermet Coatings

Directory of Open Access Journals (Sweden)

Vineet Shibe

2016-01-01

Full Text Available Thermal spray coatings can be applied economically on machine parts to enhance their requisite surface properties like wear, corrosion, erosion resistance, and so forth. Detonation gun (D-Gun thermal spray coatings can be applied on the surface of carbon steels to improve their wear resistance. In the present study, alloy powder cermet coatings WC-12% Co and Cr3C2-25% NiCr have been deposited on ASTM A36 steel with D-Gun thermal spray technique. Sliding wear behavior of uncoated ASTM A36 steel and D-Gun sprayed WC-12% Co and Cr3C2-25% NiCr coatings on base material is observed on a Pin-On-Disc Wear Tester. Sliding wear performance of WC-12% Co coating is found to be better than the Cr3C2-25% NiCr coating. Wear performance of both these cermet coatings is found to be better than uncoated ASTM A36 steel. Thermally sprayed WC-12% Co and Cr3C2-25% NiCr cermet coatings using D-Gun thermal spray technique is found to be very useful in improving the sliding wear resistance of ASTM A36 steel.

Thermal failure of nanostructured thermal barrier coatings with cold sprayed nanostructured NiCrAlY bond coat

Energy Technology Data Exchange (ETDEWEB)

Zhang, Q.; Li, Y.; Zhang, S.L.; Wang, X.R.; Yang, G.J.; Li, C.X.; Li, C.J. [Xi' an Jiaotong Univ., Xi' an (China)

2008-07-01

Nanostructured YSZ is expected to exhibit a high strain tolerability due to its low Young's modulus and consequently high durability. In this study, a porous YSZ as the thermal barrier coating was deposited by plasma spraying using an agglomerated nanostructured YSZ powder on a Ni-based superalloy Inconel 738 substrate with a cold-sprayed nanostructured NiCrAlY as the bond coat. The heat treatment in Ar atmosphere was applied to the cold-sprayed bond coat before deposition of YSZ. The isothermal oxidation and thermal cycling tests were applied to examine failure modes of plasma-sprayed nanostructured YSZ. The results showed that YSZ coating was deposited by partially melted YSZ particles. The nonmelted fraction of spray particles retains the porous nanostructure of the starting powder into the deposit. YSZ coating exhibits a bimodal microstructure consisting of nanosized particles retained from the powder and micro-columnar grains formed through the solidification of the melted fraction in spray particles. The oxidation of the bond coat occurs during the heat treatment in Ar atmosphere. The uniform oxide at the interface between the bond coat and YSZ can be formed during isothermal test. The cracks were observed at the interface between TGO/BC or TGO/YSZ after thermal cyclic test. However, the failure of TBCs mainly occurred through spalling of YSZ within YSZ coating. The failure characteristics of plasma-sprayed nanostructured YSZ are discussed based on the coating microstructure and formation of TGO on the bond coat surface. (orig.)

Influence of Roughness on Quality Molybdenum Deposit Layer by Thermal Spraying

Directory of Open Access Journals (Sweden)

Marián Bujna

2016-01-01

Full Text Available In this paper we deal with the impact of roughness on the quality of molybdenum layer. Insufficient cleaning may result in a poor quality of the sprayed layer. Our aim is to analyze the influence of surface roughness on the quality of molybdenum layer thickness applied by thermal spraying. Thermal spraying influence several physical and chemical properties of the coating surface. The most important ones include: hardness, density, porosity, corrosion resistance and adhesion. This technology of surface treatment of material is often used for its high degree of hardness. Hardness and erosion resistance are the parameters that need to be achieved particularly in working conditions where there is excessive depreciation of a component.

Impact Response of Thermally Sprayed Metal Deposits

Science.gov (United States)

Wise, J. L.; Hall, A. C.; Moore, N. W.; Pautz, S. D.; Franke, B. C.; Scherzinger, W. M.; Brown, D. W.

2017-06-01

Gas-gun experiments have probed the impact response of tantalum specimens that were additively manufactured using a controlled thermal spray deposition process. Velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response under one-dimensional (i . e . , uniaxial strain) shock compression to peak stresses ranging between 1 and 4 GPa. The acquired wave-profile data have been analyzed to determine the Hugoniot Elastic Limit (HEL), Hugoniot equation of state, and high-pressure yield strength of the thermally deposited samples for comparison to published baseline results for conventionally wrought tantalum. The effects of composition, porosity, and microstructure (e . g . , grain/splat size and morphology) are assessed to explain differences in the dynamic mechanical behavior of spray-deposited versus conventional material. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under contract DE-AC04-94AL85000.

In Situ Acoustic Monitoring of Thermal Spray Process Using High-Frequency Impulse Measurements

Science.gov (United States)

Tillmann, Wolfgang; Walther, Frank; Luo, Weifeng; Haack, Matthias; Nellesen, Jens; Knyazeva, Marina

2018-01-01

In order to guarantee their protective function, thermal spray coatings must be free from cracks, which expose the substrate surface to, e.g., corrosive media. Cracks in thermal spray coatings are usually formed because of tensile residual stresses. Most commonly, the crack occurrence is determined after the thermal spraying process by examination of metallographic cross sections of the coating. Recent efforts focus on in situ monitoring of crack formation by means of acoustic emission analysis. However, the acoustic signals related to crack propagation can be absorbed by the noise of the thermal spraying process. In this work, a high-frequency impulse measurement technique was applied to separate different acoustic sources by visualizing the characteristic signal of crack formation via quasi-real-time Fourier analysis. The investigations were carried out on a twin wire arc spraying process, utilizing FeCrBSi as a coating material. The impact of the process parameters on the acoustic emission spectrum was studied. Acoustic emission analysis enables to obtain global and integral information on the formed cracks. The coating morphology and coating defects were inspected using light microscopy on metallographic cross sections. Additionally, the resulting crack patterns were imaged in 3D by means of x-ray microtomography.

The structure, properties and performance of plasma-sprayed beryllium for fusion applications

International Nuclear Information System (INIS)

Castro, R.G.; Stanek, P.W.; Elliott, K.E.

1995-01-01

Plasma-spray technology is under investigation as a method for producing high thermal conductivity beryllium coatings for use in magnetic fusion applications. Recent investigations have focused on optimizing the plasma-spray process for depositing beryllium coatings on damaged beryllium surfaces. Of particular interest has been optimizing the processing parameters to maximize the through-thickness thermal conductivity of the beryllium coatings. Experimental results will be reported on the use of secondary H 2 gas additions to improve the melting of the beryllium powder and transferred-arc cleaning to improve the bonding between the beryllium coatings and the underlying surface. Information will also be presented on thermal fatigue tests which were done on beryllium coated ISX-B beryllium limiter tiles using 10 sec cycle times with 60 sec cooldowns and an International Thermonuclear Experimental Reactor (ITER) relevant divertor heat flux slightly in excess of 5 MW/m 2

Combating Wear of ASTM A36 Steel by Surface Modification Using Thermally Sprayed Cermet Coatings

OpenAIRE

Shibe, Vineet; Chawla, Vikas

2016-01-01

Thermal spray coatings can be applied economically on machine parts to enhance their requisite surface properties like wear, corrosion, erosion resistance, and so forth. Detonation gun (D-Gun) thermal spray coatings can be applied on the surface of carbon steels to improve their wear resistance. In the present study, alloy powder cermet coatings WC-12% Co and Cr3C2-25% NiCr have been deposited on ASTM A36 steel with D-Gun thermal spray technique. Sliding wear behavior of uncoated ASTM A36 ste...

High-temperature resistant, thermally sprayed diffusion barrier coatings on CFC lightweight materials; Hochtemperaturbestaendige, thermisch gespritzte Diffusionsbarriereschichten auf CFC-Leichtbauchargiergestellen

Energy Technology Data Exchange (ETDEWEB)

Drehmann, Rico; Rupprecht, Christian; Wielage, Bernhard; Lampke, Thomas [Technische Univ. Chemnitz (Germany). Inst. fuer Werkstoffwissenschaft und Werkstofftechnik (IWW); Gilbert, Maria; Uhlig, Volker; Trimis, Dimosthenis [Technische Univ. Bergakademie Freiberg (Germany). Inst. fuer Waermetechnik und Thermodynamik (IWTT); Heuer, Volker [ALD Vacuum Technologies GmbH, Hanau (Germany)

2013-03-15

In heat treating processes as well as in high temperature brazing processes, charge carriers enable the positioning and transport of work pieces. Recently, charge carriers consisting of graphite or carbon fibre reinforced carbon (CFC) are used. The main disadvantage of charge carriers based on CFC is the undesirable carburization of the overlying components due to diffusion processes. Under this aspect, thermally sprayed coatings are applied on CFC and tested with respect to their suitability as a high-temperature diffusion barrier. The ceramic powders aluminium oxide, aluminium oxide/chromium oxide, aluminium oxide/titanium oxide and zirconium oxide/yttrium oxide are used as a coating material which is processed by means of the powder flame spraying as well as atmospheric plasma spraying. Molybdenum and silicon carbide are used as an adhesive layer. The coating materials aluminium oxide and aluminium oxide/chromium oxide on siliconized CFC presented excellent results. This supplies a large potential of application for thermally sprayed ceramic coatings on carbon-based lightweight materials.

Tribological properties of thermally sprayed TiAl-Al2O3 composite coating

Science.gov (United States)

Salman, A.; Gabbitas, B.; Li, J.; Zhang, D.

2009-08-01

The use of thermal spray coatings provides protection to the surfaces operating in severe environments. The main goal of the current work is to investigate the possibility of using a high velocity oxy fuel (HVOF) thermally sprayed wear resistant TiAl/Al2O3 coating on tool steel (H13) which is used for making dies for aluminium high pressure die casting. A feedstock of TiAl/Al2O3 composite powder was produced from a mixture of Al and TiO2 powders by high energy mechanical milling, followed by a thermal reaction process. The feedstock was then thermally sprayed using a high velocity oxy-fuel (HVOF) technique onto H13 steel substrates to produce a composite coating. The present study describes and compares the tribological properties such as friction and sliding wear rate of the coating both at room and high temperature (700°C). The results showed that the composite coating has lower wear rate at high temperature (700°C) than the uncoated H13 sample. At Room temperature without using lubricant there is no much significant difference between the wear rate of the coated and uncoated samples. The experimental results showed that the composite coating has great potential for high temperature application due to its lower wear rate at high temperature in comparison with the uncoated sample at the same temperature. The composite coating was characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD). This paper reports the experimental observations and discusses the wear resistance performance of the coatings at room and high temperatures.

Tribological properties of thermally sprayed TiAl-Al2O3 composite coating

International Nuclear Information System (INIS)

Salman, A; Gabbitas, B; Zhang, D; Li, J

2009-01-01

The use of thermal spray coatings provides protection to the surfaces operating in severe environments. The main goal of the current work is to investigate the possibility of using a high velocity oxy fuel (HVOF) thermally sprayed wear resistant TiAl/Al 2 O 3 coating on tool steel (H13) which is used for making dies for aluminium high pressure die casting. A feedstock of TiAl/Al 2 O 3 composite powder was produced from a mixture of Al and TiO 2 powders by high energy mechanical milling, followed by a thermal reaction process. The feedstock was then thermally sprayed using a high velocity oxy-fuel (HVOF) technique onto H13 steel substrates to produce a composite coating. The present study describes and compares the tribological properties such as friction and sliding wear rate of the coating both at room and high temperature (700 deg. C). The results showed that the composite coating has lower wear rate at high temperature (700deg. C) than the uncoated H13 sample. At Room temperature without using lubricant there is no much significant difference between the wear rate of the coated and uncoated samples. The experimental results showed that the composite coating has great potential for high temperature application due to its lower wear rate at high temperature in comparison with the uncoated sample at the same temperature. The composite coating was characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD). This paper reports the experimental observations and discusses the wear resistance performance of the coatings at room and high temperatures.

Examining Thermally Sprayed Coats By Fluorescence Microscopy

Science.gov (United States)

Street, Kenneth W., Jr.; Leonhardt, Todd A.

1994-01-01

True flaws distinquished from those induced by preparation of specimens. Fluorescence microscopy reveals debonding, porosity, cracks, and other flaws in specimens of thermally sprayed coating materials. Specimen illuminated, and dye it contains fluoresces, emitting light at different wavelength. Filters emphasize contrast between excitation light and emission light. Specimen viewed directly or photographed on color film.

Anisotropic Thermal Diffusivities of Plasma-Sprayed Thermal Barrier Coatings

Science.gov (United States)

Akoshima, Megumi; Takahashi, Satoru

2017-09-01

Thermal barrier coatings (TBCs) are used to shield the blades of gas turbines from heat and wear. There is a pressing need to evaluate the thermal conductivity of TBCs in the thermal design of advanced gas turbines with high energy efficiency. These TBCs consist of a ceramic-based top coat and a bond coat on a superalloy substrate. Usually, the focus is on the thermal conductivity in the thickness direction of the TBC because heat tends to diffuse from the surface of the top coat to the substrate. However, the in-plane thermal conductivity is also important in the thermal design of gas turbines because the temperature distribution within the turbine cannot be ignored. Accordingly, a method is developed in this study for measuring the in-plane thermal diffusivity of the top coat. Yttria-stabilized zirconia top coats are prepared by thermal spraying under different conditions. The in-plane and cross-plane thermal diffusivities of the top coats are measured by the flash method to investigate the anisotropy of thermal conduction in a TBC. It is found that the in-plane thermal diffusivity is higher than the cross-plane one for each top coat and that the top coats have significantly anisotropic thermal diffusivity. The cross-sectional and in-plane microstructures of the top coats are observed, from which their porosities are evaluated. The thermal diffusivity and its anisotropy are discussed in detail in relation to microstructure and porosity.

Thermal Spray Coating of Tungsten for Tokamak Device

International Nuclear Information System (INIS)

Jiang Xianliang; Gitzhofer, F; Boulos, M I

2006-01-01

Thermal spray, such as direct current (d.c.) plasma spray or radio frequency induced plasma spray, was used to deposit tungsten coatings on the copper electrodes of a tokamak device. The tungsten coating on the outer surface of one copper electrode was formed directly through d.c. plasma spraying of fine tungsten powder. The tungsten coating/lining on the inner surface of another copper electrode could be formed indirectly through induced plasma spraying of coarse tungsten powder. Scanning electron microscopy (SEM) was used to examine the cross section and the interface of the tungsten coating. Energy Dispersive Analysis of X-ray (EDAX) was used to analyze the metallic elements attached to a separated interface. The influence of the particle size of the tungsten powder on the density, cracking behavior and adhesion of the coating is discussed. It is found that the coarse tungsten powder with the particle size of 45 ∼ 75 μm can be melted and the coating can be formed only by using induced plasma. The coating deposited from the coarse powder has much higher cohesive strength, adhesive strength and crack resistance than the coating made from the fine powder with a particle size of 5 μm

Performance Testing of Suspension Plasma Sprayed Thermal Barrier Coatings Produced with Varied Suspension Parameters

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Nicholas Curry

2015-07-01

Full Text Available Suspension plasma spraying has become an emerging technology for the production of thermal barrier coatings for the gas turbine industry. Presently, though commercial systems for coating production are available, coatings remain in the development stage. Suitable suspension parameters for coating production remain an outstanding question and the influence of suspension properties on the final coatings is not well known. For this study, a number of suspensions were produced with varied solid loadings, powder size distributions and solvents. Suspensions were sprayed onto superalloy substrates coated with high velocity air fuel (HVAF -sprayed bond coats. Plasma spray parameters were selected to generate columnar structures based on previous experiments and were maintained at constant to discover the influence of the suspension behavior on coating microstructures. Testing of the produced thermal barrier coating (TBC systems has included thermal cyclic fatigue testing and thermal conductivity analysis. Pore size distribution has been characterized by mercury infiltration porosimetry. Results show a strong influence of suspension viscosity and surface tension on the microstructure of the produced coatings.

Thermal Expansion of Vacuum Plasma Sprayed Coatings

Science.gov (United States)

Raj, S V.; Palczer, A. R.

2010-01-01

Metallic Cu-8%Cr, Cu-26%Cr, Cu-8%Cr-1%Al, NiAl and NiCrAlY monolithic coatings were fabricated by vacuum plasma spray deposition processes for thermal expansion property measurements between 293 and 1223 K. The corrected thermal expansion, (DL/L(sub 0) varies with the absolute temperature, T, as (DL/L(sub 0) = A(T - 293)(sup 3) + BIT - 293)(sup 2) + C(T - 293) + D, where, A, B, C and D are thermal, regression constants. Excellent reproducibility was observed for all of the coatings except for data obtained on the Cu-8%Cr and Cu-26%Cr coatings in the first heat-up cycle, which deviated from those determined in the subsequent cycles. This deviation is attributed to the presence of residual stresses developed during the spraying of the coatings, which are relieved after the first heat-up cycle. In the cases of Cu-8%Cr and NiAl, the thermal expansion data were observed to be reproducible for three specimens. The linear expansion data for Cu-8% Cr and Cu-26%Cr agree extremely well with rule of mixture (ROM) predictions. Comparison of the data for the Cu-8%Cr coating with literature data for Cr and Cu revealed that the thermal expansion behavior of this alloy is determined by the Cu-rich matrix. The data for NiAl and NiCrAlY are in excellent agreement with published results irrespective of composition and the methods used for processing the materials. The implications of these results on coating GRCop-84 copper alloy combustor liners for reusable launch vehicles are discussed.

Plasma spray technology process parameters and applications

International Nuclear Information System (INIS)

Sreekumar, K.P.; Karthikeyan, J.; Ananthapadmanabhan, P.V.; Venkatramani, N.; Chatterjee, U.K.

1991-01-01

The current trend in the structural design philosophy is based on the use of substrate with the necessary mechanical properties and a thin coating to exhibit surface properties. Plasma spray process is a versatile surface coating technique which finds extensive application in meeting advance technologies. This report describes the plasma spray technique and its use in developing coatings for various applications. The spray system is desribed in detail including the different variables such as power input to the torch, gas flow rate, powder properties, powder injection, etc. and their interrelation in deciding the quality of the coating. A brief write-up on the various plasma spray coatings developed for different applications is also included. (author). 15 refs., 15 figs., 2 tabs

Modeling of Thickness and Profile Uniformity of Thermally Sprayed Coatings Deposited on Cylinders

Science.gov (United States)

Yanjun, Zhang; Wenbo, Li; Dayu, Li; Jinkun, Xiao; Chao, Zhang

2018-02-01

In thermal spraying processes, kinematic parameters of the robot play a decisive role in the coating thickness and profile. In this regard, some achievements have been made to optimize the spray trajectory on flat surfaces. However, few reports have focused on nonholonomic or variable-curvature cylindrical surfaces. The aim of this study is to investigate the correlation between the coating profile, coating thickness, and scanning step, which is determined by the radius of curvature and scanning angle. A mathematical simulation model was developed to predict the thickness of thermally sprayed coatings. Experiments were performed on cylinders with different radiuses of curvature to evaluate the predictive ability of the model.

Laser Processing of Multilayered Thermal Spray Coatings: Optimal Processing Parameters

Science.gov (United States)

Tewolde, Mahder; Zhang, Tao; Lee, Hwasoo; Sampath, Sanjay; Hwang, David; Longtin, Jon

2017-12-01

Laser processing offers an innovative approach for the fabrication and transformation of a wide range of materials. As a rapid, non-contact, and precision material removal technology, lasers are natural tools to process thermal spray coatings. Recently, a thermoelectric generator (TEG) was fabricated using thermal spray and laser processing. The TEG device represents a multilayer, multimaterial functional thermal spray structure, with laser processing serving an essential role in its fabrication. Several unique challenges are presented when processing such multilayer coatings, and the focus of this work is on the selection of laser processing parameters for optimal feature quality and device performance. A parametric study is carried out using three short-pulse lasers, where laser power, repetition rate and processing speed are varied to determine the laser parameters that result in high-quality features. The resulting laser patterns are characterized using optical and scanning electron microscopy, energy-dispersive x-ray spectroscopy, and electrical isolation tests between patterned regions. The underlying laser interaction and material removal mechanisms that affect the feature quality are discussed. Feature quality was found to improve both by using a multiscanning approach and an optional assist gas of air or nitrogen. Electrically isolated regions were also patterned in a cylindrical test specimen.

Thermal spray coatings replace hard chrome

International Nuclear Information System (INIS)

Schroeder, M.; Unger, R.

1997-01-01

Hard chrome plating provides good wear and erosion resistance, as well as good corrosion protection and fine surface finishes. Until a few years ago, it could also be applied at a reasonable cost. However, because of the many environmental and financial sanctions that have been imposed on the process over the past several years, cost has been on a consistent upward trend, and is projected to continue to escalate. Therefore, it is very important to find a coating or a process that offers the same characteristics as hard chrome plating, but without the consequent risks. This article lists the benefits and limitations of hard chrome plating, and describes the performance of two thermal spray coatings (tungsten carbide and chromium carbide) that compared favorably with hard chrome plating in a series of tests. It also lists three criteria to determine whether plasma spray or hard chrome plating should be selected

Quality control of thermal spray coatings in diesel engines; Qualitaetskontrolle an thermisch gespritzten Beschichtungen in Dieselmotoren

Energy Technology Data Exchange (ETDEWEB)

Carstensen, Jesper Vejloe [MAN Diesel and Turbo, Copenhagen (Denmark). Material Technology and Research Dept.; Lindegren, Maria [Struers A/S, Ballerup (Denmark). Application Dept.

2013-06-01

Thermal spraying is a method, which is suitable for coating of large components. The coatings can e.g. improve the wear, friction and/or corrosion properties of components so that they can withstand the increased loads. The quality of the coatings is essential to ensure reliable operation of the components. However, quality control of thermally sprayed coatings is indeed nontrivial and sample preparation is a key issue. This paper shows examples of thermal spray coated components in large diesel engines and provides insight into the methods used in preparing samples for quality control. (orig.)

Thermal stability study of crystalline and novel spray-dried amorphous nilotinib hydrochloride.

Science.gov (United States)

Herbrink, Maikel; Vromans, Herman; Schellens, Jan; Beijnen, Jos; Nuijen, Bastiaan

2018-01-30

The thermal characteristics and the thermal degradation of crystalline and amorphous nilotinib hydrochloride (NH) were studied. The spray drying technique was successfully utilized for the amorphization of NH and was evaluated by spectroscopic techniques and differential scanning calorimetry (DSC). The ethanolic spray drying process yielded amorphous NH with a glass transition temperature (T g ) of 147°C. Thermal characterization of the amorphous phase was performed by heat capacity measurements using modulated DSC (mDSC). Thermal degradation was studied by thermogravimetric analysis (TGA). The derived thermodynamic properties of the amorphous NH indicate fragile behaviour and a low crystallization tendency. NH was found to be molecularly stable up to 193°C. After which, the thermal degradation displayed two phases. The values of the thermal degradation parameters were estimated using the Ozawa-Flynn-Wall and Friedman non-isothermal, model-free, isoconversional methods The results indicate the two phases to be single-step reactions. The examination of the physical stability of amorphous NH during storage and at elevated temperatures showed stability at 180°C for at least 5h and at 20-25°C/60% RH for at least 6 months. During these periods, no crystallization was observed. This study is the first to report the thermal characteristics of NH. Additionally, it is also the first to describe the full thermal analysis of a spray-dried amorphous drug. The thermal data may be used in the projection of future production processes and storage conditions of amorphous NH. Copyright © 2017 Elsevier B.V. All rights reserved.

Thermal Fatigue Behavior of Air-Plasma Sprayed Thermal Barrier Coating with Bond Coat Species in Cyclic Thermal Exposure

Directory of Open Access Journals (Sweden)

Ungyu Paik

2013-08-01

Full Text Available The effects of the bond coat species on the delamination or fracture behavior in thermal barrier coatings (TBCs was investigated using the yclic thermal fatigue and thermal-shock tests. The interface microstructures of each TBC showed a good condition without cracking or delamination after flame thermal fatigue (FTF for 1429 cycles. The TBC with the bond coat prepared by the air-plasma spray (APS method showed a good condition at the interface between the top and bond coats after cyclic furnace thermal fatigue (CFTF for 1429 cycles, whereas the TBCs with the bond coats prepared by the high-velocity oxygen fuel (HVOF and low-pressure plasma spray (LPPS methods showed a partial cracking (and/or delamination and a delamination after 780 cycles, respectively. The TBCs with the bond coats prepared by the APS, HVOF and LPPS methods were fully delaminated (>50% after 159, 36, and 46 cycles, respectively, during the thermal-shock tests. The TGO thickness in the TBCs was strongly dependent on the both exposure time and temperature difference tested. The hardness values were found to be increased only after the CFTF, and the TBC with the bond coat prepared by the APS showed the highest adhesive strength before and after the FTF.

The structure and thermal properties of plasma-sprayed beryllium for the International Thermonuclear Experimental Reactor (ITER)

International Nuclear Information System (INIS)

Castro, R.G.; Bartlett, A.; Elliott, K.E.; Hollis, K.J.

1996-01-01

Plasma spraying is being studied for in situ repair of damaged Be and W plasma facing surfaces for ITER, the next generation magnetic fusion energy device, and is also being considered for fabricating Be and W plasma-facing components for the first wall of ITER. Investigators at LANL's Beryllium Atomization and Thermal Spray Facility have concentrated on investigating the structure-property relation between as-deposited microstructures of plasma sprayed Be coatings and resulting thermal properties. In this study, the effect of initial substrate temperature on resulting thermal diffusivity of Be coatings and the thermal diffusivity at the coating/Be substrate interface (interface thermal resistance) was investigated. Results show that initial Be substrate temperatures above 600 C can improve the thermal diffusivity of the Be coatings and minimize any thermal resistance at the interface between the Be coating and Be substrate

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

Science.gov (United States)

Vackel, Andrew; Dwivedi, Gopal; Sampath, Sanjay

2015-07-01

Thermal spray coatings are used extensively for the protection and life extension of engineering components exposed to harsh wear and/or corrosion during service in aerospace, energy, and heavy machinery sectors. Cermet coatings applied via high-velocity thermal spray are used in aggressive wear situations almost always coupled with corrosive environments. In several instances (e.g., landing gear), coatings are considered as part of the structure requiring system-level considerations. Despite their widespread use, the technology has lacked generalized scientific principles for robust coating design, manufacturing, and performance analysis. Advances in process and in situ diagnostics have provided significant insights into the process-structure-property-performance correlations providing a framework-enhanced design. In this overview, critical aspects of materials, process, parametrics, and performance are discussed through exemplary studies on relevant compositions. The underlying connective theme is understanding and controlling residual stresses generation, which not only addresses process dynamics but also provides linkage for process-property relationship for both the system (e.g., fatigue) and the surface (wear and corrosion). The anisotropic microstructure also invokes the need for damage-tolerant material design to meet future goals.

Intermetallic Al-, Fe-, Co- and Ni-Based Thermal Barrier Coatings Prepared by Cold Spray for Applications on Low Heat Rejection Diesel Engines

Science.gov (United States)

Leshchinsky, E.; Sobiesiak, A.; Maev, R.

2018-02-01

Conventional thermal barrier coating (TBC) systems consist of a duplex structure with a metallic bond coat and a ceramic heat insulating topcoat. They possess the desired low thermal conductivity, but at the same time they are very brittle and sensitive to thermal shock and thermal cycling due to the inherently low coefficient of thermal expansion. Recent research activities are focused on the developing of multilayer TBC structures obtained using cold spraying and following annealing. Aluminum intermetallics have demonstrated thermal and mechanical properties that allow them to be used as the alternative TBC materials, while the intermetallic layers can be additionally optimized to achieve superior thermal physical properties. One example is the six layer TBC structure in which cold sprayed Al-based intermetallics are synthesized by annealing in nitrogen atmosphere. These multilayer coating systems demonstrated an improved thermal fatigue capability as compared to conventional ceramic TBC. The microstructures and properties of the coatings were characterized by SEM, EDS and mechanical tests to define the TBC material properties and intermetallic formation mechanisms.

Effect of thermal spray processing techniques on the microstructure and properties of Ni-based amorphous coatings

International Nuclear Information System (INIS)

Lee, S.M.; Moon, B.M.; Fleury, E.; Ahn, H.S.; Kim, D.H.; Kim, W.T.; Sordelet, D.J.

2005-01-01

Metallic amorphous materials have been widely developed thanks to the outstanding properties including high chemical stability, mechanical strength, and magnetic properties. However, with the exception of a few compositions, the limiting factor is the critical cooling rate for the formation of the amorphous phase. For many applications, it is only the contact surface properties that are important, thus the use, of coating techniques such as thermal sprayings has several attractive features. In this paper, we present the microstructure of Ni-based amorphous coatings prepared by laser cladding and vacuum plasma spraying. The utilization of plasma spraying to deposit atomized powder enabled the formation of fully amorphous coating, laser cladding resulted in mostly crystallized structures. Glass forming ability and wear properties of the coatings were discussed as a function of the coating microstructure. (orig.)

Application of thermal spray coatings for jet engines. Kokuki sangyo eno yosha no oyo

Energy Technology Data Exchange (ETDEWEB)

Muto, Y [All Nippon Airways Co. Ltd., Tokyo (Japan)

1992-10-31

Application condition of spray coating on jet engine parts and characteristics of spray reparing process are explained. Spray coating used for jet engine is classified as recovery of dimension, crevice adjustment, improvement of resistance to friction, improvement of fretting resistance and heat resistance. Titanium alloy having better adhesion and acid resistance, is used as coating for dimensional recovery, where as nickel-crome-aluminium coating is used for the improvement of heat resistance of stainless steel, etc. Crevice adjustment coatings are used in rotating parts of jet engines, and they are of two types are; gel-double coating of aluminium, nickel-aluminium, etc., abrasive coating of aluminium oxide. Tungsten carbide and cobalt are used as coatings for the friction improvement. Nickel and indium, etc., are used as fretting resistance coating. Various types of ceramics together with heat resistance steels like HS-188 are used as coating for heat resistance improvement. 4 figs., 3 tabs.

Inhalational and dermal exposures during spray application of biocides.

Science.gov (United States)

Berger-Preiss, Edith; Boehncke, Andrea; Könnecker, Gustav; Mangelsdorf, Inge; Holthenrich, Dagmar; Koch, Wolfgang

2005-01-01

Data on inhalational and potential dermal exposures during spray application of liquid biocidal products were generated. On the one hand, model experiments with different spraying devices using fluorescent tracers were carried out to investigate the influence of parameters relevant to the exposure (e.g. spraying equipment, nozzle size, direction of application). On the other hand, measurements were performed at selected workplaces (during disinfection operations in food and feed areas; pest control operations for private, public and veterinary hygiene; wood protection and antifouling applications) after application of biocidal products such as Empire 20, Responsar SC, Omexan-forte, Actellic, Perma-forte; Fendona SC, Pyrethrum mist; CBM 8, Aldekol Des 03, TAD CID, Basileum, Basilit. The measurements taken in the model rooms demonstrated dependence of the inhalation exposure on the type of spraying device used, in the following order: "spraying with low pressure" < "airless spraying" < "fogging" indicating that the particle diameter of the released spray droplets is the most important parameter. In addition inhalation exposure was lowest when the spraying direction was downward. Also for the potential dermal exposure, the spraying direction was of particular importance: overhead spraying caused the highest contamination of body surfaces. The data of inhalational and potential dermal exposures gained through workplace measurements showed considerable variation. During spraying procedures with low-pressure equipments, dose rates of active substances inhaled by the operators ranged from 7 to 230 microg active substance (a.s.)/h. An increase in inhaled dose rates (6-33 mg a.s./h) was observed after use of high application volumes/time unit during wood protection applications indoors. Spraying in the veterinary sector using medium-pressure sprayers led to inhaled dose rates between 2 and 24mga.s./h. The highest inhaled dose rates were measured during fogging (114 mg a

Evaluation of thermal cooling mechanisms for laser application to teeth.

Science.gov (United States)

Miserendino, L J; Abt, E; Wigdor, H; Miserendino, C A

1993-01-01

Experimental cooling methods for the prevention of thermal damage to dental pulp during laser application to teeth were compared to conventional treatment in vitro. Pulp temperature measurements were made via electrical thermistors implanted within the pulp chambers of extracted human third molar teeth. Experimental treatments consisted of lasing without cooling, lasing with cooling, laser pulsing, and high-speed dental rotary drilling. Comparisons of pulp temperature elevation measurements for each group demonstrated that cooling by an air and water spray during lasing significantly reduced heat transfer to dental pulp. Laser exposures followed by an air and water spray resulted in pulp temperature changes comparable to conventional treatment by drilling. Cooling by an air water spray with evacuation appears to be an effective method for the prevention of thermal damage to vital teeth following laser exposure.

Method and closing pores in a thermally sprayed doped lanthanum chromite interconnection layer

Science.gov (United States)

Singh, Prabhakar; Ruka, Roswell J.

1995-01-01

A dense, substantially gas-tight electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an air electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO.sub.3 particles doped with an element or elements selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by thermal spraying doped LaCrO.sub.3 particles, either by plasma arc spraying or flame spraying; (C) depositing a mixture of CaO and Cr.sub.2 O.sub.3 on the surface of the thermally sprayed layer; and (D) heating the doped LaCrO.sub.3 layer coated with CaO and Cr.sub.2 O.sub.3 surface deposit at from about 1000.degree. C. to 1200.degree. C. to substantially close the pores, at least at a surface, of the thermally sprayed doped LaCrO.sub.3 layer. The result is a dense, substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the nonselected portion of the air electrode. A fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell, for example for generation of electrical power.

Fabrication of Water Jet Resistant and Thermally Stable Superhydrophobic Surfaces by Spray Coating of Candle Soot Dispersion.

Science.gov (United States)

Qahtan, Talal F; Gondal, Mohammed A; Alade, Ibrahim O; Dastageer, Mohammed A

2017-08-08

A facile synthesis method for highly stable carbon nanoparticle (CNP) dispersion in acetone by incomplete combustion of paraffin candle flame is presented. The synthesized CNP dispersion is the mixture of graphitic and amorphous carbon nanoparticles of the size range of 20-50 nm and manifested the mesoporosity with an average pore size of 7 nm and a BET surface area of 366 m 2 g -1 . As an application of this material, the carbon nanoparticle dispersion was spray coated (spray-based coating) on a glass surface to fabricate superhydrophobic (water contact angle > 150° and sliding angle fabricated from direct candle flame soot deposition (candle-based coating). This study proved that water jet resistant and thermally stable superhydrophobic surfaces can be easily fabricated by simple spray coating of CNP dispersion gathered from incomplete combustion of paraffin candle flame and this technique can be used for different applications with the potential for the large scale fabrication.

Direct morphological comparison of vacuum plasma sprayed and detonation gun sprayed hydroxyapatite coatings for orthopaedic applications.

Science.gov (United States)

Gledhill, H C; Turner, I G; Doyle, C

1999-02-01

Hydroxyapatite coatings on titanium substrates were produced using two thermal spray techniques vacuum plasma spraying and detonation gun spraying. X-ray diffraction was used to compare crystallinity and residual stresses in the coatings. Porosity was measured using optical microscopy in conjunction with an image analysis system. Scanning electron microscopy and surface roughness measurements were used to characterise the surface morphologies of the coatings. The vacuum plasma sprayed coatings were found to have a lower residual stress, a higher crystallinity and a higher level of porosity than the detonation gun coatings. It is concluded that consideration needs to be given to the significance of such variations within the clinical context.

Flame spraying of polymers

International Nuclear Information System (INIS)

Varacalle, D.J. Jr.; Zeek, D.P.; Couch, K.W.; Benson, D.M.; Kirk, S.M.

1997-01-01

Statistical design-of-experiment studies of the thermal spraying of polymer powders are presented. Studies of the subsonic combustion (i.e., Flame) process were conducted in order to determine the quality and economics of polyester and urethane coatings. Thermally sprayed polymer coatings are of interest to several industries for anticorrosion applications, including the chemical, automotive, and aircraft industries. In this study, the coating design has been optimized for a site-specific application using Taguchi-type fractional-factorial experiments. Optimized coating designs are presented for the two powder systems. A substantial range of thermal processing conditions and their effect on the resultant polymer coatings is presented. The coatings were characterized by optical metallography, hardness testing, tensile testing, and compositional analysis. Characterization of the coatings yielded the thickness, bond strength, Knoop microhardness, roughness, deposition efficiency, and porosity. Confirmation testing was accomplished to verify the coating designs

Structure Analysis Of Corrosion Resistant Thermal Sprayed Coatings On Low Alloy Steels

Science.gov (United States)

Chaliampalias, D.; Vourlias, G.; Pistofidis, N.; Pavlidou, E.; Stergiou, A.; Stergioudis, G.; Polychroniadis, E. K.

2007-04-01

Metallic coatings have been proved to reduce the rate of corrosion of steel in various atmospheres. In this work the structure of Al, Cu-Al and Zn thermal sprayed coatings is examined. The as formed coatings are extremely rough, and they are composed of several phases which increase corrosion resistance as it was determined Salt Spray Chamber tests.

Epitaxial Growth and Cracking Mechanisms of Thermally Sprayed Ceramic Splats

Science.gov (United States)

Chen, Lin; Yang, Guan-jun

2018-02-01

In the present study, the epitaxial growth and cracking mechanisms of thermally sprayed ceramic splats were explored. We report, for the first time, the epitaxial growth of various splat/substrate combinations at low substrate temperatures (100 °C) and large lattice mismatch (- 11.26%). Our results suggest that thermal spray deposition was essentially a liquid-phase epitaxy, readily forming chemical bonding. The interface temperature was also estimated. The results convincingly demonstrated that atoms only need to diffuse and rearrange over a sufficiently short range during extremely rapid solidification. Concurrently, severe cracking occurred in the epitaxial splat/substrate systems, which indicated high tensile stress was produced during splat deposition. The origin of the tensile stress was attributed to the strong constraint of the locally heated substrate by its cold surroundings.

Thermal stability study of crystalline and novel spray-dried amorphous nilotinib hydrochloride

NARCIS (Netherlands)

Herbrink, Maikel; Vromans, Herman; Schellens, Jan Hm; Beijnen, Jos H; Nuijen, Bastiaan

2018-01-01

The thermal characteristics and the thermal degradation of crystalline and amorphous nilotinib hydrochloride (NH) were studied. The spray drying technique was successfully utilized for the amorphization of NH and was evaluated by spectroscopic techniques and differential scanning calorimetry (DSC).

A comparison of biological effect and spray liquid distribution and deposition for different spray application techniques in different crops

OpenAIRE

Larsolle, Anders; Wretblad, Per; Westberg, Carl

2002-01-01

The objective of this study was to compare a selection of spray application techniques with different application volumes, with respect to the spray liquid distribution on flat surfaces, the deposition in fully developed crops and the biological effect. The spray application techniques in this study were conventional spray technique with three different nozzles: Teelet XR, Lechler ID and Lurmark DriftBeta, and also AirTec, Danfoil, Hardi Twin, Kyndestoit and Släpduk. The dynamic spray liquid ...

Overview on Recent Developments of Bondcoats for Plasma-Sprayed Thermal Barrier Coatings

Science.gov (United States)

Naumenko, D.; Pillai, R.; Chyrkin, A.; Quadakkers, W. J.

2017-12-01

The performance of MCrAlY (M = Ni, Co) bondcoats for atmospheric plasma-sprayed thermal barrier coatings (APS-TBCs) is substantially affected by the contents of Co, Ni, Cr, and Al as well as minor additions of Y, Hf, Zr, etc., but also by manufacturing-related properties such as coating thickness, porosity, surface roughness, and oxygen content. The latter properties depend in turn on the exact technology and set of parameters used for bondcoat deposition. The well-established LPPS process competes nowadays with alternative technologies such as HVOF and APS. In addition, new technologies have been developed for bondcoats manufacturing such as high-velocity APS or a combination of HVOF and APS for application of a flashcoat. Future developments of the bondcoat systems will likely include optimization of thermal spraying methods for obtaining complex bondcoat roughness profiles required for extended APS-TBC lifetimes. Introduction of the newest generation single-crystal superalloys possessing low Cr and high Al and refractory metals (Re, Ru) contents will require definition of new bondcoat compositions and/or multilayered bondcoats to minimize interdiffusion issues. The developments of new bondcoat compositions may be substantially facilitated using thermodynamic-kinetic modeling, the vast potential of which has been demonstrated in recent years.

Sealing of thermally-sprayed stainless steel coatings against corrosion using nickel electroplating technique

Directory of Open Access Journals (Sweden)

Hathaipat Koiprasert

2007-07-01

Full Text Available Electric arc spraying (EAS is one of the thermal spray techniques used for restoration and to providecorrosion resistance. It can be utilized to build up coatings to thicknesses of several millimeters, It is easy to use on-site. Most importantly, the cost of this technique is lower than other thermal spraying techniques thatmay be suitable for part restoration. A major disadvantage associated with the electric arc sprayed coating is its high porosity, which can be as high as 3-8% making it not appropriate for use in immersion condition. This work was carried out around the idea of using electroplating to seal off the pore of the EAS coating, with an aim to improve the corrosion resistance of the coating in immersion condition. This research compared the corrosion behavior of a stainless steel 316 electric arc sprayed coating in 2M NaOH solution at 25oC. It was found that the Ni plating used as sealant can improve the corrosion resistance of the EAS coating. Furthermore, the smoothened and plated stainless steel 316 coating has a better corrosion resistance than the plated EAS coating that was not ground to smoothen the surface before plating.

Evaluation of thermal sprayed metallic coatings for use on the structures at Launch Complex 39

Science.gov (United States)

Welch, Peter J.

1990-01-01

The current status of the evaluation program is presented. The objective was to evaluate the applicability of Thermal Sprayed Coatings (TSC) to protect the structures in the high temperature acid environment produced by exhaust of the Solid Rocket Boosters during the launches of the Shuttle Transportation System. Only the relatively low cost aluminum TSC which provides some cathodic protection for steel appears to be a practical candidate for further investigation.

Fatigue Crack Growth in Bodies with Thermally Sprayed Coating

Czech Academy of Sciences Publication Activity Database

Kovářík, O.; Haušild, P.; Medřický, Jan; Tomek, L.; Siegl, J.; Mušálek, Radek; Curry, N.; Björklund, S.

2016-01-01

Roč. 25, 1-2 (2016), s. 311-320 ISSN 1059-9630. [ITSC 2015: International Thermal Spray Conference and Exposition. Long Beach, California, 11.05.2015-14.05.2015] R&D Projects: GA ČR GB14-36566G Institutional support: RVO:61389021 Keywords : Thermal barrier coating * fatigue * crack growth * digital image correlation * digital image correlation Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.488, year: 2016 http://link.springer.com/article/10.1007%2Fs11666-015-0329-9

Role of Oxides and Porosity on High-Temperature Oxidation of Liquid-Fueled HVOF Thermal-Sprayed Ni50Cr Coatings

Science.gov (United States)

Song, B.; Bai, M.; Voisey, K. T.; Hussain, T.

2017-02-01

High chromium content in Ni50Cr thermally sprayed coatings can generate a dense and protective scale at the surface of coating. Thus, the Ni50Cr coating is widely used in high-temperature oxidation and corrosion applications. A commercially available gas atomized Ni50Cr powder was sprayed onto a power plant steel (ASME P92) using a liquid-fueled high velocity oxy-fuel thermal spray with three processing parameters in this study. Microstructure of as-sprayed coatings was examined using oxygen content analysis, mercury intrusion porosimetry, scanning electron microscope (SEM), energy-dispersive x-ray spectroscopy (EDX) and x-ray diffraction (XRD). Short-term air oxidation tests (4 h) of freestanding coatings (without boiler steel substrate) in a thermogravimetric analyzer at 700 °C were performed to obtain the kinetics of oxidation of the as-sprayed coating. Long-term air oxidation tests (100 h) of the coated substrates were performed at same temperature to obtain the oxidation products for further characterization in detail using SEM/EDX and XRD. In all samples, oxides of various morphologies developed on top of the Ni50Cr coatings. Cr2O3 was the main oxidation product on the surface of all three coatings. The coating with medium porosity and medium oxygen content has the best high-temperature oxidation performance in this study.

Thermal spray coating for corrosion under insulation (CUI) prevention

Science.gov (United States)

Fuad, Mohd Fazril Irfan Ahmad; Razak, Khalil Abdul; Alias, Nur Hashimah; Othman, Nur Hidayati; Lah, Nik Khairul Irfan Nik Ab

2017-12-01

Corrosion under insulation (CUI) is one of the predominant issues affecting process of Oil and Gas and Petrochemical industries. CUI refers to external corrosion, but it is difficult to be detected as the insulation cover masks the corrosion problem. One of the options to prevent CUI is by utilizing the protective coating systems. Thermal spray coating (TSC) is an advanced coating system and it shows promising performance in harsh environment, which could be used to prevent CUI. However, the application of TSC is not attractive due to the high initial cost. This work evaluates the potential of TSC based on corrosion performance using linear polarization resistance (LPR) method and salt spray test (SST). Prior to the evaluation, the mechanical performance of TSC was first investigated using adhesion test and bend test. Microstructure characterization of the coating was investigated using Scanning Electron Microscope (SEM). The LPR test results showed that low corrosion rate of 0.05 mm/years was obtained for TSC in compared to the bare steel especially at high temperature of 80 °C, where usually normal coating would fail. For the salt spray test, there was no sign of corrosion products especially at the center (fully coated region) was observed. From SEM images, no corrosion defects were observed after 336 hours of continuous exposure to salt fog test. This indicates that TSC protected the steel satisfactorily by acting as a barrier from a corrosive environment. In conclusion, TSC can be a possible solution to minimize the CUI in a long term. Further research should be done on corrosion performance and life cycle cost by comparing TSC with other conventional coating technology.

Development and evaluation of suspension plasma sprayed yttria stabilized zirconia coatings as thermal barriers

Science.gov (United States)

van Every, Kent J.

The insulating effects from thermal barrier coatings (TBCs) in gas turbine engines allow for increased operational efficiencies and longer service lifetimes. Consequently, improving TBCs can lead to enhanced gas turbine engine performance. This study was conducted to investigate if yttria-stabilized zirconia (YSZ) coatings, the standard industrial choice for TBCs, produced from nano-sized powder could provide better thermal insulation than current commericial YSZ coatings generated using micron-sized powders. The coatings for this research were made via the recently developed suspension plasma spraying (SPS) process. With SPS, powders are suspended in a solvent containing dispersing agents; the suspension is then injected directly into a plasma flow that evaporates the solvent and melts the powder while transporting it to the substrate. Although related to the industrial TBC production method of air plasma spraying (APS), SPS has two important differences---the ability to spray sub-micron diameter ceramic particles, and the ability to alloy the particles with chemicals dissolved in the solvent. These aspects of SPS were employed to generate a series of coatings from suspensions containing ˜100 nm diameter YSZ powder particles, some of which were alloyed with neodymium and ytterbium ions from the solvent. The SPS coatings contained columnar structures not observed in APS TBCs; thus, a theory was developed to explain the formation of these features. The thermal conductivity of the coatings was tested to evaluate the effects of these unique microstructures and the effects of the alloying process. The results for samples in the as-sprayed and heat-treated conditions were compared to conventional YSZ TBCs. This comparison showed that, relative to APS YSZ coatings, the unalloyed SPS samples typically exhibited higher as-sprayed and lower heat-treated thermal conductivities. All thermal conductivity values for the alloyed samples were lower than conventional YSZ TBCs

Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings

Science.gov (United States)

Wang, Hsin; Muralidharan, Govindarajan; Leonard, Donovan N.; Haynes, J. Allen; Porter, Wallace D.; England, Roger D.; Hays, Michael; Dwivedi, Gopal; Sampath, Sanjay

2018-02-01

Multilayer, graded ceramic/metal coatings were prepared by an air plasma spray method on Ti-6Al-4V, 4140 steel and graphite substrates. The coatings were designed to provide thermal barriers for diesel engine pistons to operate at higher temperatures with improved thermal efficiency and cleaner emissions. A systematic, progressive variation in the mixture of yttria-stabilized zirconia and bondcoat alloys (NiCoCrAlYHfSi) was designed to provide better thermal expansion match with the substrate and to improve thermal shock resistance and cycle life. Heat transfer through the layers was evaluated by a flash diffusivity technique based on a model of one-dimensional heat flow. The aging effect of the as-sprayed coatings was captured during diffusivity measurements, which included one heating and cooling cycle. The hysteresis of thermal diffusivity due to aging was not observed after 100-h annealing at 800 °C. The measurements of coatings on substrate and freestanding coatings allowed the influence of interface resistance to be evaluated. The microstructure of the multilayer coating was examined using scanning electron microscope and electron probe microanalysis.

Thermal fatigue behavior of thermal barrier coatings by air plasma spray

Energy Technology Data Exchange (ETDEWEB)

Lee, Han Sang; Kim, Eui Hyun [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Lee, Jung Hyuk [Korea Plant Service and Engineering Co. Ltd., Incheon (Korea, Republic of)

2008-06-15

Effects of top coat morphology and thickness on thermal fatigue behavior of Thermal Barrier Coatings (TBC) were investigated in this study. Thermal fatigue tests were conducted on three coating specimens with different top coat morphology and thickness, and then the test data were compared via microstructures, cycles to failure, and fracture surfaces. In the air plasma spray specimens (APS1, APS2), top coat were 200 and 300 {mu}m respectively. The thickness of top coat was about 700 {mu}m in the Perpendicular Cracked Specimen (PCS). Under thermal fatigue condition at 1,100 .deg. C, the cycles to top coat failure of APS1, APS2, and PCS were 350, 560 and 480 cycles, respectively. The cracks were initiated at the interface of top coat and Thermally Grown Oxide (TGO) and propagated into TGO or top coat as the number of thermal fatigue cycles increased. For the PCS specimen, additive cracks were initiated and propagated at the starting points of perpendicular cracks in the top coat. Also, the thickness of TGO and the decrease of aluminium concentration in bond coat do not affect the cycles to failure.

Failure analysis of thermally cycled columnar thermal barrier coatings produced by high-velocity-air fuel and axial-suspension-plasma spraying: A design perspective

Czech Academy of Sciences Publication Activity Database

Ganvir, A.; Vaidhyanathan, V.; Markocsan, N.; Gupta, M.; Pala, Zdeněk; Lukáč, František

2018-01-01

Roč. 44, č. 3 (2018), s. 3161-3172 ISSN 0272-8842 Institutional support: RVO:61389021 Keywords : Columnar Thermal Barrier Coatings * Axial Suspension Plasma spraying * Thermal Cyclic Fatigue * High Velocity Air Fuel Spraying Subject RIV: JK - Corrosion ; Surface Treatment of Materials OBOR OECD: Coating and films Impact factor: 2.986, year: 2016 https://www.sciencedirect.com/science/article/pii/S0272884217325403

X-rays characterisation of thermal sprayed bioceramics and composites

International Nuclear Information System (INIS)

Khor, K.A.; Cheang, P.; White, T.

2000-01-01

Materials characterization using x-rays plays an important role in the ongoing endeavour to develop superior materials for biomedical devices. Current emphasis on biomaterials worldwide has highlighted the prominence of materials in successful implementation of implants to improve the quality of human lives. A clear example can be seen in the artificial hip implant where a layer of bioactive material, hydroxyapatite (HA), drastically aids the pain during the post-operation recovery process. Thermal spray is a process whereby powders are injected into a high temperature flame. Instantaneous melting takes place and the molten droplets are projected at a very high velocities onto a suitably prepared substrate. The adoption of this process by most biomedical companies manufacturing artificial hip implants is based on the efficacy of the process and the economic benefits such as high production rate and relatively low installation cost. However, material decomposition often occurs in the high temperature environment of thermal spray. Subsequent development of proper process parameters, customised powder characteristics and better process control nonetheless help mitigate this effect. A constant demand in the escalating usage of biomaterials in human body is reliability. Implants should preferably remain in the body for at least 5-10 years with minimal occurrences of revision. To ensure an acceptable level of reliability, materials characterisation is needed at practically every stage of its development and manufacture. The role that x-rays play in biomaterials development can be categorised as: (1) phase identification and structural determination and (2) chemical analysis. This paper will present the characterisation of biomaterials using x-rays in the development of new generation of biomaterials and composites that posses superior properties than the present group of materials. Specifically, this paper will highlight the problems encountered in phase identification

In vitro characterization of hydroxyapatite layers deposited by APS and HVOF thermal spraying methods

Directory of Open Access Journals (Sweden)

Radu Alexandru Roşu

2012-03-01

Full Text Available Titanium alloys are successfully used in medicine as implants due to their high mechanical properties and good biocompatibility. To improve implant osseointegration of titanium alloys, they are covered with hydroxyapatite because of its bioactive properties. Coating the implants with hydroxyapatite by thermal spraying, due to the temperatures developed during the deposition process, the structure can be degraded, leading to formation of secondary phases, such as TCP, TT CP, CaO. The paper presents the experimental results of hydroxyapatite layers deposition by two thermal spraying methods: Atmospheric Plasma Spraying (APS and High Velocity Oxy-Fuel (HVOF. The microstructure of the deposited layers is characterized by X-ray diffraction analysis and electronic microscopy. The bioactivity of the hydroxyapatite layers was investigated in Simulated Body Fluid (SBF by immersing the covered samples deposited by the two thermal spraying methods. In both cases the coatings did not present defects as cracks or microcracks. X-ray diffraction performed on hydroxyapatite deposited layers shows that the structure was strongly influenced by plasma jet temperature, the structure consisting mainly of TCP (Ca3PO42. The samples deposited by HVO F after immersing in SBF lead to formation of biological hydroxyapatite, certifying the good bioactivity of the coatings.

Thermal spraying of corrosion protection layers in biogas plants; Erzeugung von Korrosionsschutzschichten fuer Bioenergieanlagen mittels Thermischen Spritzens

Energy Technology Data Exchange (ETDEWEB)

Crimmann, P.; Dimaczek, G.; Faulstich, M. [ATZ Entwicklungszentrum, Sulzbach-Rosenberg (Germany)

2004-07-01

Corrosion in plants for the energetic conversion of biomass is a severe problem that often causes premature damage of components. Thermal spraying is a process for the creation of corrosion protection layer. An advantage of thermal spraying is that as well as each material can be used as layer material. First practical results demonstrated that thermal spraying has the potential to create coatings to protect components against high temperature corrosion as well as biocorrosion. Layer materials are for example nickel base alloys (high temperature corrosion) and titan alloys (biocorrosion). Further investigations are necessary in order to examine whether cost-efficient coatings also contribute to the corrosion protection (e.g. polymer materials against biocorrosion). (orig.)

Spatially-resolved velocities of thermally-produced spray droplets using a velocity-divided Abel inversion of photographed streaks

Science.gov (United States)

Kawaguchi, Y.; Kobayashi, N.; Yamagata, Y.; Miyazaki, F.; Yamasaki, M.; Muraoka, K.

2017-10-01

Droplet velocities of thermal spray are known to have profound effects on important coating qualities, such as adhesive strength, porosity, and hardness, for various applications. For obtaining the droplet velocities, therefore, the TOF (time-of-flight) technique has been widely used, which relies on observations of emitted radiation from the droplets, where all droplets along the line-of-sight contribute to signals. Because droplets at and near the flow axis mostly contribute coating layers, it has been hoped to get spatially resolved velocities. For this purpose, a velocity-divided Abel inversion was devised from CMOS photographic data. From this result, it has turned out that the central velocity is about 25% higher than that obtained from the TOF technique for the case studied (at the position 150 mm downstream of the plasma spray gun, where substrates for spray coatings are usually placed). Further implications of the obtained results are discussed.

Optical monitoring systems for thermal spray processes: droplets behavior and substrate pre-treatments

Science.gov (United States)

Kawaguchi, Y.; Kobayashi, N.; Yamagata, Y.; Miyazaki, F.; Yamasaki, M.; Tanaka, J.; Muraoka, K.

2017-11-01

Thermal spray is a technique to form molten droplets using either plasma- or combustion-heating, which impinge upon substrates to form coating layers for various purposes, such as anti-corrosion and anti-wear layers. Although it is an established technique having a history of more than a century, operations of spray guns together with preparing suitable substrate surfaces for obtaining good coating layers still rely on experienced technicians. Because of the necessity of meeting more and more stringent requirements for coating quality and cost from customers, there has been a strong need to try to monitor spray processes, so as to obtain the best possible spray coating layers. The basic requirements for such monitoring systems are *reasonably cheap, *easy operation for laypersons, *easy access to targets to be investigated, and *an in-situ capability. The purpose of the present work is to provide suitable optical monitoring systems for (1) droplets behavior and (2) substrate pre-treatments. For the former (1), the first result was already presented at the 17th laser-aided plasma diagnostics meeting (LAPD17) in 2015 in Sapporo, and the results of its subsequent applications into real spray environments are shown in this article in order to validate the previous proposal. Topic (2) is new in the research program, and the proof-of-principle experiment for the proposed method yielded a favorable result. Based on this positive result, an overall strategy is being planned to fulfill the final objective of the optical monitoring of substrate pre-treatments. Details of these two programs (1) and (2) together with the present status are described.

BEHAVIOR OF THERMAL SPRAY COATINGS AGAINST HYDROGEN ATTACK

OpenAIRE

Vargas, Fabio; Latorre, Guillermo; Uribe, Iván

2003-01-01

The behavior of nickel and chrome alloys applied as thermal spray coatings to be used as protection against embrittlement by hydrogen is studied. Coatings were applied on a carbon steel substrate, under conditions that allow obtain different crystalline structures and porosity levels, in order to determine the effect of these variables on the hydrogen permeation kinetics and as a protection means against embrittlement caused this element. In order to establish behaviors as barriers and protec...

Thermal decomposition of uranylnitrate by the Spray-Dryer process

International Nuclear Information System (INIS)

Wildhagen, G.R.S.; Silva, G.C. da

1988-01-01

The proposal of this work consist in the thermal decomposition of uranyl nitrate solutions by the Spray-Dryer process aiming the production of highly reactive fluidized UO 3 , adequate for the use in posterior of reduction to UO 2 and hydrofluorination to UF 4 , in a fluidized bed for the obtention of UF 6 in the cicle of nuclear fuels. (author) [pt

Integrated thermal control and system assessment in plug-chip spray cooling enclosure

International Nuclear Information System (INIS)

Zhang, Wei-Wei; Cheng, Wen-Long; Shao, Shi-Dong; Jiang, Li-Jia; Hong, Da-Liang

2016-01-01

Highlights: • A novel multi-heat source plug-chip spray cooling enclosure was designed. • Enhanced surfaces with different geometric were analyzed in integrated enclosure. • Overall thermal control with adjustable parameters in enclosure was studied. • Temperature disequilibrium of multi-heat source in enclosure was tested. • A comprehensive assessment system used to evaluate the practicality was proposed. - Abstract: Practical and integrated spray cooling system is urgently needed for the cooling of high-performance electronic chips due to the growth requirements of thermal management in workstation. The integration of multi heat sources and the management of integral system are particularly lacking. In order to fill the vacancies in the study of plug-chip spray cooling, an integrated cooling enclosure was designed in this paper. Multi heat sources were placed in sealed space and the heat was removed by spray. The printed circuit board plug-ins and radio frequency resistors were used as analog motherboards and chips, respectively. The enhanced surfaces with four different geometries and the plain surface were studied under the conditions of different inclination angles. The results were compared and the maximum critical heat flux (CHF) was obtained. Moreover, with the intention of the overall management of multi-heat source in integrated enclosure, the effect of the flow rate and the temperature disequilibrium, and the pulse heating in the process of transient cooling were also analyzed. In addition, a comprehensive assessment system, used to evaluate the practicality of spray cooling experimental devices, was proposed and the performance of enclosure was evaluated.

Antibacterial characteristics of thermal plasma spray system.

Science.gov (United States)

Goudarzi, M; Saviz, Sh; Ghoranneviss, M; Salar Elahi, A

2018-03-15

The objective of this study is to investigate antibacterial characteristics of a thermal plasma spray system. For this purpose, copper powder was coated on a handmade atmospheric plasma spraying system made by the stainless steel 316 substrate, which is preheated at different temperatures before spraying. A number of deposition characteristics such as antibacterial characteristics, adhesion strength and hardness of coating, was investigated. All of the spray parameters are fixed except the substrate temperature. The chemical composition was analyzed by X-ray diffraction (XRD). A scanning electron microscopy (SEM) and back scattering electron microscopy (BSE) were used to show the coating microstructure, its thickness and also the powder micrograph. The energy dispersive X-ray spectroscopy (EDX) was used to analyze the coating particles. Hardness of the deposition was examined by Vickers tester (HV0.1). Its adhesion strength was declared by cross cut tester (TQC). In addition, the percentage of bactericidal coating was evidenced with Staphylococcus aurous and Escherichia coli bacteria. Study results show that as the substrates temperature increases, the number of splats in the shape of pancake increases, the greatness and percentage of the deposition porosity both decrease. The increment of the substrate temperature leads to more oxidation and makes thicker dendrites on the splat. The enhancement of the substrate temperature also enlarges thickness and efficiency of coating. The interesting results are that antibacterial properties of coatings against the Escherichia coli are more than Staphylococcus aurous bacteria. However the bactericidal percentage of the coatings against Staphylococcus aurous and Escherichia coli bacteria roughly does not change with increasing the substrate temperature. Furthermore, by increment of the substrate temperature, coatings with both high adhesion and hardness are obtained. Accordingly, the temperature of substrate can be an

Calcium titanate (CaTiO{sub 3}) dielectrics prepared by plasma spray and post-deposition thermal treatment

Energy Technology Data Exchange (ETDEWEB)

Ctibor, Pavel [Materials Engineering Department, Institute of Plasma Physics ASCR, v.v.i., Za Slovankou 3, Prague 8 (Czech Republic); Kotlan, Jiri, E-mail: kotlan@ipp.cas.cz [Materials Engineering Department, Institute of Plasma Physics ASCR, v.v.i., Za Slovankou 3, Prague 8 (Czech Republic); Department of Electrotechnology, Faculty of Electrical Engineering, Czech Technical University in Prague, Technicka 2, Prague 6 (Czech Republic); Pala, Zdenek [Materials Engineering Department, Institute of Plasma Physics ASCR, v.v.i., Za Slovankou 3, Prague 8 (Czech Republic); Sedlacek, Josef [Department of Electrotechnology, Faculty of Electrical Engineering, Czech Technical University in Prague, Technicka 2, Prague 6 (Czech Republic); Hajkova, Zuzana; Grygar, Tomas Matys [Institute of Inorganic Chemistry ASCR, v.v.i., Husinec-Rez 1001, Rez (Czech Republic)

2015-12-15

Highlights: • Calcium titanate was sprayed by two different plasma spray systems. • Significant improvement of dielectric properties after annealing was observed. • Calcium titanate self-supporting parts can be fabricated by plasma spraying. - Abstract: This paper studies calcium titanate (CaTiO{sub 3}) dielectrics prepared by plasma spray technology. A water stabilized plasma gun (WSP) as well as a widely used gas stabilized plasma gun (GSP) were employed in this study to deposit three sample sets at different spray conditions. Prepared specimens were annealed in air at atmospheric pressure for 2 h at various temperatures from 530 to 1170 °C. X-ray diffraction (XRD), Raman spectroscopy and porosity measurements were used for sample characterization. Dielectric spectroscopy was applied to obtain relative permittivity, conductivity and loss factor frequency dependence. Band gap energy was estimated from reflectance measurements. The work is focused on the explanation of changes in microstructure and properties of a plasma sprayed deposit after thermal annealing. Obtained results show significant improvement of dielectric properties after thermal annealing.

Release mitigation spray safety systems for chemical demilitarization applications.

Energy Technology Data Exchange (ETDEWEB)

Leonard, Jonathan; Tezak, Matthew Stephen; Brockmann, John E.; Servantes, Brandon; Sanchez, Andres L.; Tucker, Mark David; Allen, Ashley N.; Wilson, Mollye C.; Lucero, Daniel A.; Betty, Rita G.

2010-06-01

Sandia National Laboratories has conducted proof-of-concept experiments demonstrating effective knockdown and neutralization of aerosolized CBW simulants using charged DF-200 decontaminant sprays. DF-200 is an aqueous decontaminant, developed by Sandia National Laboratories, and procured and fielded by the US Military. Of significance is the potential application of this fundamental technology to numerous applications including mitigation and neutralization of releases arising during chemical demilitarization operations. A release mitigation spray safety system will remove airborne contaminants from an accidental release during operations, to protect personnel and limit contamination. Sandia National Laboratories recently (November, 2008) secured funding from the US Army's Program Manager for Non-Stockpile Chemical Materials Agency (PMNSCMA) to investigate use of mitigation spray systems for chemical demilitarization applications. For non-stockpile processes, mitigation spray systems co-located with the current Explosive Destruction System (EDS) will provide security both as an operational protective measure and in the event of an accidental release. Additionally, 'tented' mitigation spray systems for native or foreign remediation and recovery operations will contain accidental releases arising from removal of underground, unstable CBW munitions. A mitigation spray system for highly controlled stockpile operations will provide defense from accidental spills or leaks during routine procedures.

Aluminium-12wt% silicon coating prepared by thermal spraying technique: Part 1 optimization of spray condition based on a design of experiment

Directory of Open Access Journals (Sweden)

Jiansirisomboon, S.

2006-03-01

Full Text Available At present, thermal spray technology is used for maintenance parts of various machines in many industries. This technology can be used to improve the surface wear resistance. Therefore, this technology can significantly reduce cost of manufacturing. Al-12wt%Si alloy is an interesting and popular material used in the automotive industry. This research studies the suitable condition for spraying of Al-12wt%Si powder. This powder was sprayed by a flame spray technique onto low carbon steel substrates. The suitable conditions for spraying can be achieved by a design of experiment (DOE principle, which provided statistical data defined at 90% confidence. This research used control factors, which were oxygen flow rate, acetylene flow rate and spray distance. The satisfaction levels of these factors were set at 3 levels, i.e. low, medium and high, in order to determine suitable responses, which were hardness, thickness, wear rate and percentage volume fraction of porosity. It was found that the optimized condition for spraying Al-12wt%Si powder consisted of 38 ft3/hr (1.026 m3/hr of oxygen flow rate, 27 ft3/hr (0.729 m3/hr of acetylene flow rate and 58 mm of spray distance.

Influence of powder and spray parameters on erosion and corrosion properties of HVOF sprayed WC-Co-Cr coatings

Energy Technology Data Exchange (ETDEWEB)

Berget, John

1998-07-01

Thermal spraying is a generic term including various processes used to deposit coatings on surfaces. The coating material is in the form of powder or a wire and is melted or softened by means of a heat source. A gas stream accelerates the material towards a prepared surface and deposits it there to form the coating. Examples of components being maintained by application of thermal spray coatings are gate valves and ball valves for the offshore industry and turbine blades in power generations installations. Recent investigation has shown that the commonly used coating material WC-Co is not corrosion resistant. But it can be improved by the addition of Cr. The main objective of this thesis is to study the influence of spray process control variables and powder characteristics on the erosion and erosion-corrosion properties of the coatings. Spray process variables investigated include energy input, powder feed rate and spray distance. Powder characteristics studied are average size of the WC particles, relative proportions of Co and Cr in the metal phase and powder grain size distribution.

Thermal Conductivity and Wear Behavior of HVOF-Sprayed Fe-Based Amorphous Coatings

Directory of Open Access Journals (Sweden)

Haihua Yao

2017-10-01

Full Text Available To protect aluminum parts in vehicle engines, metal-based thermal barrier coatings in the form of Fe59Cr12Nb5B20Si4 amorphous coatings were prepared by high velocity oxygen fuel (HVOF spraying under two different conditions. The microstructure, thermal transport behavior, and wear behavior of the coatings were characterized simultaneously. As a result, this alloy shows high process robustness during spraying. Both Fe-based coatings present dense, layered structure with porosities below 0.9%. Due to higher amorphous phase content, the coating H-1 exhibits a relatively low thermal conductivity, reaching 2.66 W/(m·K, two times lower than the reference stainless steel coating (5.85 W/(m·K, indicating a good thermal barrier property. Meanwhile, the thermal diffusivity of amorphous coatings display a limited increase with temperature up to 500 °C, which guarantees a steady and wide usage on aluminum alloy. Furthermore, the amorphous coating shows better wear resistance compared to high carbon martensitic GCr15 steel at different temperatures. The increased temperature accelerating the tribological reaction, leads to the friction coefficient and wear rate of coating increasing at 200 °C and decreasing at 400 °C.

Stress analysis of thermal sprayed coatings using a semi-destructive hole-drilling strain gauge method

International Nuclear Information System (INIS)

Dolhof, V.; Musil, J.; Cepera, M.; Zeman, J.

1995-01-01

Residual stress is an important parameter in coating technology since it often relates to the maximum coating thickness which can be deposited without spallation, and this applies to coatings produced by different thermal spray and thin film technologies. Indeed, the mechanisms by which residual stress is built up or locked into a coating depends markedly on the deposition process and coating structure (growth structure, phase composition) in the same way too. Methods for determining residual stresses in materials include both destructive and non-destructive methods. This contribution describes semi-destructive hole-drilling strain gauge method modified for measurement of residual stresses in thermal sprayed coatings. This method of stress analysis was used for determination of stress levels in thermal sprayed WC-17% Co coatings onto 13% Cr steel substrates. Results show that deposition conditions and final coating structure influence directly the residual stress level in the coatings. It is proved that semi-destructive hole-tube drilling measurement is effective reproducible method of coating stress analysis and good solution for optimization of deposition process

Study by X-ray diffraction and mechanical analysis of the residual stress generation during thermal spraying

International Nuclear Information System (INIS)

Pina, J.; Dias, A.; Lebrun, J.L.

2003-01-01

Thermally sprayed coatings are formed by the deposition of molten or partially molten particles, propelled onto a substrate where they impact, spread and solidify rapidly. Residual stresses are expected within the sprayed deposit as a consequence of the release of thermal and kinetic energies. A wide range of materials and two spraying techniques are considered in this study, namely atmospheric plasma spraying (APS) and high-velocity oxygen fuel. Stresses were determined by the X-ray diffraction (XRD) method. The results were compared with those calculated by mechanical analysis of stress relief in coatings detached from the substrate. Comparison of the results for adherent and free-standing coatings shows that the residual stress state can be resolved in terms of the components suggested by models that propose two stages of stress generation: quenching stresses and secondary-cooling stresses. The in-depth distribution of residual stresses, through the coating thickness, is discussed in terms of the nature of the coating system

Ventilation Guidance for Spray Polyurethane Foam Application

Science.gov (United States)

Properly designed ventilation can reduce airborne levels of aerosols, mists, and vapors generated during spray application and can help protect SPF applicators, helpers, and others who may be working in adjacent areas.

A comparative study of tribological behavior of plasma and D-gun sprayed coatings under different wear modes

International Nuclear Information System (INIS)

Sundararajan, G.; Rao, D.S.; Prasad, K.U.M.; Joshi, S.V.

1998-01-01

In recent years, thermal sprayed protective coatings have gained widespread acceptance for a variety of industrial applications. A vast majority of these applications involve the use of thermal sprayed coatings to combat wear. While plasma spraying is the most versatile variant of all the thermal spray processes, the detonation gun (D-gun) coatings have been a novelty until recently because of their proprietary nature. The present study is aimed at comparing the tribological behavior of coatings deposited using the two above techniques by focusing on some popular coating materials that are widely adopted for wear resistant applications, namely, WC-12% Co, Al 2 O 3 , and Cr 3 C 2 -NiCr. To enable a comprehensive comparison of the above indicated thermal spray techniques as well as coating materials, the deposited coatings were extensively characterized employing microstructural evaluation, microhardness measurements, and XRD analysis for phase constitution. The behavior of these coatings under different wear modes was also evaluated by determining their tribological performance when subjected to solid particle erosion tests, rubber wheel sand abrasion tests, and pin-on-disk sliding wear tests. Among all the coating materials studied, D-gun sprayed WC-12% Co, in general, yields the best performance under different modes of wear, whereas plasma sprayed Al 2 O 3 shows least wear resistance to every wear mode

Thermal Diffusivity Measurement for Thermal Spray Coating Attached to Substrate Using Laser Flash Method

Science.gov (United States)

Akoshima, Megumi; Tanaka, Takashi; Endo, Satoshi; Baba, Tetsuya; Harada, Yoshio; Kojima, Yoshitaka; Kawasaki, Akira; Ono, Fumio

2011-11-01

Ceramic-based thermal barrier coatings are used as heat and wear shields of gas turbine blades. There is a strong need to evaluate the thermal conductivity of coating for thermal design and use. The thermal conductivity of a bulk material is obtained as the product of thermal diffusivity, specific heat capacity, and density above room temperature in many cases. Thermal diffusivity and thermal conductivity are unique for a given material because they are sensitive to the structure of the material. Therefore, it is important to measure them in each sample. However it is difficult to measure the thermal diffusivity and thermal conductivity of coatings because coatings are attached to substrates. In order to evaluate the thermal diffusivity of a coating attached to the substrate, we have examined the laser flash method with the multilayer model on the basis of the response function method. We carried out laser flash measurements in layered samples composed of a CoNiCrAlY bond coating and a 8YSZ top coating by thermal spraying on a Ni-based superalloy substrate. It was found that the procedure using laser flash method with the multilayer model is useful for the thermal diffusivity evaluation of a coating attached to a substrate.

Replacement of Chromium Electroplating on Gas Turbine Engine Components Using Thermal Spray Coatings

National Research Council Canada - National Science Library

Sartwell, Bruce D; Legg, Keith O; Schell, Jerry; Bondaruk, Bob; Alford, Charles; Natishan, Paul; Lawrence, Steven; Shubert, Gary; Bretz, Philip; Kaltenhauser, Anne

2005-01-01

.... This document constitutes the final report on a project to qualify high-velocity oxygen-fuel (HVOF) and plasma thermal spray coatings as a replacement for hard chrome plating on gas turbine engine components...

Spray cooling heat transfer: Technology overview and assessment of future challenges for micro-gravity application

International Nuclear Information System (INIS)

Silk, Eric A.; Golliher, Eric L.; Paneer Selvam, R.

2008-01-01

Advanced on-board flight systems for future NASA space exploration programs consist of components such as laser-diode arrays (LDA's) and multi-chip modules (MCM's). Thermal management of these systems require high heat flux cooling capability (≥100 W/cm 2 ), tight temperature control (approx. ±2 deg. C), reliable start-up (on demand) and long term stability. Traditional multiphase thermal control technologies for space flight (e.g., loop heat pipes, capillary pumped loops, etc.) satisfy the temperature control, start-up and stability requirements, but their heat flux removal capabilities are limited. Spray cooling can provide high heat fluxes in excess of 100 W/cm 2 using fluorinerts and over 1000 W/cm 2 with water while allowing tight temperature control at low coolant fluid flow rates. Spray cooling has been flight proven in an open loop configuration through the Space shuttle's flash evaporator system (FES). However, several closed system issues require investigation to further advance the technology to a technology readiness level (TRL) appropriate for closed system space flight application. This paper provides a discussion of the current status of spray cooling technology as well as NASA's goals, current direction, and challenges associated with the implementation and practice of this technology in the micro-gravity environment

Preparation of high critical temperature YBa2Cu3O7 superconducting coatings by thermal spray

International Nuclear Information System (INIS)

Lacombe, Jacques

1991-01-01

The objective of this research thesis is the elaboration of YBa 2 Cu 3 O 7 superconducting coatings by thermal spray. These coatings must have a high adherence, a high cohesion, and the best possible electrical characteristics. The author first briefly presents physical-chemical characteristics of this ceramic, and proposes a bibliographical synthesis on thick coatings prepared by thermal spray. In the next parts, he studies and describes conditions of elaboration of poly-granular coatings of YBa 2 Cu 3 O 7 , and their structural and electric characteristics [fr

LSPRAY-V: A Lagrangian Spray Module

Science.gov (United States)

Raju, M. S.

2015-01-01

LSPRAY-V is a Lagrangian spray solver developed for application with unstructured grids and massively parallel computers. It is mainly designed to predict the flow, thermal and transport properties of a rapidly vaporizing spray encountered over a wide range of operating conditions in modern aircraft engine development. It could easily be coupled with any existing gas-phase flow and/or Monte Carlo Probability Density Function (PDF) solvers. The manual provides the user with an understanding of various models involved in the spray formulation, its code structure and solution algorithm, and various other issues related to parallelization and its coupling with other solvers. With the development of LSPRAY-V, we have advanced the state-of-the-art in spray computations in several important ways.

Demonstration of Thermally Sprayed Metal and Polymer Coatings for Steel Structures at Fort Bragg, NC

Science.gov (United States)

2017-09-01

ER D C/ CE RL T R- 17 -3 0 DoD Corrosion Prevention and Control Program Demonstration of Thermally Sprayed Metal and Polymer Coatings...and Polymer Coatings for Steel Structures at Fort Bragg, NC Final Report on Project F07-AR10 Larry D. Stephenson, Alfred D. Beitelman, Richard G...5 2.1.2 Thermoplastic polymer coating (flame spray

In situ spray deposition of cell-loaded, thermally and chemically gelling hydrogel coatings for tissue regeneration.

Science.gov (United States)

Pehlivaner Kara, Meryem O; Ekenseair, Adam K

2016-10-01

In this study, the efficacy of creating cellular hydrogel coatings on warm tissue surfaces through the minimally invasive, sprayable delivery of thermoresponsive liquid solutions was investigated. Poly(N-isopropylacrylamide)-based (pNiPAAm) thermogelling macromers with or without addition of crosslinking polyamidoamine (PAMAM) macromers were synthesized and used to produce in situ forming thermally and chemically gelling hydrogel systems. The effect of solution and process parameters on hydrogel physical properties and morphology was evaluated and compared to poly(ethylene glycol) and injection controls. Smooth, fast, and conformal hydrogel coatings were obtained when pNiPAAm thermogelling macromers were sprayed with high PAMAM concentration at low pressure. Cellular hydrogel coatings were further fabricated by different spraying techniques: single-stream, layer-by-layer, and dual stream methods. The impact of spray technique, solution formulation, pressure, and spray solution viscosity on the viability of fibroblast and osteoblast cells encapsulated in hydrogels was elucidated. In particular, the early formation of chemically crosslinked micronetworks during bulk liquid flow was shown to significantly affect cell viability under turbulent conditions compared to injectable controls. The results demonstrated that sprayable, in situ forming hydrogels capable of delivering cell populations in a homogeneous therapeutic coating on diseased tissue surfaces offer promise as novel therapies for applications in regenerative medicine. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 104A: 2383-2393, 2016. © 2016 Wiley Periodicals, Inc.

Preparation of the Wire of ZChSnSb11-6 Used for Remanufacturing Thermal Spraying

Science.gov (United States)

Zhang, B.; Yang, Z. Y.; Fu, D. X.; Li, X. F.; Chen, W.

Tin base Babbitt alloy widely used in bearing bush production and repair, the performance of ZChSnSb11-6 is better than ZChSnSb8-4.But as a result of as-cast structure of ZChSnSb11-6 is rich in big hard phase, its processing performance is bad, in this paper, through the optimization of smelting, casting, extrusion, drawing and other processes we have been successfully prepared ZChSnSb11-6 wire suitable for thermal spraying. Through metallographic examination, micro hardness, bond strength and porosity testing, it was proved that the wire meet the requirements of bearing manufacturing thermal spraying.

Yttria-stabilized zirkonia / gadolinium zirconate double-layer plasma-sprayed thermal barrier coating systems (TBCs)

International Nuclear Information System (INIS)

Bakan, Emine

2015-01-01

Thermal barrier coating (TBC) research and development is driven by the desirability of further increasing the maximum inlet temperature in a gas turbine engine. A number of new top coat ceramic materials have been proposed during the last decades due to limited temperature capability (1200 C) of the state-of-the-art yttria-stabilized zirconia (7 wt. % Y 2 O 3 -ZrO 2 , YSZ) at long term operation. Zirconate pyrochlores of the large lanthanides((Gd → La) 2 Zr 2 O 7 ) have been particularly attractive due to their higher temperature phase stability than that of the YSZ. Nonetheless, the issues related with the implementation of pyrochlores such as low fracture toughness and formation of deleterious interphases with thermally grown oxide (TGO, Al 2 O 3 ) were reported. The implication was the requirement of an interlayer between the pyrochlores and TGO, which introduced double-layer systems to the TBC literature. Furthermore, processability issues of pyrochlores associated with the different evaporation rates of lanthanide oxides and zirconia resulting in unfavorable composition variations in the coatings were addressed in different studies. After all, although the material properties are available, there is a paucity of data in the literature concerning the properties of the coatings made of pyrochlores. From the processability point of view the most reported pyrochlore is La 2 Zr 2 O 7 . Hence, the goal of this research was to investigate plasma-sprayed Gd 2 Zr 2 O 7 (GZO) coatings and YSZ/GZO double-layer TBC systems. Three main topics were examined based on processing, performance and properties: (i) the plasma spray processing of the GZO and its impact on the microstructural and compositional properties of the GZO coatings; (ii) the cycling lifetime of the YSZ/GZO double-layer systems under thermal gradient at a surface temperature of 1400 C; (iii) the properties of the GZO and YSZ coatings such as thermal conductivity, coefficient of thermal expansion as well

Spray freeze-dried nanofibrillated cellulose aerogels with thermal superinsulating properties.

Science.gov (United States)

Jiménez-Saelices, Clara; Seantier, Bastien; Cathala, Bernard; Grohens, Yves

2017-02-10

Nanofibrillated cellulose (NFC) aerogels were prepared by spray freeze-drying (SFD). Their structural, mechanical and thermal insulation properties were compared to those of NFC aerogels prepared by conventional freeze-drying (CFD). The purpose of this investigation is to develop superinsulating bioaerogels by reducing their pore size. Severe reduction of the aerogel pore size and skeleton architecture were observed by SEM, aerogels prepared by SFD method show a fibril skeleton morphology, which defines a mesoporous structure. BET analyses confirm the appearance of a new organization structure with pores of nanometric sizes. As a consequence, the thermal insulation properties were significantly improved for SFD materials compared to CFD aerogel, reaching values of thermal conductivity as low as 0.018W/(mK). Moreover, NFC aerogels have a thermal conductivity below that of air in ambient conditions, making them one of the best cellulose based thermal superinsulating material. Copyright © 2016 Elsevier Ltd. All rights reserved.

Thermal Shock Resistance of Stabilized Zirconia/Metal Coat on Polymer Matrix Composites by Thermal Spraying Process

Science.gov (United States)

Zhu, Ling; Huang, Wenzhi; Cheng, Haifeng; Cao, Xueqiang

2014-12-01

Stabilized zirconia/metal coating systems were deposited on the polymer matrix composites by a combined thermal spray process. Effects of the thicknesses of metal layers and ceramic layer on thermal shock resistance of the coating systems were investigated. According to the results of thermal shock lifetime, the coating system consisting of 20 μm Zn and 125 μm 8YSZ exhibited the best thermal shock resistance. Based on microstructure evolution, failure modes and failure mechanism of the coating systems were proposed. The main failure modes were the formation of vertical cracks and delamination in the outlayer of substrate, and the appearance of coating spallation. The residual stress, thermal stress and oxidation of substrate near the substrate/metal layer interface were responsible for coating failure, while the oxidation of substrate near the substrate/coating interface was the dominant one.

Fullerene monolayer formation by spray coating

NARCIS (Netherlands)

Cervenka, J.; Flipse, C.F.J.

2010-01-01

Many large molecular complexes are limited in thin film applications by their insufficient thermal stability, which excludes deposition via commonly used vapour phase deposition methods. Here we demonstrate an alternative way of monolayer formation of large molecules by a simple spray coating method

Thermophysical Properties of Cold and Vacuum Plasma Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings. Part 1; Electrical and Thermal Conductivity, Thermal Diffusivity, and Total Hemispherical Emissivity

Science.gov (United States)

Raj, S. V.

2017-01-01

This two-part paper reports the thermophysical properties of several cold and vacuum plasma sprayed monolithic Cu and Ni-based alloy coatings. Part I presents the electrical and thermal conductivity, thermal diffusivity, and total hemispherical emissivity data while Part II reports the specific heat capacity data for these coatings. Metallic copper alloys, stoichiometric NiAl and NiCrAlY coatings were fabricated by either the cold sprayed or the vacuum plasma spray deposition processes for thermal property measurements between 77 and 1223 K. The temperature dependencies of the thermal conductivities, thermal diffusivities, electrical conductivities and total hemispherical emissivities of these cold and vacuum sprayed monolithic coatings are reported in this paper. The electrical and thermal conductivity data correlate reasonably well for Cu-8%Cr-1%Al, Cu-23%Cr-5%Al and NiAl in accordance with the Wiedemann-Franz (WF) law although a better fit is obtained using the Smith-Palmer relationship. The Lorentz numbers determined from the WF law are close to the theoretical value.

LSPRAY-IV: A Lagrangian Spray Module

Science.gov (United States)

Raju, M. S.

2012-01-01

LSPRAY-IV is a Lagrangian spray solver developed for application with parallel computing and unstructured grids. It is designed to be massively parallel and could easily be coupled with any existing gas-phase flow and/or Monte Carlo Probability Density Function (PDF) solvers. The solver accommodates the use of an unstructured mesh with mixed elements of either triangular, quadrilateral, and/or tetrahedral type for the gas flow grid representation. It is mainly designed to predict the flow, thermal and transport properties of a rapidly vaporizing spray. Some important research areas covered as a part of the code development are: (1) the extension of combined CFD/scalar-Monte- Carlo-PDF method to spray modeling, (2) the multi-component liquid spray modeling, and (3) the assessment of various atomization models used in spray calculations. The current version contains the extension to the modeling of superheated sprays. The manual provides the user with an understanding of various models involved in the spray formulation, its code structure and solution algorithm, and various other issues related to parallelization and its coupling with other solvers.

Advanced homogenization strategies in material modeling of thermally sprayed TBCs

International Nuclear Information System (INIS)

Bobzin, K.; Lugscheider, E.; Nickel, R.; Kashko, T.

2006-01-01

Thermal barrier coatings (TBC), obtained by atmospheric plasma spraying (APS), have a complex microstructure (lamellar, porous, micro-cracked). Process parameters take an influence on this microstructure. Two methods based on the homogenization for periodic structures are presented in this article. The methods are used to calculate the effective material behavior of APS-TBCs made of partially yttria stabilized zirconia (PYSZ) depending on the microstructure. (Abstract Copyright [2006], Wiley Periodicals, Inc.)

X-ray photoelectron spectroscopy study of the passive films formed on thermally sprayed and wrought Inconel 625

Energy Technology Data Exchange (ETDEWEB)

Bakare, M.S. [Materials, Mechanics and Structures Research Division, Faculty of Engineering, University of Nottingham, University Park, Nottingham, NG7 2RD (United Kingdom); Voisey, K.T., E-mail: Katy.voisey@nottingham.ac.uk [Materials, Mechanics and Structures Research Division, Faculty of Engineering, University of Nottingham, University Park, Nottingham, NG7 2RD (United Kingdom); Roe, M.J.; McCartney, D.G. [Materials, Mechanics and Structures Research Division, Faculty of Engineering, University of Nottingham, University Park, Nottingham, NG7 2RD (United Kingdom)

2010-11-15

There is a well known performance gap in corrosion resistance between thermally sprayed corrosion resistant coatings and the equivalent bulk materials. Interconnected porosity has an important and well known effect, however there are additional relevant microstructural effects. Previous work has shown that a compositional difference exists between the regions of resolidified and non-melted material that exist in the as-sprayed coatings. The resolidified regions are depleted in oxide forming elements due to formation of oxides during coating deposition. Formation of galvanic cells between these different regions is believed to decrease the corrosion resistance of the coating. In order to increase understanding of the details of this effect, this work uses X-ray photoelectron spectroscopy (XPS) to study the passive films formed on thermally sprayed coatings (HVOF) and bulk Inconel 625, a commercially available corrosion resistant Ni-Cr-Mo-Nb alloy. Passive films produced by potentiodynamic scanning to 400 mV in 0.5 M sulphuric acid were compared with air-formed films. The poorer corrosion performance of the thermally sprayed coatings was attributed to Ni(OH){sub 2}, which forms a loose, non-adherent and therefore non-protective film. The good corrosion resistance of wrought Inconel 625 is due to formation of Cr, Mo and Nb oxides.

Experimental evidence of the thermal effect of lubricating oil sprayed in sliding-vane air compressors

Directory of Open Access Journals (Sweden)

Gianluca Valenti

2014-11-01

Full Text Available A way to increase the efficiency of positive-displacement air compressor is spraying the lube oil to exploit it not only as lubricating and sealing agent but also as thermal ballast. This work seeks the experimental evidence in sliding-vane compressors by measuring the air standard volume flow rate and the electrical power input of three diverse configurations. The first configuration, taken as the reference, employs a conventional injection system comprising calibrated straight orifices. The other two, referred to as advanced, adopt smaller orifices and pressure-swirl full-cone nozzles designed for the purpose; the third configuration utilizes a pump to boost the oil pressure. The laser imagining technique shows that the nozzles generate sprays that break-up within a short distance into spherical droplets, ligaments, ramifications and undefined structures. Tests on the packaged compressors reveal that the advanced configurations provide almost the same air flow rate while utilizing half of the oil because the sprays generate a good sealing. Moreover, the sprayed oil is acting as a thermal ballast because the electrical input is reduced by 3.5% and 3.0%, respectively, if the pump is present or not , while the specific energy requirement, accounting for the slightly reduced air flow, by 2.4% and 2.9%, respectively.

Characterisation of WC-12Co thermal spray powders and HPHVOF wear resistant coatings

CSIR Research Space (South Africa)

Lovelock, HDL

1998-01-01

Full Text Available were selected for the deposition of thermal spray coatings using the JP 5000 high pressure high velocity oxyfuel (HPHVOF) system. Dry sand rubber wheel abrasion tests were performed on the coatings in order to determine the effect of powder...

An experimental methodology to quantify the spray cooling event at intermittent spray impact

International Nuclear Information System (INIS)

Moreira, Antonio L.N.; Carvalho, Joao; Panao, Miguel R.O.

2007-01-01

The present paper describes an experimental methodology devised to study spray cooling with multiple-intermittent sprays as those found in fuel injection systems of spark-ignition and diesel engines, or in dermatologic surgery applications. The spray characteristics and the surface thermal behaviour are measured by combining a two-component phase-Doppler anemometer with fast response surface thermocouples. The hardware allows simultaneous acquisition of Doppler and thermocouple signals which are processed in Matlab to estimate the time-varying heat flux and fluid-dynamic characteristics of the spray during impact. The time resolution of the acquisition system is limited by the data rate of validation of the phase-Doppler anemometer, but it has been shown to be accurate for the characterization of spray-cooling processes with short spurt durations for which the transient period of spray injection plays an important role. The measurements are processed in terms of the instantaneous heat fluxes, from which phase-average values of the boiling curves are obtained. Two of the characteristic parameters used in the thermal analysis of stationary spray cooling events, the critical heat flux (CHF) and Leidenfrost phenomenon, are then inferred in terms of operating conditions of the multiple-intermittent injections, such as the frequency, duration and pressure of injection. An integral method is suggested to describe the overall process of heat transfer, which accounts for the fluid-dynamic heterogeneities induced by multiple and successive droplet interactions within the area of spray impact. The method considers overall boiling curves dependant on the injection conditions and provides an empirical tool to characterize the heat transfer processes on the impact of multiple-intermittent sprays. The methodology is tested in a preliminary study of the effect of injection conditions on the heat removed by a fuel spray striking the back surface of the intake valve as in spark

Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review

Science.gov (United States)

Toma, Filofteia-Laura; Potthoff, Annegret; Berger, Lutz-Michael; Leyens, Christoph

2015-10-01

Research and development work for about one decade have demonstrated many unique thermal spray coating properties, particularly for oxide ceramic coatings by using suspensions of fine powders as feedstock in APS and HVOF processes. Some particular advantages are direct feeding of fine nano- and submicron-scale particles avoiding special feedstock powder preparation, ability to produce coating thicknesses ranging from 10 to 50 µm, homogeneous microstructure with less anisotropy and lower surface roughness compared to conventional coatings, possibility of retention of the initial crystalline phases, and others. This paper discusses the main aspects of thermal spraying with suspensions which have been taken into account in order to produce these coatings on an economical way. The economic efficiency of the process depends on the availability of suitable additional system components (suspension feeder, injectors), on the development and handling of stable suspensions, as well as on the high process stability for acceptance at industrial scale. Special focus is made on the development and processability of highly concentrated water-based suspensions. While costs and operational safety clearly speak for use of water as a liquid media for preparing suspensions on an industrial scale, its use is often critically discussed due to the required higher heat input during spraying compared to alcoholic suspensions.

Yttria-stabilized zirkonia / gadolinium zirconate double-layer plasma-sprayed thermal barrier coating systems (TBCs)

Energy Technology Data Exchange (ETDEWEB)

Bakan, Emine

2015-07-01

Thermal barrier coating (TBC) research and development is driven by the desirability of further increasing the maximum inlet temperature in a gas turbine engine. A number of new top coat ceramic materials have been proposed during the last decades due to limited temperature capability (1200 C) of the state-of-the-art yttria-stabilized zirconia (7 wt. % Y{sub 2}O{sub 3}-ZrO{sub 2}, YSZ) at long term operation. Zirconate pyrochlores of the large lanthanides((Gd → La){sub 2}Zr{sub 2}O{sub 7}) have been particularly attractive due to their higher temperature phase stability than that of the YSZ. Nonetheless, the issues related with the implementation of pyrochlores such as low fracture toughness and formation of deleterious interphases with thermally grown oxide (TGO, Al{sub 2}O{sub 3}) were reported. The implication was the requirement of an interlayer between the pyrochlores and TGO, which introduced double-layer systems to the TBC literature. Furthermore, processability issues of pyrochlores associated with the different evaporation rates of lanthanide oxides and zirconia resulting in unfavorable composition variations in the coatings were addressed in different studies. After all, although the material properties are available, there is a paucity of data in the literature concerning the properties of the coatings made of pyrochlores. From the processability point of view the most reported pyrochlore is La{sub 2}Zr{sub 2}O{sub 7}. Hence, the goal of this research was to investigate plasma-sprayed Gd{sub 2}Zr{sub 2}O{sub 7} (GZO) coatings and YSZ/GZO double-layer TBC systems. Three main topics were examined based on processing, performance and properties: (i) the plasma spray processing of the GZO and its impact on the microstructural and compositional properties of the GZO coatings; (ii) the cycling lifetime of the YSZ/GZO double-layer systems under thermal gradient at a surface temperature of 1400 C; (iii) the properties of the GZO and YSZ coatings such as

Study on Metal Microfilter Coated with Ceramics by Using Plasma Thermal Spray Method

International Nuclear Information System (INIS)

Song, In Gyu; Shin, Hyun Myung; Choi, Hae Woon; Lee, Young Min

2011-01-01

This research was performed on a microfilter made of a hybrid material (ceramic + metal) that was coated with ceramics on the metal-filter surface by using the thermal spray method. The ceramic powders used were Al 2 O 3 +40TiO 2 powder with a particle size of 20 μm and Al 2 O 3 (98%+)powder with a particle size of 45 μm. The metal filters were filter-grade 20 μm, 30 μm, and 50 μm sintered metal powder filters (SIKA-R 20 IS, 30 IS, 50 IS: Sinter Metals Filters) and filter-grade 75 μm sintered mesh filter with five layers. Ceramic-coated filters that were coated using the thermal spray method had a great influence on powder material, particle size, and coating thickness. However, these filters showed a fine performance when used as micro-filters

Study on Metal Microfilter Coated with Ceramics by Using Plasma Thermal Spray Method

Energy Technology Data Exchange (ETDEWEB)

Song, In Gyu; Shin, Hyun Myung; Choi, Hae Woon [Keimyung University, Daegu (Korea, Republic of); Lee, Young Min [Korea Polytechincs VI, Daegu (Korea, Republic of)

2011-09-15

This research was performed on a microfilter made of a hybrid material (ceramic + metal) that was coated with ceramics on the metal-filter surface by using the thermal spray method. The ceramic powders used were Al{sub 2}O{sub 3}+40TiO{sub 2} powder with a particle size of 20 {mu}m and Al{sub 2}O{sub 3} (98%+)powder with a particle size of 45 {mu}m. The metal filters were filter-grade 20 {mu}m, 30 {mu}m, and 50 {mu}m sintered metal powder filters (SIKA-R 20 IS, 30 IS, 50 IS: Sinter Metals Filters) and filter-grade 75 {mu}m sintered mesh filter with five layers. Ceramic-coated filters that were coated using the thermal spray method had a great influence on powder material, particle size, and coating thickness. However, these filters showed a fine performance when used as micro-filters.

Spray cooling

International Nuclear Information System (INIS)

Rollin, Philippe.

1975-01-01

Spray cooling - using water spraying in air - is surveyed as a possible system for make-up (peak clipping in open circuit) or major cooling (in closed circuit) of the cooling water of the condensers in thermal power plants. Indications are given on the experiments made in France and the systems recently developed in USA, questions relating to performance, cost and environmental effects of spray devices are then dealt with [fr

Tribological Properties of Ti(Al,O)/Al2O3 Composite Coating by Thermal Spraying

Science.gov (United States)

Salman, Asma; Gabbitas, Brian; Cao, Peng; Zhang, Deliang

The use of thermal spray coatings provides protection to the surfaces operating in severe environments. The main goal of the current work is to investigate the possibility of using a high velocity air fuel (HVAF) thermally sprayed wear resistant Ti(Al,O)/Al2O3 coating on tool steel (H13) which is used for making dies for aluminium high pressure die casting and dummy blocks aluminium extrusion. A feedstock of Ti(Al,O)/Al2O3 composite powder was produced from a mixture of Al and TiO2 powders by high energy mechanical milling, followed by a thermal reaction process. The feedstock was then thermally sprayed using a high velocity air-fuel (HVAF) technique onto H13 steel substrates to produce a composite coating. The present study describes and compares the tribological properties such as friction and sliding wear rate of the coating both at room and high temperature (700°C). The wear resistance of the coating was investigated by a tribometer using a spherical ended alumina pin as a counter body under dry and lubricating conditions. The results showed that composite coating has lower wear rate at high temperature than at room temperature without using lubricant. The composite coating was characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD). This paper reports the experimental observations and discusses the wear resistance performance of the coatings at room and high temperatures.

The effect of processing parameters on plasma sprayed beryllium for fusion applications

International Nuclear Information System (INIS)

Castro, R.G.; Stanek, P.W.; Jacobson, L.A.; Cowgill, D.F.; Snead, L.L.

1993-01-01

Plasma spraying is being investigated as a potential coating technique for applying thin (0.1--5mm) layers of beryllium on plasma facing surfaces of blanket modules in ITER and also as an in-situ repair technique for repairing eroded beryllium surfaces in high heat flux divertor regions. High density spray deposits (>98% of theoretical density) of beryllium will be required in order to maximize the thermal conductivity of the beryllium coatings. A preliminary investigation was done to determine the effect of various processing parameters (particle size, particle morphology, secondary gas additions and reduced chamber pressure) on the as-deposited density of beryllium. The deposits were made using spherical beryllium feedstock powder which was produced by centrifugal atomization at Los Alamos National Laboratory (LANL). Improvements in the as-deposited densities and deposit efficiencies of the beryllium spray deposits will be discussed along with the corresponding thermal conductivity and outgassing behavior of these deposits

The effect of processing parameters on plasma sprayed beryllium for fusion applications

International Nuclear Information System (INIS)

Castro, R.G.; Stanek, P.W.; Jacobson, L.W.; Cowgill, D.F.

1993-01-01

Plasma spraying is being investigated as a potential coating technique for applying thin (0.1-5mm) layers of beryllium on plasma facing surfaces of blanket modules in ITER and also as an in-situ repair technique for repairing eroded beryllium surfaces in high heat flux divertor regions. High density spray deposits (>98% of theoretical density) of beryllium will be required in order to maximize the thermal conductivity of the beryllium coatings. A preliminary investigation was done to determine the effect of various processing parameters (particle size, particle morphology, secondary gas additions and reduced chamber pressure) on the as-deposited density of beryllium. The deposits were made using spherical beryllium feedstock powder which was produced by centrifugal atomization at Los Alamos National Laboratory (LANL). Improvements in the as-deposited densities and deposit efficiencies of the beryllium spray deposits will be discussed along with the corresponding thermal conductivity and outgassing behavior of these deposits. (orig.)

Plasma spraying of beryllium and beryllium-aluminum-silver alloys

International Nuclear Information System (INIS)

Castro, R.G.; Stanek, P.W.; Elliott, K.E.; Jacobson, L.A.

1994-01-01

A preliminary investigation on plasma-spraying of beryllium and a beryllium-aluminum-4% silver alloy was done at the Los Alamos National Laboratory's Beryllium Atomization and Thermal Spray Facility (BATSF). Spherical Be and Be-Al-4%Ag powders, which were produced by centrifugal atomization, were used as feedstock material for plasma-spraying. The spherical morphology of the powders allowed for better feeding of fine (<38 μm) powders into the plasma-spray torch. The difference in the as-deposited densities and deposit efficiencies of the two plasma-sprayed powders will be discussed along with the effect of processing parameters on the as-deposited microstructure of the Be-Al-4%Ag. This investigation represents ongoing research to develop and characterize plasma-spraying of beryllium and beryllium-aluminum alloys for magnetic fusion and aerospace applications

Plasma spraying of beryllium and beryllium-aluminum-silver alloys

International Nuclear Information System (INIS)

Castro, R.G.; Stanek, P.W.; Elliott, K.E.; Jacobson, L.A.

1993-01-01

A preliminary investigation on plasma-spraying of beryllium and a beryllium-aluminum 4% silver alloy was done at the Los Alamos National Laboratory's Beryllium Atomization and Thermal Spray Facility (BATSF). Spherical Be and Be-Al-4%Ag powders, which were produced by centrifugal atomization, were used as feedstock material for plasma-spraying. The spherical morphology of the powders allowed for better feeding of fine (<38 μm) powders into the plasma-spray torch. The difference in the as-deposited densities and deposit efficiencies of the two plasma-sprayed powders will be discussed along with the effect of processing parameters on the as-deposited microstructure of the Be-Al-4%Ag. This investigation represents ongoing research to develop and characterize plasma-spraying of beryllium and beryllium-aluminum alloys for magnetic fusion and aerospace applications

Evaluation of bond strength of isothermally aged plasma sprayed thermal barrier coating

Energy Technology Data Exchange (ETDEWEB)

Kim, Dae Jin; Lee, Dong Hoon; Koo, Jae Mean; Song, Sung Jin; Seok, Chang Sung [Sungkyunkwan University, Suwon (Korea, Republic of); Kim, Mun Young [Korea Plant Service and Engineering Co., Ltd., Seongnam (Korea, Republic of)

2008-07-15

In this study, disk type of thermal barrier coating system for gas turbine blade was isothermally aged in the furnace changing exposure time and temperature. For each aging condition, bond tests for three samples were conducted for evaluating degradation of adhesive or cohesive strength of thermal barrier coating system. For as-sprayed condition, the location of fracture in the bond test was in the middle of epoxy which have bond strength of 57 MPa. As specimens are degraded by thermal aging, bond strength gradually decreased and the location of failure was also changed from within top coat at the earlier stage of thermal aging to the interface between top coat and TGO at the later stage due to the delamination in the coating.

Powder consolidation using cold spray process modeling and emerging applications

CERN Document Server

Moridi, Atieh

2017-01-01

This book first presents different approaches to modeling of the cold spray process with the aim of extending current understanding of its fundamental principles and then describes emerging applications of cold spray. In the coverage of modeling, careful attention is devoted to the assessment of critical and erosion velocities. In order to reveal the phenomenological characteristics of interface bonding, severe, localized plastic deformation and material jet formation are studied. Detailed consideration is also given to the effect of macroscopic defects such as interparticle boundaries and subsequent splat boundary cracking on the mechanical behavior of cold spray coatings. The discussion of applications focuses in particular on the repair of damaged parts and additive manufacturing in various disciplines from aerospace to biomedical engineering. Key aspects include a systematic study of defect shape and the ability of cold spray to fill the defect, examination of the fatigue behavior of coatings for structur...

Comparative of the Tribological Performance of Hydraulic Cylinders Coated by the Process of Thermal Spray HVOF and Hard Chrome Plating

Directory of Open Access Journals (Sweden)

R.M. Castro

2014-03-01

Full Text Available Due to the necessity of obtaining a surface that is resistant to wear and oxidation, hydraulic cylinders are typically coated with hard chrome through the process of electroplating process. However, this type of coating shows an increase of the area to support sealing elements, which interferes directly in the lubrication of the rod, causing damage to the seal components and bringing oil leakage. Another disadvantage in using the electroplated hard chromium process is the presence of high level hexavalent chromium Cr+6 which is not only carcinogenic, but also extremely contaminating to the environment. Currently, the alternative process of high-speed thermal spraying (HVOF - High Velocity Oxy-Fuel, uses composite materials (metal-ceramic possessing low wear rates. Research has shown that some mechanical properties are changed positively with the thermal spray process in industrial applications. It is evident that a coating based on WC has upper characteristics as: wear resistance, low friction coefficient, with respect to hard chrome coatings. These characteristics were analyzed by optical microscopy, roughness measurements and wear test.

Ceramic plasma-sprayed coating of melting crucibles for casting metal fuel slugs

International Nuclear Information System (INIS)

Kim, Ki Hwan; Lee, Chong Tak; Lee, Chan Bock; Fielding, R.S.; Kennedy, J.R.

2013-01-01

Thermal cycling and melt reaction studies of ceramic coatings plasma-sprayed on Nb substrates were carried out to evaluate the performance of barrier coatings for metallic fuel casting applications. Thermal cycling tests of the ceramic plasma-sprayed coatings to 1450 °C showed that HfN, TiC, ZrC, and Y 2 O 3 coating had good cycling characteristics with few interconnected cracks even after 20 cycles. Interaction studies by 1550 °C melt dipping tests of the plasma-sprayed coatings also indicated that HfN and Y 2 O 3 do not form significant reaction layer between U–20 wt.% Zr melt and the coating layer. Plasma-sprayed Y 2 O 3 coating exhibited the most promising characteristics among HfN, TiC, ZrC, and Y 2 O 3 coating

Supplementary Microstructural Features Induced During Laser Surface Melting of Thermally Sprayed Inconel 625 Coatings

Science.gov (United States)

Ahmed, Nauman; Voisey, K. T.; McCartney, D. G.

2014-02-01

Laser surface melting of thermally sprayed coatings has the potential to enhance their corrosion properties by incorporating favorable microstructural changes. Besides homogenizing the as-sprayed structure, laser melting may induce certain microstructural modifications (i.e., supplementary features) in addition to those that directly improve the corrosion performance. Such features, being a direct result of the laser treatment process, are described in this paper which is part of a broader study in which high velocity oxy-fuel sprayed Inconel 625 coatings on mild-steel substrates were treated with a diode laser and the modified microstructure characterized using optical and scanning electron microscopy and x-ray diffraction. The laser treated coating features several different zones, including a region with a microstructure in which there is a continuous columnar dendritic structure through a network of retained oxide stringers.

Replacement of corrosion protection chromate primers and paints used in cryogenic applications on the Space Shuttle with wire arc sprayed aluminum coatings

Science.gov (United States)

Daniel, R. L.; Sanders, H. L.; Zimmerman, F. R.

1995-01-01

With the advent of new environmental laws restricting volatile organic compounds and hexavalent chrome emissions, 'environmentally safe' thermal spray coatings are being developed to replace the traditional corrosion protection chromate primers. A wire arc sprayed aluminum coating is being developed for corrosion protection of low pressure liquid hydrogen carrying ducts on the Space Shuttle Main Engine. Currently, this hardware utilizes a chromate primer to provide protection against corrosion pitting and stress corrosion cracking induced by the cryogenic operating environment. The wire are sprayed aluminum coating has been found to have good potential to provide corrosion protection for flight hardware in cryogenic applications. The coating development, adhesion test, corrosion test and cryogenic flexibility test results will be presented.

Crop adapted spray application (CASA) - precise and safe plant protection in fruit growing

NARCIS (Netherlands)

Doruchowski, G.; Balsari, P.; Marucco, P.; Zande, van de J.C.; Wenneker, M.

2012-01-01

The Crop Adapted Spray Application (CASA) system for orchards integrates disease detection based on reflectance imaging, crop identification with ultrasonic sensors, wind measurement and DGPS navigation. Through the automatic adjustment of spray application parameters according to the crop

The evaluation of integrity and elasticity of thermally sprayed ceramic coatings by ultrasonics

Energy Technology Data Exchange (ETDEWEB)

Kauppinen, P. [VTT Manufacturing Technology, Espoo (Finland). Materials and Structural Integrity

1997-12-31

Thermally sprayed ceramic coatings are widely used in industrial applications where the coated component is subject to, e.g. high thermal loads or mechanical wear. The mechanical properties of the coating are finally created in the coating process and the chemical composition of the powder used as raw material can only give some hints about the properties of the final coating. Several non-destructive testing techniques are available for the detection of defects in ceramic materials or for the evaluation of density and density variations. In addition to this, ultrasonic techniques can be used for quantitative evaluation of elastic properties of materials. This evaluation is based on the measurement of sound velocities of different wave modes in the material and is normally applied only to relatively simple-shaped specimens having parallel surfaces. Acoustic microscopy operating at very high (> 100 MHz) frequencies has been used to measure the sound velocities in homogeneous and thin coatings. With this type of equipment, reliable and accurate results have been achieved in laboratory measurements. A lot of development work has been carried out world-wide to develop the measurement techniques and acoustic lenses (transducers) used in acoustic microscopy. However, less attention has been paid on the development of techniques for industrial applications on-site. The present work was focused on the development of measurement techniques for industrial applications. A new type of large-aperture low-frequency transducer was designed and constructed for the measurement of sound velocities in thermally sprayed ceramic coatings. The major difference to the lenses used in acoustic microscopy is that in the new transducer no separate lens is needed for focusing the sound beam. The piezoelectric element in the new transducer is a plastic (PVDF)-film that can be shaped to create the required focus. The practical measurement of the sound velocity is based on a modification of the V

Gas Dynamic Spray Technology Demonstration Project Management. Joint Test Report

Science.gov (United States)

Lewis, Pattie

2011-01-01

The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are sUbject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by Air Force Space Command (AFSPC) and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GOS) technology (also known as Cold Spray) was evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GOS coatings also have no VOCs and are environmentally preferable coatings. The primary objective of this effort was to demonstrate GDS technology as a repair method for TSCs. The aim was that successful completion of this project would result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations to improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Internal Diameter HVAF Spraying for Wear and Corrosion Applications

Science.gov (United States)

Lyphout, C.; Björklund, S.

2015-01-01

Electrolytic hard chrome (EHC) methods are still widely utilized in the printing, automotive and off-shore industries. Alternative methods to EHC have been widely developed in the past decade by conventional HVOF processes and more recently HVAF systems, which are processing at higher kinetic energy and more particularly at lower temperature, significantly increasing wear and corrosion resistance properties. A dedicated internal diameter HVAF system is here presented, and coatings characteristics are compared to the one obtained by standard HVAF coatings. Specially R&D designed fixtures with inside bore of 200 mm have been manufactured for this purpose, with a possibility to spray samples at increasing depth up to 400 mm while simulating closed bottom bore spraying. WC-based and Cr3C2-based powder feedstock materials have been deposited onto high-strength steel substrates. Respective coating microstructures, thermally induced stresses and corrosion resistance are discussed for further optimization of coating performances. The fact that the ID-HVAF system is utilized both for spraying and gritblasting procedures is also given a particular interest.

Coating Properties of WC-Ni Cold Spray Coating for the Application in Secondary Piping System of Nuclear Power Plants

Energy Technology Data Exchange (ETDEWEB)

Kim, JeongWon; Kim, Seunghyun; Kim, Ji Hyun [UNIST, Ulsan (Korea, Republic of)

2015-10-15

As a result of FAC(flow accelerated corrosion), severe accidents, failure of carbon steel like a Mihama Unit-3 occurred. Chemical composition change of carbon steel or coating to inner surface is one of methods to improve corrosion properties. Among them, thermal spray coating is convenient solution to apply at industry. Powder is melted at blast furnace and ejected to substrate. After adhesion, substrate and coating layer is cooled down and coated layer protects steel from corrosion finally. However high thermal energy is transferred to substrate and coating layer so it leads high thermal residual stress in coating procedure. Besides, high temperature for melting powder makes unexpected chemical reaction of powder like an oxidation or carburization. Whereas, cold spray uses low temperature comparing with other thermal spray. Thermal energy is used for not melting powder but high kinetic energy of powder and plastic deformation during collision. Therefore, fuel such as oxygen-acetylene gas is not needed. It needs carrier gas, compressed air, nitrogen or helium, to increase kinetic energy of powder and move powder to substrate. Comparing cold spray with high velocity oxy fuel (HVOF), one of thermal spray, cold spray coating layer contains only WC and Co. One of other problem about WC is brittleness during coating. To improve deformability of WC, binder metal is added. For example, Co, Cr, Ni, Cu, Al, Fe or etc. Additionally, binder metal lowering melting temperature of composite powder increases coating properties. Among them, Co which is widely used as binder metal maintains mechanical properties like a hardness and improves corrosion properties. Therefore Co is not suitable for binder metal of WC coating. In contrast, Ni has better corrosion resistance to alkaline environment and makes lower melting temperature. Moreover, in a view of cold spray, FCC structure has better deformability than BCC or HCP, and BCC has lowest deformability. WC is BCC structure so it

Spray deposition of organic electroluminescent coatings for application in flexible light emitting devices

Directory of Open Access Journals (Sweden)

Mariya Aleksandrova

2015-12-01

Full Text Available Organic electroluminescent (EL films of tris(8-hydroxyquinolinatoaluminum (Alq3 mixed with polystyrene (PS binder were produced by spray deposition. The influence of the substrate temperature on the layer’s morphology and uniformity was investigated. The deposition conditions were optimized and simple flexible light-emitting devices consisting of indium-tin oxide/Alq3:PS/aluminum were fabricated on polyethylene terephthalate (PET foil to demonstrate the advantages of the sprayed organic coatings. Same structure was produced by thermal evaporation of Alq3 film as a reference. The influence of the deposition method on the film roughness and contact resistance at the electrode interfaces for both types of structures was estimated. The results were related to the devices’ efficiency. It was found that the samples with sprayed films turn on at 4 V, which is 2 V lower in comparison to the device with thermal evaporated Alq3. The current through the sprayed device is six times higher as well (17 mA vs. 2.8 mA at 6.5 V, which can be ascribed to the lower contact resistance at the EL film/electrode interfaces. This is due to the lower surface roughness of the pulverized layers.

Spray pesticide applications in Mediterranean citrus orchards: Canopy deposition and off-target losses.

Science.gov (United States)

Garcerá, Cruz; Moltó, Enrique; Chueca, Patricia

2017-12-01

Only a portion of the water volume sprayed is deposited on the target when applying plant protection products with air-assisted axial-fan airblast sprayers in high growing crops. A fraction of the off-target losses deposits on the ground, but droplets also drift away from the site. This work aimed at assessing the spray distribution to different compartments (tree canopy, ground and air) during pesticide applications in a Mediterranean citrus orchard. Standard cone nozzles (Teejet D3 DC35) and venturi drift reducing nozzles (Albuz TVI 80 03) were compared. Applications were performed with a conventional air-assisted sprayer, with a spray volume of around 3000lha -1 in a Navel orange orchard. Brilliant Sulfoflavine (BSF) was used as a tracer. Results showed that only around 46% of the applied spray was deposited on the target trees and around 4% of the spray was deposited on adjacent trees from adjoining rows independently of the nozzle type. Applications with standard nozzles produced more potential airborne spray drift (23%) than those with the drift reducing nozzles (17%) but fewer direct losses to the ground (22% vs. 27%). Indirect losses (sedimenting spray drift) to the ground of adjacent paths were around 7-9% in both cases. The important data set of spray distribution in the different compartments around sprayed orchard (air, ground, vegetation) generated in this work is highly useful as input source of exposure to take into account for the risk assessment in Mediterranean citrus scenario. Copyright © 2017 Elsevier B.V. All rights reserved.

A Review on Atomization and Sprays of Biofuels for IC Engine Applications

Directory of Open Access Journals (Sweden)

Prasad Boggavarapu

2013-06-01

Full Text Available Ever increasing energy requirements, environmental concerns and energy security needs are strongly influencing engine researchers to consider renewable biofuels as alternatives to fossil fuels. Spray process being important in IC engine combustion, existing literature on various biofuel sprays is reviewed and summarized. Both experimental and computational research findings are reviewed in a detailed manner for compression ignition (CI engine sprays and briefly for spark ignition (SI engine sprays. The physics of basic atomization process of sprays from various injectors is included to highlight the most recent research findings followed by discussion highlighting the effect of physico-chemical properties on spray atomization for both biofuels and fossil fuels. Biodiesel sprays are found to penetrate faster and have narrow spray plume angle and larger droplet sizes compared to diesel. Results of analytical and computational models are shown to be useful in shedding light on the actual process of atomization. However, further studies on understanding primary atomization and the effect of fuel properties on primary atomization are required. As far as secondary atomization is concerned, changes in regimes are observed to occur at higher air-jet velocities for biodiesel compared to those of diesel. Evaporating sprays revealed that the liquid length is longer for biodiesel. Pure plant oil sprays with potential use in CI engines may require alternative injector technology due to slower breakup as compared to diesel. Application of ethanol to gasoline engines may be feasible without any modifications to port fuel injection (PFI engines. More studies are required on the application of alternative fuels to high pressure sprays used in Gasoline Direct Injection (GDI engines.

Construction of mechanically durable superhydrophobic surfaces by thermal spray deposition and further surface modification

Science.gov (United States)

Chen, Xiuyong; Gong, Yongfeng; Suo, Xinkun; Huang, Jing; Liu, Yi; Li, Hua

2015-11-01

Here we report a simple and cost-effective technical route for constructing superhydrophobic surfaces with excellent abrasion resistance on various substrates. Rough surface structures were fabricated by thermal spray deposition of a variety of inorganic materials, and further surface modification was made by applying a thin layer of polytetrafluoroethylene. Results show that the Al, Cu, or NiCrBSi coatings with the surface roughness of up to 13.8 μm offer rough surface profile to complement the topographical morphology in micro-/nano-scaled sizes, and the hydrophobic molecules facilitate the hydrophobicity. The contact angles of water droplets of ∼155° with a sliding angle of up to 3.5° on the samples have been achieved. The newly constructed superhydrophobic coatings tolerate strong abrasion, giving clear insight into their long-term functional applications.

A two-wavelength imaging pyrometer for measuring particle temperature, velocity and size in thermal spray processes

International Nuclear Information System (INIS)

Craig, J.E.; Parker, R.A.; Lee, D.Y.; Biancaniello, F.; Ridder, S.

1999-01-01

An imaging pyrometer has been developed to measure the surface temperature of hot metal objects and to measure particle temperature, velocity and size in thermal spray, spray-fonning and atomization processes. The two-wavelength surface imaging pyrometer provides true temperature measurement with high resolution, even when the surface has emissivity variation caused by roughness or oxidation. The surface imaging pyrometer has been calibrated for use in a material processing lab calibration over the range of 1000 to 3000 deg K, and these results are described. The particle imaging pyrometer has a field of view that spans the entire particle stream in typical thermal spray devices, and provides continuous measurement of the entire particle stream. Particle temperature and velocity are critical parameters for producing high quality spray coatings efficiently and reliably. The software locates the particle streaks in the image, and determines the intensity ratio for each particle streak pair to obtain the temperature. The dimensions of the particle streak image are measured to determine the velocity and size. Because the vision-based sensor samples the entire particle stream in every video frame, the particle temperature, velocity and size data are updated at 30 Hz at all points in the particle stream. Particle measurements in a plasma spray at NIST are described. In this paper, we will describe our experiments with ceramic powders, in which measurements have been made at several positions along the particle stream. The particle data are represented as profiles across the particle stream, histograms of the full particle stream or time histories of the full-stream average. The results are compared and calibrated with other temperature and diagnostic measurement systems. (author)

3D-simulation of residual stresses in TBC plasma sprayed coating

International Nuclear Information System (INIS)

Kundas, S.; Kashko, T.; Hurevich, V.E.; Lugscheider, E.; Hayn, G. von; Ilyuschenko, A.

2001-01-01

Thermal barrier coatings (TBC) are used in gas turbine technology in order to protect against overheating of the nickel alloy turbine blades. This coatings allows to increase turbine inlet temperatures and improve their efficiency. Plasma spraying processes are widely used since several years in thermal barrier coating technology. Although the plasma spraying process of TBC's is largely successful, a fundamental understanding of the process parameters influencing the TBC microstructure and mechanical properties is necessary. But this investigation has received much less attention so they could lead to considerable advances in performance of plasma sprayed thermal barrier coatings. The main reason of this mate is difficulties in experimental investigation of high temperature and high velocity process. One of the most effective ways to accelerate the process optimization is the application of computer simulation for the modeling of plasma spraying. This enables the achievement of a maximum of information about the investigated process by carrying out a minimum number of experiments. The main problem of plasma spray TBC coatings is crack information during the deposition process and coating cooling. The reasons for this are quenched and residual stresses in the coating-substrate system, and peculiarities of TBC coating properties. The problem of deposition and solidification of plasma sprayed coatings have received little attention to date and remains one of the unintelligible parts of process. A fundamental understanding of heat transfer in the coating-substrate system and particles deformation processes are, however, critical for the prediction of the microstructural characteristics of the deposited coatings, the understanding of the mechanisms involved in formation of thermal stresses and defects (cracks, debonding etc.). (author)

Optimization of the spray application technology in bay laurel (Laurus nobilis).

Science.gov (United States)

Nuyttens, D; Braekman, P; Foque, D

2009-01-01

Bay laurel is an evergreen, commercially grown and expensive ornamental pot plant, which is susceptible to different pests like aphids, scale and lerp insects, thrips, caterpillars of codling moth and sooty moulds. Recently, caterpillars of the Mediterranean carnation leafroller (Cacoecimorpha pronubana) cause more and more problems. These pests can lead to important financial losses for the growers. During summer the individual pot plants are placed on a field-container in a fairly dense configuration. Crop protection is traditionally done by moving with a spray lance between the rows of pot plants and treating each individual plant from bottom to top. Good penetration is clearly an important advantages of this spray technique but it is very time-consuming, unhealthy and laborious. Some other growers use a 'spray platform' on a high-clearance tractor. Plants sprayed from this platform are exclusively approached from above resulting in an inferior spray deposition on the lower parts of the plants. To overcome the disadvantages of both available techniques, the potential of an automated tunnel sprayer was investigated. Five different nozzle types were evaluated under laboratory conditions i.e. hollow cone, standard flat fan, air inclusion flat fan, deflector flat fan and twin air inclusion flat fan at spray pressures varying from 3.0 to 7.0 bar depending on the type of nozzle. For each nozzle type, three nozzle sizes were included in the experiments which resulted in 15 different spray application techniques. All experiments were done at a speed of 2.5 km x h(-1). This resulted in three different application volumes: 2450, 4900 and 7300 l x ha(-1). After optimizing the nozzle configuration (distance and orientation) using water-sensitive paper, deposition tests with five different mineral chelates as tracer elements were performed. Filter papers were used as collectors at 20 different positions to measure spray deposition, distribution and penetration in the canopy

Optimizing Compliance and Thermal Conductivity of Plasma Sprayed Thermal Barrier Coatings via Controlled Powders and Processing Strategies

Science.gov (United States)

Tan, Yang; Srinivasan, Vasudevan; Nakamura, Toshio; Sampath, Sanjay; Bertrand, Pierre; Bertrand, Ghislaine

2012-09-01

The properties and performance of plasma-sprayed thermal barrier coatings (TBCs) are strongly dependent on the microstructural defects, which are affected by starting powder morphology and processing conditions. Of particular interest is the use of hollow powders which not only allow for efficient melting of zirconia ceramics but also produce lower conductivity and more compliant coatings. Typical industrial hollow spray powders have an assortment of densities resulting in masking potential advantages of the hollow morphology. In this study, we have conducted process mapping strategies using a novel uniform shell thickness hollow powder to control the defect microstructure and properties. Correlations among coating properties, microstructure, and processing reveal feasibility to produce highly compliant and low conductivity TBC through a combination of optimized feedstock and processing conditions. The results are presented through the framework of process maps establishing correlations among process, microstructure, and properties and providing opportunities for optimization of TBCs.

Ground experimental investigations into an ejected spray cooling system for space closed-loop application

Directory of Open Access Journals (Sweden)

Zhang Hongsheng

2016-06-01

Full Text Available Spray cooling has proved its superior heat transfer performance in removing high heat flux for ground applications. However, the dissipation of vapor–liquid mixture from the heat surface and the closed-loop circulation of the coolant are two challenges in reduced or zero gravity space environments. In this paper, an ejected spray cooling system for space closed-loop application was proposed and the negative pressure in the ejected condenser chamber was applied to sucking the two-phase mixture from the spray chamber. Its ground experimental setup was built and experimental investigations on the smooth circle heat surface with a diameter of 5 mm were conducted with distilled water as the coolant spraying from a nozzle of 0.51 mm orifice diameter at the inlet temperatures of 69.2 °C and 78.2 °C under the conditions of heat flux ranging from 69.76 W/cm2 to 311.45 W/cm2, volume flow through the spray nozzle varying from 11.22 L/h to 15.76 L/h. Work performance of the spray nozzle and heat transfer performance of the spray cooling system were analyzed; results show that this ejected spray cooling system has a good heat transfer performance and provides valid foundation for space closed-loop application in the near future.

Field experiment on spray drift: Deposition and airborne drift during application to a winter wheat crop

NARCIS (Netherlands)

Wolters, A.; Linnemann, V.; Zande, van de J.C.; Vereecken, H.

2008-01-01

A field experiment was performed to evaluate various techniques for measuring spray deposition and airborne drift during spray application to a winter wheat crop. The application of a spraying agent containing the fluorescent dye Brilliant Sulfo Flavine by a conventional boom sprayer was done

Effect of spray application technique on spray deposition in greenhouse strawberries and tomatoes.

Science.gov (United States)

Braekman, Pascal; Foque, Dieter; Messens, Winy; Van Labeke, Marie-Christine; Pieters, Jan G; Nuyttens, David

2010-02-01

Increasingly, Flemish greenhouse growers are using spray booms instead of spray guns to apply plant protection products. Although the advantages of spray booms are well known, growers still have many questions concerning nozzle choice and settings. Spray deposition using a vertical spray boom in tomatoes and strawberries was compared with reference spray equipment. Five different settings of nozzle type, size and pressure were tested with the spray boom. In general, the standard vertical spray boom performed better than the reference spray equipment in strawberries (spray gun) and in tomatoes (air-assisted sprayer). Nozzle type and settings significantly affected spray deposition and crop penetration. Highest overall deposits in strawberries were achieved using air-inclusion or extended-range nozzles. In tomatoes, the extended-range nozzles and the twin air-inclusion nozzles performed best. Using smaller-size extended-range nozzles above the recommended pressure range resulted in lower deposits, especially inside the crop canopy. The use of a vertical spray boom is a promising technique for applying plant protection products in a safe and efficient way in tomatoes and strawberries, and nozzle choice and setting should be carefully considered.

Tribological Behavior of Thermal Spray Coatings, Deposited by HVOF and APS Techniques, and Composite Electrodeposits Ni/SiC at Both Room Temperature and 300 °C

Directory of Open Access Journals (Sweden)

A. Lanzutti

2013-06-01

Full Text Available The Both the thermal spray and the electroplating coatings are widely used because of their high wear resistance combined with good corrosion resistance. In particular the addition of both micro particles or nano‐particles to the electro deposited coatings could lead to an increase of the mechanical properties, caused by the change of the coating microstructure. The thermal spray coatings were deposited following industrial standards procedures, while the Ni/SiC composite coatings were produced at laboratory scale using both micro‐and nano‐sized ceramic particles. All the produced coatings were characterized regarding their microstructure,mechanical properties and the wear resistance. The tribological properties were analyzed using a tribometer under ball on disk configuration at both room temperature and 300oC. The results showed that the cermet thermal spray coatings have a high wear resistance, while the Ni nano‐composite showed good anti wear properties compared to the harder ceramic/cermet coatings deposited by thermal spray technique.

Y2O3-MgO Nano-Composite Synthesized by Plasma Spraying and Thermal Decomposition of Solution Precursors

Science.gov (United States)

Muoto, Chigozie Kenechukwu

This research aims to identify the key feedstock characteristics and processing conditions to produce Y2O3-MgO composite coatings with high density and hardness using solution precursor plasma spray (SPPS) and suspension plasma spray (SPS) processes, and also, to explore the phenomena involved in the production of homogenized nano-composite powders of this material system by thermal decomposition of solution precursor mixtures. The material system would find potential application in the fabrication of components for optical applications such as transparent windows. It was shown that a lack of major endothermic events during precursor decomposition and the resultant formation of highly dense particles upon pyrolysis are critical precursor characteristics for the deposition of dense and hard Y2O3-MgO coatings by SPPS. Using these principles, a new Y2O3-MgO precursor solution was developed, which yielded a coating with Vickers hardness of 560 Hv. This was a considerable improvement over the hardness of the coatings obtained using conventional solution precursors, which was as low as 110 Hv. In the thermal decomposition synthesis process, binary solution precursor mixtures of: yttrium nitrate (Y[n]) or yttrium acetate (Y[a]), with magnesium nitrate (Mg[n]) or magnesium acetate (Mg[a]) were used in order to study the effects of precursor chemistry on the structural characteristics of the resultant Y2O3-MgO powders. The phase domains were coarse and distributed rather inhomogeneously in the materials obtained from the Y[n]Mg[n] and Y[a]Mg[a] mixtures; finer and more homogeneously-distributed phase domains were obtained for ceramics produced from the Y[a]Mg[n] and Y[n]Mg[a] mixtures. It was established that these phenomena were related to the thermal characteristics for the decomposition of the precursors and their effect on phase separation during oxide crystallization. Addition of ammonium acetate to the Y[n[Mg[n] mixture changed the endothermic process to exothermic

Electrically conductive, black thermal control coatings for spacecraft applications. III - Plasma-deposited ceramic matrix

Science.gov (United States)

Hribar, V. F.; Bauer, J. L.; O'Donnell, T. P.

1987-01-01

Five black, electrically-conductive thermal control coatings have been formulated and tested for application on the Galileo spacecraft. The coatings consist of both organic and inorganic systems applied on titanium, aluminum, and glass/epoxy composite surfaces. The coatings were tested under simulated space environment conditions. Coated specimens were subjected to thermal radiation, convective and combustive heating, and cryogenic conditions over a temperature range between -196 C and 538 C. Mechanical, physical, thermal, electrical, and thermooptical properties are presented for one of these coatings. This paper describes the preparation, characteristics, and spraying of iron titanate on titanium and aluminum, and presents performance results.

Microstructural evolution and growth kinetics of thermally grown oxides in plasma sprayed thermal barrier coatings

Directory of Open Access Journals (Sweden)

Xiaoju Liu

2016-02-01

Full Text Available The formation of thermally grown oxide (TGO during high temperature is a key factor to the degradation of thermal barrier coatings (TBCs applied on hot section components. In the present study both the CoNiCrAlY bond coat and ZrO2-8 wt.% Y2O3 (8YSZ ceramic coat of TBCs were prepared by air plasma spraying (APS. The composition and microstructure of TGO in TBCs were investigated using scanning electron microscopy (SEM, energy dispersive spectroscopy (EDS and X-ray diffraction (XRD analysis. The growth rate of TGO for TBC and pure BC were gained after isothermal oxidation at 1100 °C for various times. The results showed that as-sprayed bond coat consisted of β and γ/γ′phases, β phase reducesd as the oxidation time increased. The TGO comprised α-Al2O3 formed in the first 2 h. CoO, NiO, Cr2O3 and spinel oxides appeared after 20 h of oxidation. Contents of CoO and NiO reduced while that of Cr2O3 and spinel oxides increased in the later oxidation stage. The TGO eventually consisted of a sub-Al2O3 layer with columnar microstructure and the upper porous CS clusters. The TGO growth kinetics for two kinds of samples followed parabolic laws, with oxidation rate constant of 0.344 μm/h0.5 for TBCs and 0.354 μm/h0.5 for pure BCs.

40 CFR 417.150 - Applicability; description of the manufacture of spray dried detergents subcategory.

Science.gov (United States)

2010-07-01

... detergents, including but not limited to assembly and storage of raw materials, crutching, spray drying... manufacture of spray dried detergents subcategory. 417.150 Section 417.150 Protection of Environment... POINT SOURCE CATEGORY Manufacture of Spray Dried Detergents Subcategory § 417.150 Applicability...

Corrosion characteristics of several thermal spray cermet-coating/alloy systems

International Nuclear Information System (INIS)

Ashary, A.A.; Tucker, R.C. Jr.

1991-01-01

The corrosion characteristics of a thermal spray multiphase cermet coating can be quite complex. Factors such as porosity and galvanic effects between different phases in the coating and the substrate, as well as the inherent general and localized corrosion resistance of each phase, can play an important role. The present paper describes the corrosion of several cermet-coating/alloy systems as studied by a potentiodynamic cyclic polarization technique. The corrosion of these coating systems was found to be most often dominated by corrosion of the metallic phases in the coating or of the substrate alloy. (orig.)

Corrosion performance of atmospheric plasma sprayed alumina coatings on AZ31B magnesium alloy under immersion environment

OpenAIRE

D. Thirumalaikumarasamy; K. Shanmugam; V. Balasubramanian

2014-01-01

Plasma sprayed ceramic coatings are successfully used in many industrial applications, where high wear and corrosion resistance with thermal insulation are required. The alumina powders were plasma sprayed on AZ31B magnesium alloy with three different plasma spraying parameters. In the present work, the influence of plasma spray parameters on the corrosion behavior of the coatings was investigated. The corrosion behavior of the coated samples was evaluated by immersion corrosion test in 3.5 w...

Corrosion prevention of the rail by thermal spray coating of Zn-Al alloy; Zn-Al gokin yosha hifuku ni yoru reru no boshoku

Energy Technology Data Exchange (ETDEWEB)

Mizoguchi, S. [Nippon Steel Corp., Kitakyushu (Japan)] Urashima, C. [Kyushu Techno Research Corp., Fukuoka (Japan); Itai, K. [Nippon Steel Corp., Kitakyushu, Fukuoka (Japan). Technical Research Inst. of Yawata Works; Ichiriki, T.; Nishiki, M. [Kyushu Rail way comdany, Fukuoka (Japan)

1997-03-30

Replacement of the rail in under-sea tunnel such as the Kammon Tunnel is carried out very five years because of the severe corrosion caused by the humid state due to the leakage of sea water or the mist of sea water swept up by the passing trains. In this study, salt water spraying or sea water spraying test is carried out using Zn-Al alloy with the corrosion resistance and thermal spray efficiency even higher than those of Zn or Al. A rail coated by thermal spray of Zn-15mass%Al alloy has been laid by trial in the practical rail road of Kammon Tunnel for 5 years and 3 months, the deterioration degree of the coating, pitting depth, actual fatigue strength, etc. are evaluated. Further, these factors of a rail re-coated by Zincrich Primer+Tar Epoxy and a bare rail laid at the same time are evaluated for comparison. It is presumed by the results of the examination about the service life of a rail coated by the thermal spray of Zn-Al alloy based on the pitting depth in the rail base that the service life of such coated rail is more than twice as that of the bare rails used currently. 5 refs., 14 figs., 3 tabs.

Synthesis and Characterization of Calcium Phosphate Powders for Biomedical Applications by Plasma Spray Coating

OpenAIRE

Sasidharan Pillai, Rahul

2015-01-01

This PhD work mainly focus on the synthesis and characterization of calcium phosphate powders for plasma spray coating. The preparation of high temperature phase stabilized βTCP and HA/βTCP powders for plasma spray coating applications has been the topic of investigation. Nowadays plasma sprayed coatings are widely used for biomedical applications especially in the dental and orthopaedic implantation field. Previously Ti based alloys were widely used for the orthopaedic and dental implant ap...

Skin Sterility After Application of a Vapocoolant Spray Part 2.

Science.gov (United States)

Mlynek, Karolina; Lyahn, Hwang; Richards, Bryson; Schleicher, William; Bassiri Gharb, Bahar; Procop, Gary; Tuohy, Marion; Zins, James

2015-08-01

Refrigerant sprays have been used for pain relief at the time of minor office procedures. However, their sterility remains in question. This study investigates the microbiologic effect of this vapocoolant when sprayed after 70 % isopropyl alcohol skin preparation. In 50 healthy volunteers, three skin culture samples were collected: Group 1 prior to alcohol application; Group 2 after preparation with alcohol, and Group 3 after preparation with alcohol followed with vapocoolant spray. Samples were cultured in a blinded fashion and analyzed after 5 days of incubation. Gram staining was performed when cultures were positive. Bacterial growth was found in 98 % of samples prior to any skin preparation. This was reduced to 54 % after alcohol use (Group 2). Spraying with the skin refrigerant further reduced bacterial growth to 46 % (Group 3). The results showed a significant reduction in the number of positive bacterial cultures following skin preparation with alcohol and when alcohol prep was followed by vapocoolant spray (p < 0.001) compared to initial cultures. No statistical difference was observed between Groups 2 and 3 (p = 0.74). The use of the vapocoolant spray does not compromise the sterility of the skin following alcohol prep. Both 70 % isopropyl alcohol antiseptic preparation and skin preparation followed by vapocoolant spray significantly reduce skin colonization when compared to unprepared skin (p < 0.001).

High Temperature Oxidation of Spark Plasma Sintered and Thermally Sprayed FeAl-Based Iron Aluminides

Czech Academy of Sciences Publication Activity Database

Haušild, P.; Karlík, M.; Skiba, T.; Sajdl, P.; Dubský, Jiří; Palm, M.

2012-01-01

Roč. 122, č. 3 (2012), s. 465-468 ISSN 0587-4246. [International Symposium on Physics of Materials (ISPMA)/12./. Prague, 04.09.2011-08.09.2011] Institutional support: RVO:61389021 Keywords : thermal spraying * plasma sintering Subject RIV: JH - Ceramics, Fire-Resistant Materials and Glass Impact factor: 0.531, year: 2012

Study of thermal phenomena in niobium superconducting cavities when stiffened by thermal spray coating; Etude des phenomenes thermiques dans les cavites acceleratrices supraconductrices en niobium rigidifiees par projection thermique

Energy Technology Data Exchange (ETDEWEB)

Bousson, S

2000-02-01

The first objective of this thesis is to study a new superconducting cavity stiffening method based on thermal spraying. The principle is to add on the cavity external walls a copper layer using the thermal spraying process. Several tests on samples allowed to measure the thermal and mechanical properties of the layers deposited by several different processes. Measurements performed on 3 and 1.3 GHz niobium cavities, before and after copper deposition, proved the interest and feasibility of the method. The study showed the need to have very dense layers (porosity reduced to the minimum in order to have good mechanical characteristics), and not oxidised (to reduce the coating thermal resistance). As a conclusion, the spraying process performed under controlled atmosphere seems to be the most suited for superconducting cavity stiffening. The tools and analysing methods which have been developed for this study allowed to investigate other phenomena involved in the cavity thermal stability, and particularly the quench, a phenomenon often studied but not in its dynamic. A model is proposed in this thesis to analyse the quench dynamic behaviour using only the fast RF signal measurement during a quench. It has been shown that the quench propagation velocity depends essentially on the accelerating field and the niobium thermal conductivity. A study on the thermometer response time used as diagnostics on cavities proved that the transients during a quench are not efficiently measured with Allen-Bradley sensors: for this application Cernox thermometers are to be preferred due to their lower time response. The development of a thermometer acquisition device for the 3 GHz cavities, used for the study on cavity stiffening, has been adapted for anomalous heating measurements on high gradient 1.3 GHz cavities. It has been possible to prove that anomalous RF losses are responsible of the quality factor degradation, that they are not localised in a small of the cavity, but

Deposition of Coating to Protect Waste Water Reservoir in Acidic Solution by Arc Thermal Spray Process

Directory of Open Access Journals (Sweden)

Han-Seung Lee

2018-01-01

Full Text Available The corrosion characteristics of 304 stainless steel (SS and titanium (Ti coatings deposited by the arc thermal spray process in pH 4 solution were assessed. The Ti-sprayed coating exhibits uniform, less porous, and adherent coating morphology compared to the SS-sprayed coating. The electrochemical study, that is, electrochemical impedance spectroscopy (EIS, revealed that as exposure periods to solution were increased, the polarization resistance (Rp decreased and the charge transfer resistance (Rct increased owing to corrosion of the metallic surface and simultaneously at the same time the deposition of oxide films/corrosion on the SS-sprayed surface, while Ti coating transformed unstable oxides into the stable phase. Potentiodynamic studies confirmed that both sprayed coatings exhibited passive tendency attributed due to the deposition of corrosion products on SS samples, whereas the Ti-sprayed sample formed passive oxide films. The Ti coating reduced the corrosion rate by more than six times compared to the SS coating after 312 h of exposure to sulfuric acid- (H2SO4- contaminated water solution, that is, pH 4. Scanning electron microscope (SEM results confirmed the uniform and globular morphology of the passive film on the Ti coating resulting in reduced corrosion. On the other hand, the corrosion products formed on SS-sprayed coating exhibit micropores with a net-like microstructure. X-ray diffraction (XRD revealed the presence of the composite oxide film on Ti-sprayed samples and lepidocrocite (γ-FeOOH on the SS-coated surface. The transformation of TiO and Ti3O into TiO2 (rutile and anatase and Ti3O5 after 312 h of exposure to H2SO4 acid reveals the improved corrosion resistance properties of Ti-sprayed coating.

Thermal response of plasma sprayed tungsten coating to high heat flux

International Nuclear Information System (INIS)

Liu, X.; Yang, L.; Tamura, S.; Tokunaga, K.; Yoshida, N.; Noda, N.; Xu, Z.

2004-01-01

In order to investigate the thermal response of tungsten coating on carbon and copper substrates by vacuum plasma spray (VPS) or inert gas plasma spray (IPS), annealing and cyclic heat load experiments of these coatings were conducted. It is indicated that the multi-layered tungsten and rhenium interface of VPS-W/CFC failed to act as a diffusion barrier at elevated temperature and tungsten carbides were developed after 1 h incubation time when annealing temperature was higher than 1600 deg. C. IPS-W/Cu and W/C without an intermediate bonding layer were failed by the detachment of the tungsten coating at 900 and 1200 deg. C annealing for several hours, respectively. Cyclic heat load of electron beam with 35 MW/m 2 and 3-s pulse duration indicated that IPS-W/Cu samples failed with local detachment of the tungsten coating within 200 cycles and IPS-W/C showed local cracks by 300 cycles, but VPS-W/CFC withstood 1000 cycles without visible damages. However, crack creation and propagation in VPS-W/CFC were also observed under higher heat load

Analysis of several Boolean operation based trajectory generation strategies for automotive spray applications

Science.gov (United States)

Gao, Guoyou; Jiang, Chunsheng; Chen, Tao; Hui, Chun

2018-05-01

Industrial robots are widely used in various processes of surface manufacturing, such as thermal spraying. The established robot programming methods are highly time-consuming and not accurate enough to fulfil the demands of the actual market. There are many off-line programming methods developed to reduce the robot programming effort. This work introduces the principle of several based robot trajectory generation strategy on planar surface and curved surface. Since the off-line programming software is widely used and thus facilitates the robot programming efforts and improves the accuracy of robot trajectory, the analysis of this work is based on the second development of off-line programming software Robot studio™. To meet the requirements of automotive paint industry, this kind of software extension helps provide special functions according to the users defined operation parameters. The presented planning strategy generates the robot trajectory by moving an orthogonal surface according to the information of coating surface, a series of intersection curves are then employed to generate the trajectory points. The simulation results show that the path curve created with this method is successive and smooth, which corresponds to the requirements of automotive spray industrial applications.

An investigation of the effects of droplet impact angle in thermal spray deposition

International Nuclear Information System (INIS)

Smith, M.F.; Neiser, R.A.; Dykhuizen, R.C.

1994-01-01

It is widely held that spraying at off-normal angles can influence deposition efficiency and the properties of the deposited material. However, little quantitative information on such effects has been published. This paper reports on a series of experiments to investigate the angular dependence of deposition efficiency, surface roughness, and porosity for several thermal spray materials and processes at incidence angles ranging from 90 degree to 30 degree relative to the substrate surface. At incidence angles from 90 degree out to 60 degree, the observed changes were small and often statistically insignificant. Some significant changes began to appear at 45 degree, and at 30 degree significant changes were observed for nearly all materials and processes: deposition efficiency decreased while surface roughness and porosity increased. It is proposed that droplet splashing may cause some of the observed effects

Head spray nozzle in reactor pressure vessel

International Nuclear Information System (INIS)

Hatano, Shun-ichi.

1990-01-01

In a reactor pressure vessel of a BWR type reactor, a head spray nozzle is used for cooling the head of the pressure vessel and, in view of the thermal stresses, it is desirable that cooling is applied as uniformly as possible. A conventional head spray is constituted by combining full cone type nozzles. Since the sprayed water is flown down upon water spraying and the sprayed water in the vertical direction is overlapped, the flow rate distribution has a high sharpness to form a shape as having a maximum value near the center and it is difficult to obtain a uniform flow rate distribution in the circumferential direction. Then, in the present invention, flat nozzles each having a spray water cross section of laterally long shape, having less sharpness in the circumferential distribution upon spraying water to the inner wall of the pressure vessel and having a wide angle of water spray are combined, to make the flow rate distribution of spray water uniform in the inner wall of the pressure vessel. Accordingly, the pressure vessel can be cooled uniformly and thermal stresses upon cooling can be decreased. (N.H.)

Electrochemical corrosion behaviour of Mg-Al alloys with thermal spray Al/SiCp composite coatings; Comportamiento a la corrosion electroquimica de aleaciones MgAl con recubrimientos de materiales compuestos Al/SiCp mediante proyeccion termica

Energy Technology Data Exchange (ETDEWEB)

Pardo, A.; Feliu Jr, S.; Merino, M. C.; Mohedano, M.; Casajus, P.; Arrabal, R.

2010-07-01

The corrosion protection of Mg-Al alloys by flame thermal spraying of Al/SiCp composite coatings was evaluated by electrochemical impedance spectroscopy in 3.5 wt.% NaCl solution. The volume fraction of SiC particles (SiCp) varied between 5 and 30%. The as-sprayed Al/SiCp composite coatings revealed a high number of micro-channels, largely in the vicinity of the SiC particles, that facilitated the penetration of the electrolyte and the subsequent galvanic corrosion of the magnesium substrates. The application of a cold-pressing post-treatment reduced the degree of porosity of the coatings and improved the bonding at the coating/substrate and Al/SiC interfaces. This resulted in improved corrosion resistance of the coated specimens. The effectiveness of the coatings slightly decreased with the addition of 5-30 vol.% SiCp compared with the un reinforced thermal spray aluminium coatings. (Author) 31 refs.

An Overview of Spray Modeling With OpenNCC and its Application to Emissions Predictions of a LDI Combustor at High Pressure

Science.gov (United States)

Raju, M. S.

2016-01-01

The open national combustion code (Open- NCC) is developed with the aim of advancing the current multi-dimensional computational tools used in the design of advanced technology combustors. In this paper we provide an overview of the spray module, LSPRAY-V, developed as a part of this effort. The spray solver is mainly designed to predict the flow, thermal, and transport properties of a rapidly evaporating multi-component liquid spray. The modeling approach is applicable over a wide-range of evaporating conditions (normal, superheat, and supercritical). The modeling approach is based on several well-established atomization, vaporization, and wall/droplet impingement models. It facilitates large-scale combustor computations through the use of massively parallel computers with the ability to perform the computations on either structured & unstructured grids. The spray module has a multi-liquid and multi-injector capability, and can be used in the calculation of both steady and unsteady computations. We conclude the paper by providing the results for a reacting spray generated by a single injector element with 600 axially swept swirler vanes. It is a configuration based on the next-generation lean-direct injection (LDI) combustor concept. The results include comparisons for both combustor exit temperature and EINOX at three different fuel/air ratios.

The Properties of Arc-Sprayed Aluminum Coatings on Armor-Grade Steel

Directory of Open Access Journals (Sweden)

Marcin Adamiak

2018-02-01

Full Text Available This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating. Aluminum coatings were characterized in accordance with ASTM G 65-00 abrasion resistance test, ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV0.1 hardness tests and metallographic analyses. Results demonstrate properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required.

High temperature oxidation and corrosion in marine environments of thermal spray deposited coatings

International Nuclear Information System (INIS)

Chaliampalias, D.; Vourlias, G.; Pavlidou, E.; Stergioudis, G.; Skolianos, S.; Chrissafis, K.

2008-01-01

Flame spraying is a widely used technique for depositing a great variety of materials in order to enforce the mechanical or the anticorrosion characteristics of the substrate. Its high rate application is due to the rapidity of the process, its effectiveness and its low cost. In this work, flame-sprayed Al coatings are deposited on low carbon steels in order to enhance their anticorrosion performance. The main adhesion mechanism of the coating is mechanical anchorage, which can provide the necessary protection to steel used in several industrial and constructive applications. To evaluate the corrosion resistance of the coating, the as-coated samples are subjected in a salt spray chamber and in elevated temperature environments. The examination and characterization of the corroded samples is done by scanning electron microscopy and X-ray diffraction analysis. The as-formed coatings are extremely rough and have a lamellic homogeneous morphology. It is also found that Al coatings provide better protection in marine atmospheres, while at elevated temperatures a thick oxide layer is formed, which can delaminate after long oxidation periods due to its low adherence to the underlying coating, thus eliminating the substrate protection

Analytical methods to characterize heterogeneous raw material for thermal spray process: cored wire Inconel 625

Science.gov (United States)

Lindner, T.; Bonebeau, S.; Drehmann, R.; Grund, T.; Pawlowski, L.; Lampke, T.

2016-03-01

In wire arc spraying, the raw material needs to exhibit sufficient formability and ductility in order to be processed. By using an electrically conductive, metallic sheath, it is also possible to handle non-conductive and/or brittle materials such as ceramics. In comparison to massive wire, a cored wire has a heterogeneous material distribution. Due to this fact and the complex thermodynamic processes during wire arc spraying, it is very difficult to predict the resulting chemical composition in the coating with sufficient accuracy. An Inconel 625 cored wire was used to investigate this issue. In a comparative study, the analytical results of the raw material were compared to arc sprayed coatings and droplets, which were remelted in an arc furnace under argon atmosphere. Energy-dispersive X-ray spectroscopy (EDX) and X-ray fluorescence (XRF) analysis were used to determine the chemical composition. The phase determination was performed by X-ray diffraction (XRD). The results were related to the manufacturer specifications and evaluated in respect to differences in the chemical composition. The comparison between the feedstock powder, the remelted droplets and the thermally sprayed coatings allows to evaluate the influence of the processing methods on the resulting chemical and phase composition.

Progressive damage during thermal shock cycling of D-gun sprayed thermal barrier coatings with hollow spherical ZrO{sub 2}-8Y{sub 2}O{sub 3}

Energy Technology Data Exchange (ETDEWEB)

Ke, P.L. [State Key Lab for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China) and School of Metallurgy and Materials, University of Birmingham, Birmingham B15 2TT (United Kingdom)]. E-mail: csun@imr.ac.cn; Wang, Q.M. [State Key Lab for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Gong, J. [State Key Lab for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Sun, C. [State Key Lab for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Zhou, Y.C. [State Key Lab for Corrosion and Protection, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China)

2006-11-05

Thermal shock cycling behaviors of D-gun sprayed TBCs with a hollow spherical ZrO{sub 2}-8Y{sub 2}O{sub 3} (HSP-YSZ) top coat and NiCrAlY bond coat on directionally solidified Ni-base superalloys DZ125 were investigated at high temperature (1100 deg. C) {r_reversible} room temperature (RT) repeatedly by water quenching. Scanning electron microscopy (SEM) was used to characterize the coating microstructure and failure morphology. The results showed that failure of the D-gun sprayed TBC starts with crack initiation along the splats boundary in the ceramic top coat and the non-alumina oxides. The cracks propagate and coalesce with the increasing thermal cycling. The extensive cracking of the rapidly formed non-alumina oxides, resulting from the depletion of aluminum in the bond coat, aids to delamination of the outer ceramic layer. The stress distributions in TGO layer at different thermal shock cycles was measured by luminescence spectroscopy to investigate the failure mechanism of TBC system.

Corrosion And Thermal Processing In Cold Gas Dynamic Spray Deposited Austenitic Stainless Steel Coatings

Science.gov (United States)

2016-06-01

Champagne have demonstrated this use of the cold spray technique in the repair of helicopter mast supports in U.S. Army aircraft, with over 50...Process: Fundamentals and Applications, Champagne , V. K., Ed., Woodhead, Boca Raton, FL Chap. 3. [3] Schiel, J. F., 2014, “The cold gas-dynamic spray... Champagne , V. K., Ed., Woodhead, Boca Raton, FL Chap. 2. [15] Han, W., Meng, X. M., Zhang, J. B., and Zhao, J., 2012, “Elastic modulus of 304 stainless

Method and Process Development of Advanced Atmospheric Plasma Spraying for Thermal Barrier Coatings

Science.gov (United States)

Mihm, Sebastian; Duda, Thomas; Gruner, Heiko; Thomas, Georg; Dzur, Birger

2012-06-01

Over the last few years, global economic growth has triggered a dramatic increase in the demand for resources, resulting in steady rise in prices for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened potential of savings and form the basis for securing future competitive advantages in the market. In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the optimization of the APS coating process is the use of the existing coating equipment. Furthermore, the current coating quality and characteristics must not change so as to avoid new qualification and testing. Using experience in APS and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow-rate, the electrical power, the arrangement and angle of the powder injectors in relation to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedures such as spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity and temperature), powder injection conditions (injection point, injection speed, grain size and distribution) and the coating lamination (coating pattern and spraying distance) are examined. The optimized process and resulting coating were compared to the current situation using several diagnostic methods. The improved process significantly reduces costs and achieves the requirement of comparable coating quality. Furthermore, a contribution was made towards better comprehension of the APS of ceramics and the definition of a better method for future process developments.

Enhanced ductility in thermally sprayed titania coating synthesized using a nanostructured feedstock

International Nuclear Information System (INIS)

Lima, R.S.; Marple, B.R.

2005-01-01

Nanostructured and conventional titania (TiO 2 ) feedstock powders were thermally sprayed via high velocity oxy-fuel (HVOF). The microstructure, porosity, Vickers hardness, crack propagation resistance, bond strength (ASTM C633), abrasion behavior (ASTM G65) and the wear scar characteristics of these two types of coatings were analyzed and compared. The coating made from the nanostructured feedstock exhibited a bimodal microstructure, with regions containing particles that were fully molten (conventional matrix) and regions with embedded particles that were semi-molten (nanostructured zones) during the thermal spraying process. The bimodal coating also exhibited higher bond strength and higher wear resistance when compared to the conventional coating. By comparing the wear scars of both coatings (via scanning electron microscopy and roughness measurements) it was observed that when the coatings were subjected to the same abrasive conditions the wear scar of the bimodal coating was smoother, with more plastically deformed regions than the conventional coating. It was concluded that this enhanced ductility of the bimodal coating was caused by its higher toughness. The results suggest that nanostructured zones randomly distributed in the microstructure of the bimodal coating act as crack arresters, thereby enhancing toughness and promoting higher critical depth of cut, which provides a broader plastic deformation range than that exhibited by the conventional coating. This work provides evidence that the enhanced ductility of the bimodal coating is a nanostructured-related property, not caused by any other microstructural artifact

High-speed flame spraying, an alternative process for producing thermal insulation layers; Hochgeschwindigkeitsflammspritzen - Ein alternatives Verfahren zum Herstellen von Waermedaemmschichten

Energy Technology Data Exchange (ETDEWEB)

Steffens, H.D.; Wilden, J.; Josefiak, L.; Moebus, S. [Dortmund Univ. (Germany). Lehrstuhl fuer Werkstofftechnologie

1996-12-31

Ceramic thermal insulation layers on a ZrO{sub 2} basis produced by high-speed flame spraying differ in their structure from layers produced by atmospheric plasma spraying. If suitable powder modifications are chosen, the reulting layer structure can compensate thermally induced stresses efficiently. The layers also had a higher thermoshock resistance than APS layers. [Deutsch] Mittels Hochgeschwindigkeitsflammspritzens erzeugte keramische Waermedaemmschichten auf Basis von ZrO{sub 2} unterscheiden sich bezueglich ihrer Gefuegestruktur deutlich von atmosphaerisch plasmagespritzten WDS. Bei der Wahl geeigneter Pulvermodifikationen ermoeglicht die entstehende Schichtstruktur in hohem Mass den Ausgleich thermisch induzierter Spannungen. In vergleichenden Thermoschockversuchen erreichten HGFS-gespritzte WDS bei gleicher thermischer Isolationsfaehigkeit bessere Werte der Thermoschockbestaendigkeit als ASP-gespritzte. (orig.)

Development and Preliminary Evaluation of a Spray Deposition Sensing System for Improving Pesticide Application.

Science.gov (United States)

Kesterson, Melissa A; Luck, Joe D; Sama, Michael P

2015-12-17

An electronic, resistance-based sensor array and data acquisition system was developed to measure spray deposition from hydraulic nozzles. The sensor surface consisted of several parallel tin plated copper traces of varying widths with varying gap widths. The system contained an embedded microprocessor to monitor output voltage corresponding to spray deposition every second. In addition, a wireless module was used to transmit the voltage values to a remote laptop. Tests were conducted in two stages to evaluate the performance of the sensor array in an attempt to quantify the spray deposition. Initial tests utilized manual droplet placement on the sensor surface to determine the effects of temperature and droplet size on voltage output. Secondary testing utilized a spray chamber to pass nozzles at different speeds above the sensor surface to determine if output varied based on different application rates or spray droplet classification. Results from this preliminary analysis indicated that manual droplets of 5 and 10 μL resulted in significantly different values from the sensors while temperature did not consistently affect output. Spray chamber test results indicated that different application rates and droplet sizes could be determined using the sensor array.

Validation of HVOF WC/Co Thermal Spray Coatings as a Replacement for Hard Chrome Plating on Aircraft Landing Gear

National Research Council Canada - National Science Library

Sartwell, Bruce

2004-01-01

.... This document constitutes the final report on a project to quality high-velocity oxygen-fuel (HVOF) thermal spray WC/Co coatings as a replacement for hard chrome plating on landing gear components...

Effect of spray angle and spray volume on deposition of a medium droplet spray with air support in ivy pot plants.

Science.gov (United States)

Foqué, Dieter; Pieters, Jan G; Nuyttens, David

2014-03-01

Spray boom systems, an alternative to the predominantly-used spray guns, have the potential to considerably improve crop protection management in glasshouses. Based on earlier experiments, the further optimization of the deposits of a medium spray quality extended range flat fan nozzle type using easy adjustable spray boom settings was examined. Using mineral chelate tracers and water sensitive papers, the spray results were monitored at three plant levels, on the upper side and the underside of the leaves, and on some off-target collectors. In addition, the deposition datasets of all tree experiments were compared. The data showed that the most efficient spray distribution with the medium spray quality flat fan nozzles was found with a 30° forward angled spray combined with air support and an application rate of 1000 L ha(-1) . This technique resulted in a more uniform deposition in the dense canopy and increased spray deposition on the lower side of the leaves compared with the a standard spray boom application. Applying 1000 L ha(-1) in two subsequent runs instead of one did not seem to show any added value. Spray deposition can be improved hugely simply by changing some spray boom settings like nozzle type, angling the spray, using air support and adjusting the spray volume to the crop. © 2013 Society of Chemical Industry.

Yb2Si2O7 Environmental Barrier Coatings Deposited by Various Thermal Spray Techniques: A Preliminary Comparative Study

Science.gov (United States)

Bakan, Emine; Marcano, Diana; Zhou, Dapeng; Sohn, Yoo Jung; Mauer, Georg; Vaßen, Robert

2017-08-01

Dense, crack-free, uniform, and well-adhered environmental barrier coatings (EBCs) are required to enhance the environmental durability of silicon (Si)-based ceramic matrix composites in high pressure, high gas velocity combustion atmospheres. This paper represents an assessment of different thermal spray techniques for the deposition of Yb2Si2O7 EBCs. The Yb2Si2O7 coatings were deposited by means of atmospheric plasma spraying (APS), high-velocity oxygen fuel spraying (HVOF), suspension plasma spraying (SPS), and very low-pressure plasma spraying (VLPPS) techniques. The initial feedstock, as well as the deposited coatings, were characterized and compared in terms of their phase composition. The as-sprayed amorphous content, microstructure, and porosity of the coatings were further analyzed. Based on this preliminary investigation, the HVOF process stood out from the other techniques as it enabled the production of vertical crack-free coatings with higher crystallinity in comparison with the APS and SPS techniques in atmospheric conditions. Nevertheless, VLPPS was found to be the preferred process for the deposition of Yb2Si2O7 coatings with desired characteristics in a controlled-atmosphere chamber.

Sequential cryogen spraying for heat flux control at the skin surface

Science.gov (United States)

Majaron, Boris; Aguilar, Guillermo; Basinger, Brooke; Randeberg, Lise L.; Svaasand, Lars O.; Lavernia, Enrique J.; Nelson, J. Stuart

2001-05-01

Heat transfer rate at the skin-air interface is of critical importance for the benefits of cryogen spray cooling in combination with laser therapy of shallow subsurface skin lesions, such as port-wine stain birthmarks. With some cryogen spray devices, a layer of liquid cryogen builds up on the skin surface during the spurt, which may impair heat transfer across the skin surface due to relatively low thermal conductivity and potentially higher temperature of the liquid cryogen layer as compared to the spray droplets. While the mass flux of cryogen delivery can be adjusted by varying the atomizing nozzle geometry, this may strongly affect other spray properties, such as lateral spread (cone), droplet size, velocity, and temperature distribution. We present here first experiments with sequential cryogen spraying, which may enable accurate mass flux control through variation of spray duty cycle, while minimally affecting other spray characteristics. The observed increase of cooling rate and efficiency at moderate duty cycle levels supports the above described hypothesis of isolating liquid layer, and demonstrates a novel approach to optimization of cryogen spray devices for individual laser dermatological applications.

NACOM - a code for sodium spray fire analysis

International Nuclear Information System (INIS)

Rao, P.M.; Kannan, S.E.

2002-01-01

Full text: In liquid metal fast breeder reactors (LMFBR), leakage of sodium can result in a spray fire. Because of higher burning rates in droplet form combustion of sodium in spray fire, thermal consequences are more severe than that in a sodium pool fire. The code NACOM was developed for the analysis of sodium spray fires in LMFBRs facilities. The code uses the validated model for estimating the falling droplet burning rates in pre-ignition and vapour phase combustion stages. It uses a distribution system to generate the droplet groups of different diameters that represent the spray. The code requires about 20 input parameters like sodium leak rates, sodium temperature, initial cell conditions like oxygen concentration, temperature and dimensions. NACOM is a validated code based on experiments with sodium inventory up to 650 kg in 0 to 21 % O 2 atmospheres. The paper brings out the salient features of the code along with the sensitivity analysis of the main input parameters like spray volume mean diameter, oxygen concentration etc. based on the results obtained. The limitations of the code and the confidence margins applicable to results obtained are also brought out

Effect of the spray application technique on the deposition of entomopathogenic nematodes in vegetables.

Science.gov (United States)

Brusselman, Eva; Beck, Bert; Pollet, Sabien; Temmerman, Femke; Spanoghe, Pieter; Moens, Maurice; Nuyttens, David

2012-03-01

The present study compared entomopathogenic nematode delivery at the base of savoy cabbage and cauliflower, at the lower side of savoy cabbage and cauliflower leaves and in leek stems and the ground deposition using a five-nozzle spray boom equipped with an ISO 08 flat fan, an air induction flat fan and Twinjet spray nozzles. Additionally, an air support system and a row application system were evaluated. Approximately 40% of the applied nematodes did not reach the foot of the cabbage plants. The use of an air support system or a row application system improved nematode deposition at the savoy cabbage base. Relative nematode deposition on the lower side of savoy cabbage leaves was 27.20%, while only 2.64% of the applied nematodes reached the lower side of cauliflower leaves. After spraying leek with a standard boom, a low relative nematode deposition (26.64%) was measured in the leek stem. Nozzle type affected the distribution of nematodes in droplet spots. Nozzle type has a minor effect on the number of entomopathogenic nematodes delivered on difficult-to-reach targets. The use of modified spray application techniques directing the spray to the target site are necessary to increase the chances of contact of entomopathogenic nematodes with their target. Copyright © 2011 Society of Chemical Industry.

Spray characteristics and spray cooling heat transfer in the non-boiling regime

International Nuclear Information System (INIS)

Cheng, Wen-Long; Han, Feng-Yun; Liu, Qi-Nie; Fan, Han-Lin

2011-01-01

Spray cooling is an effective method for dissipating high heat fluxes in the field of electronics thermal control. In this study, experiments were performed with distilled water as a test liquid to study the spray cooling heat transfer in non-boiling regime. A Phase Doppler Anemometry (PDA) was used to study the spray characteristics. The effects of spray flow rate, spray height, and inlet temperature on spray cooling heat transfer were investigated. It was found that the parameters affect heat transfer of spray cooling in non-boiling regime by the spray characteristics and working fluid thermophysical properties. Then the corresponding droplet axial velocity and Sauter mean diameter (SMD) were successfully correlated with mean absolute error of 15%, which were based upon the orifice diameter, the Weber and Reynolds numbers of the orifice flow prior to liquid breakup, dimensionless spray height and spray cross-section radius. The heat transfer in non-boiling regime was correlated with a mean absolute error of 7%, which was mainly associated with the working fluid thermophysical properties, the Weber and Reynolds numbers hitting the heating surface, dimensionless heating surface temperature and diameter. -- Highlights: → The spray flow rate, spray height, and inlet temperature affect heat transfer of spray cooling in non-boiling regime by the spray characteristics and the working fluid thermophysical properties. → Then the corresponding droplet axial velocity and Sauer mean diameter (SMD) were successfully correlated with mean absolute error of 15%. → The heat transfer in non-boiling regime was correlated with a mean absolute error of 7%.

Substrate system for spray forming

Energy Technology Data Exchange (ETDEWEB)

Chu, Men G. (Export, PA); Chernicoff, William P. (Harrisburg, PA)

2002-01-01

A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

SiC fiber and yttria-stabilized zirconia composite thick thermal barrier coatings fabricated by plasma spray

Science.gov (United States)

Ma, Rongbin; Cheng, Xudong; Ye, Weiping

2015-12-01

Approximately 4 mm-thick SiC fiber/yttria-stabilized zirconia (YSZ) composite thermal barrier coatings (TBCs) were prepared by atmospheric plasma spray (APS). The composite coatings have a 'reinforced concrete frame structure', which can protect the coating from failure caused by increasing thickness of coating. The SiC fiber plays an important role in reducing the residual stress level of the composite coatings. The thermal conductivity (TC) value of the composite coatings is 0.632 W/m K, which is about 50% reduction compared to that of typical APS YSZ TBCs. And the composite coatings have higher fracture toughness and better thermal shock resistance than the YSZ TBCs.

Review and evaluation of information on the thermal performance of ultimate heat sinks: spray ponds and cooling ponds

International Nuclear Information System (INIS)

Drake, R.L.

1975-09-01

A report is presented which identifies and evaluates available information and data useful in validating and improving existing models for the thermal performance of ultimate heat sinks. Included are discussions of the thermal elements of cooling ponds and spray ponds, the available information and data pertinent to the problem, and the requirements and needs for further research and performance data. An outline is presented of the necessary elements required for a performance test of an ultimate heat sink before the system is thermally approved. (auth)

WC-Co coatings deposited by the electro-thermal chemical spray method

Energy Technology Data Exchange (ETDEWEB)

Zhitomirsky, V.N. [Tel Aviv Univ. (Israel). Faculty of Engineering; Wald, S.; Rabani, L.; Zoler, D. [Propulsion Physics Division, SOREQ NRC, 81800, Yavne (Israel); Factor, M.; Roman, I. [School of Applied Sciences, The Hebrew University, 91904, Jerusalem (Israel); Cuperman, S.; Bruma, C. [School of Physics and Astronomy, Tel-Aviv University, 69978, Tel-Aviv (Israel)

2000-10-02

A novel thermal spray technology - an electro-thermal chemical spray (ETCS) for producing hard coatings is presented. The experimental coating apparatus consists of a machine gun barrel, a cartridge containing the coating material in powder form, a solid propellant, and a plasma ignition system. The plasma ignition system produces plasma in pulsed mode to ignite the solid propellant. On ignition, the drag force exerted by the combustion gases accelerates the powder particles towards the substrate. Using the ETCS technique, the process of single-shot WC-Co coating deposition on stainless steel substrate was studied. The influence of process parameters (plasma energy, mass of the solid propellant and the coated powder, distance between the gun muzzle and the substrate) on the coating structure and some of its properties were investigated. It was shown that ECTS technique effectively deposited the WC-Co coating with deposition thicknesses of 100-200 {mu}m per shot, while deposition yield of {proportional_to}70% was attained. The WC-Co coatings consisted of carbide particles distributed in amorphous matrix. The powder particle velocity was found to depend on the solid propellant mass and was weakly dependent on the plasma energy, while the particle processing temperature was strongly dependent on the plasma energy and almost independent of the solid propellant mass. Whilst increasing the solid propellant mass from 5 to 7 g, the deposition rate and yield correspondingly increased. When increasing the plasma energy, the temperature of the powder particles increased, the average carbide particle size decreased and their shape became more rounded. The deposition yield and microhardness at first increased and then achieved saturation by increasing the plasma energy. (orig.)

Impact of sea spray on the Yellow and East China Seas thermal structure during the passage of Typhoon Rammasun (2002)

Science.gov (United States)

Zhang, Lianxin; Zhang, Xuefeng; Chu, P. C.; Guan, Changlong; Fu, Hongli; Chao, Guofang; Han, Guijun; Li, Wei

2017-10-01

Strong winds lead to large amounts of sea spray in the lowest part of the atmospheric boundary layer. The spray droplets affect the air-sea heat fluxes due to their evaporation and the momentum due to the change of sea surface, and in turn change the upper ocean thermal structure. In this study, impact of sea spray on upper ocean temperatures in the Yellow and East China Seas (YES) during typhoon Rammasun's passage is investigated using the POMgcs ocean model with a sea spray parameterization scheme, in which the sea spray-induced heat fluxes are based on an improved Fairall's sea spray heat fluxes algorithm, and the sea spray-induced momentum fluxes are derived from an improved COARE version 2.6 bulk model. The distribution of the sea spray mediated turbulent fluxes was primarily located at Rammasun eye-wall region, in accord with the maximal wind speeds regions. When Rammasun enters the Yellow sea, the sea spray mediated latent (sensible) heat flux maximum is enhanced by 26% (13.5%) compared to that of the interfacial latent (sensible) heat flux. The maximum of the total air-sea momentum fluxes is enhanced by 43% compared to the counterpart of the interfacial momentum flux. Furthermore, the sea spray plays a key role in enhancing the intensity of the typhoon-induced "cold suction" and "heat pump" processes. When the effect of sea spray is considered, the maximum of the sea surface cooling in the right side of Rammasun's track is increased by 0.5°C, which is closer to the available satellite observations.

An analysis of heat removal during cryogen spray cooling and effects of simultaneous airflow application.

Science.gov (United States)

Torres, J H; Tunnell, J W; Pikkula, B M; Anvari, B

2001-01-01

Cryogen spray cooling (CSC) is a method used to protect the epidermis from non-specific thermal injury that may occur as a result of various dermatological laser procedures. However, better understanding of cryogen deposition and skin thermal response to CSC is needed to optimize the technique. Temperature measurements and video imaging were carried out on an epoxy phantom as well as human skin during CSC with and without simultaneous application of airflow which was intended to accelerate cryogen evaporation from the substrate surface. An inverse thermal conduction model was used to estimate heat flux and total heat removed. Lifetime of the cryogen film deposited on the surface of skin and epoxy phantom lasted several hundred milliseconds beyond the spurt, but could be reduced to the spurt duration by application of airflow. Values over 100 J/cm(3) were estimated for volumetric heat removed from the epidermis using CSC. "Film cooling" instead of "evaporative cooling" appears to be the dominant mode of CSC on skin. Estimated values of heat removed from the epidermis suggest that a cryogen spurt as long as 200 milliseconds is required to counteract heat generated by high laser fluences (e.g., in treatment of port wine stains) in patients with high concentration of epidermal melanin. Additional cooling beyond spurt termination can be avoided by simultaneous application of airflow, although it is unclear at the moment if avoiding the additional cooling would be beneficial in the actual clinical situation. Copyright 2001 Wiley-Liss, Inc.

Field experiment on spray drift: deposition and airborne drift during application to a winter wheat crop.

Science.gov (United States)

Wolters, André; Linnemann, Volker; van de Zande, Jan C; Vereecken, Harry

2008-11-01

A field experiment was performed to evaluate various techniques for measuring spray deposition and airborne drift during spray application to a winter wheat crop. The application of a spraying agent containing the fluorescent dye Brilliant Sulfo Flavine by a conventional boom sprayer was done according to good agricultural practice. Deposition was measured by horizontal collectors in various arrangements in and outside the treated area. Airborne spray drift was measured both with a passive and an active air collecting system. Spray deposits on top of the treated canopy ranged between 68 and 71% of the applied dose and showed only small differences for various arrangements of the collectors. Furthermore, only small variations were measured within the various groups of collectors used for these arrangements. Generally, the highest spray deposition outside the treated area was measured close to the sprayed plot and was accompanied by a high variability of values, while a rapid decline of deposits was detected in more remote areas. Estimations of spray deposits with the IMAG Drift Calculator were in accordance with experimental findings only for areas located at a distance of 0.5-4.5 m from the last nozzle, while there was an overestimation of a factor of 4 at a distance of 2.0-3.0 m, thus revealing a high level of uncertainty of the estimation of deposition for short distances. Airborne spray drift measured by passive and active air collecting systems was approximately at the same level, when taking into consideration the collector efficiency of the woven nylon wire used as sampling material for the passive collecting system. The maximum value of total airborne spray drift for both spray applications (0.79% of the applied dose) was determined by the active collecting system. However, the comparatively high variability of measurements at various heights above the soil by active and passive collecting systems revealed need for further studies to elucidate the spatial

Protection by high velocity thermal spraying coatings on thick walled permanent and interim store components for the diminution of repairs, corrosion and costs 'SHARK'. Overview at the end of the project

International Nuclear Information System (INIS)

Behrens, Sabine; Hassel, Thomas; Bach, Friedrich-Wilhelm

2012-01-01

The corrosion protection of the internal space of thick-walled interim and permanent storage facility components, such as Castor copyright containers, are ensured nowadays by a galvanic nickel layer. The method has proved itself and protects the base material of the containers at the underwater loading in the Nuclear power station from a corrosive attack. Although, the galvanic nickel plating is a relatively time consuming method, it lasts for several days for each container, and is with a layer thickness of 1,000 μm also expensive. To develop an alternative, faster and more economical method, a BMBF research project named - 'SHARK - protection by high velocity thermal spraying layers on thick-walled permanent and interim store components for the diminution of repairs, corrosion and costs' in cooperation between Siempelkamp Nukleartechnik GmbH and the Institute of Materials Science of the Leibniz University of Hanover was established to investigate the suitability of the high velocity oxy fuel spraying technology (HVOF) for the corrosion protective coating of thickwalled interim and permanent storage facility components. Since the permanent storage depot components are manufactured from cast iron with globular graphite, this material was exclusively used as a base material in this project. The evaluation of the economical features of the application of different nickel base spraying materials on cast iron substratum was in focus, as well as the scientific characterization of the coating systems with regard to the corrosion protective properties. Furthermore, the feasibility of the transfer of the laboratory results on a large industrial setup as well as a general suitability of the coating process for a required repair procedure was to be investigated. The preliminary examination program identified chromium containing spraying materials as successful. Results of the preliminary examination program have been used for investigations with the CASOIK demonstration

Pesticide residues in individual versus composite samples of apples after fine or coarse spray quality application

NARCIS (Netherlands)

Poulsen, M.; Wenneker, M.; Withagen, J.C.M.; Christensen, H.B.

2012-01-01

In this study, field trials on fine and coarse spray quality application of pesticides on apples were performed. The main objectives were to study the variation of pesticide residue levels in individual fruits versus composite samples, and the effect of standard fine spray quality application versus

Improved methods for testing bond and intrinsic strength and fatigue of thermally sprayed metallic and ceramic coatings

International Nuclear Information System (INIS)

Schweitzer, K.K.; Ziehl, M.H.; Schwaminger, C.

1991-01-01

Conventional bond strength tests for thermally sprayed coatings represent only a rough means of obtaining overall strength values, with no differentiation between adhesion at the interface and intrinsic coating properties. In order to obtain information about the influence of substrate surface preparation on the adhesion of a Tribaloy T700 coating, tensile bond strength and modified crack-opening displacement (COD) specimens were tested by deliberate crack initiation at the interface. Crack initiation was achieved by weakening of the interface at the outer diameter in the case of bond strength specimens or at the notch root in the case of COD specimens. This made it possible to look at the influence of surface roughness and grit contamination on the coating adhesion separately. Modified COD specimens with the notch in the centre of the coating were used to determine crack-opening energies and critical stress intensity factors of atmospheric plasma-sprayed NiAl and low pressure plasma-sprayed CoNiCrAlY bond coatings and a ZrO 2 7Y 2 O 3 thermal barrier coating (TBC). Additionally, bond strength specimens were stressed dynamically, and it could be demonstrated that Woehler (S/N) diagrams can be established for a metallic NiAl bond coating and even for a ceramic ZrO 2 7Y 2 O 3 TBC. (orig.)

Status of emergency spray modelling in the integral code ASTEC

International Nuclear Information System (INIS)

Plumecocq, W.; Passalacqua, R.

2001-01-01

Containment spray systems are emergency systems that would be used in very low probability events which may lead to severe accidents in Light Water Reactors. In most cases, the primary function of the spray would be to remove heat and condense steam in order to reduce pressure and temperature in the containment building. Spray would also wash out fission products (aerosols and gaseous species) from the containment atmosphere. The efficiency of the spray system in the containment depressurization as well as in the removal of aerosols, during a severe accident, depends on the evolution of the spray droplet size distribution with the height in the containment, due to kinetic and thermal relaxation, gravitational agglomeration and mass transfer with the gas. A model has been developed taking into account all of these phenomena. This model has been implemented in the ASTEC code with a validation of the droplets relaxation against the CARAIDAS experiment (IPSN). Applications of this modelling to a PWR 900, during a severe accident, with special emphasis on the effect of spray on containment hydrogen distribution have been performed in multi-compartment configuration with the ASTEC V0.3 code. (author)

High-volume use of self-cementing spray dry absorber material for structural applications

Science.gov (United States)

Riley, Charles E.

Spray dry absorber (SDA) material, or spray dryer ash, is a byproduct of energy generation by coal combustion and sulfur emissions controls. Like any resource, it ought to be used to its fullest potential offsetting as many of the negative environmental impacts of coal combustion as possible throughout its lifecycle. Its cementitious and pozzolanic properties suggest it be used to augment or replace another energy and emissions intensive product: Portland cement. There is excellent potential for spray dryer ash to be used beneficially in structural applications, which will offset CO2 emissions due to Portland cement production, divert landfill waste by further utilizing a plentiful coal combustion by-product, and create more durable and sustainable structures. The research into beneficial use applications for SDA material is relatively undeveloped and the material is highly underutilized. This dissertation explored a specific self-cementing spray dryer ash for use as a binder in structural materials. Strength and stiffness properties of hydrated spray dryer ash mortars were improved by chemical activation with Portland cement and reinforcement with polymer fibers from automobile tire recycling. Portland cement at additions of five percent of the cementitious material was found to function effectively as an activating agent for spray dryer ash and had a significant impact on the hardened properties. The recycled polymer fibers improved the ductility and toughness of the material in all cases and increased the compressive strength of weak matrix materials like the pure hydrated ash. The resulting hardened materials exhibited useful properties that were sufficient to suggest that they be used in structural applications such as concrete, masonry block, or as a hydraulic cement binder. While the long-term performance characteristics remain to be investigated, from an embodied-energy and carbon emissions standpoint the material investigated here is far superior to

Cold Spray for Repair of Magnesium Components

Science.gov (United States)

2011-11-01

Readiness Center East GM General Motors He helium hex-Cr hexavalent chromium HP-Al High Purity Aluminum HVOF High Velocity Oxygen Fuel ID inner...process is the hexavalent chromium (hex-Cr) permissible exposure limit (PEL) as established by the Occupational Safety and Health Administration (OSHA...project related to replacement of hard chrome plating on helicopter dynamic components using HVOF thermal spray coatings. FRC-E has a thermal spray

Characterization of plasma sprayed NiCrAlY-Yttria stabilized zirconia coatings

International Nuclear Information System (INIS)

Bhave, V.S.; Rakhasia, R.H.; Tripathy, P.K.; Hubli, R.C.; Sengupta, P.; Bhanumurthy; Satpute, R.U.; Sreekumar, K.P.; Thiyagarajan, T.K.; Padmanabhan, P.V.A.

2004-01-01

Plasma sprayed coatings of yttria stabilized zirconia are used in many advanced technologies for thermal and chemical barrier applications. Development and characterization of NiCrAlY-yttria stabilized zirconia duplex coatings on Inconel substrates is reported in this paper. Plasma spraying was carried out using the 40 kW atmospheric plasma spray facility at the Laser and Plasma Technology Division, BARC. A bond coat of NiCrAlY was deposited on Inconel substrates and yttria stabilized zirconia (YSZ) was deposited over the bond coat. The coatings have been characterized by x-ray diffraction and EPMA. It is observed that the coating characteristics are affected by the input power to the torch. (author)

Plasma sprayed coatings on crankshaft used steels

Science.gov (United States)

Mahu, G.; Munteanu, C.; Istrate, B.; Benchea, M.

2017-08-01

Plasma spray coatings may be an alternative to conventional heat treatment of main journals and crankpins of the crankshaft. The applications of plasma coatings are various and present multiple advantages compared to electric arc wire spraying or flame spraying. The study examines the layers sprayed with the following powders: Cr3C2- 25(Ni 20Cr), Al2O3- 13TiO2, Cr2O3-SiO2- TiO2 on the surface of steels used in the construction of a crankshaft (C45). The plasma spray coatings were made with the Spray wizard 9MCE facility at atmospheric pressure. The samples were analyzed in terms of micro and morphological using optical microscopy, scanning electron microscopy and X-ray diffraction. Wear tests on samples that have undergone simulates extreme working conditions of the crankshafts. In order to emphasize adherence to the base material sprayed layer, were carried out tests of microscratches and micro-indentation. Results have showed a relatively compact morphological aspect given by the successive coatings with splat-like specific structures. Following the microscratch analysis it can be concluded that Al2O3-13TiO2 coating has a higher purpose in terms of hardness compared to Cr3C2-(Ni 20Cr) and Cr2O3-SiO2- TiO2 powders. Thermal coatings of the deposited powders have increased the mechanical properties of the material. The results stand to confirm that plasma sprayed Al2O3-13TiO2 powder is in fact a efficient solution for preventing mechanical wear, even with a faulty lubrication system.

Hard tissue ablation with a spray-assisted mid-IR laser

International Nuclear Information System (INIS)

Kang, H W; Rizoiu, I; Welch, A J

2007-01-01

The objective of this study was to understand the dominant mechanism(s) for dental enamel ablation with the application of water spray. A free-running Er,Cr:YSGG (yttrium, scandium, gallium, garnet) laser was used to ablate human enamel tissue at various radiant exposures. During dental ablation, distilled water was sprayed on the sample surface, and these results were compared to ablation without a spray (dry ablation). In order to identify dominant ablation mechanisms, transient acoustic waves were compared to ablation thresholds and the volume of material removed. The ablation profile and depth were measured using optical coherence tomography (OCT). Irregular surface modification, charring and peripheral cracks were associated with dry ablation, whereas craters for spray samples were relatively clean without thermal damage. In spite of a 60% higher ablation threshold for spray associated irradiations owing to water absorption, acoustic peak pressures were six times higher and ablation volume was up to a factor of 2 larger compared to dry ablation. The enhanced pressure and ablation performance of the spray-assisted process was the result of rapid water vaporization, material ejection with recoil stress, interstitial water explosion and possibly liquid-jet formation. With water cooling and abrasive/disruptive mechanical effects, the spray ablation can be a safe and efficient modality for dental treatment

Hard tissue ablation with a spray-assisted mid-IR laser

Science.gov (United States)

Kang, H. W.; Rizoiu, I.; Welch, A. J.

2007-12-01

The objective of this study was to understand the dominant mechanism(s) for dental enamel ablation with the application of water spray. A free-running Er,Cr:YSGG (yttrium, scandium, gallium, garnet) laser was used to ablate human enamel tissue at various radiant exposures. During dental ablation, distilled water was sprayed on the sample surface, and these results were compared to ablation without a spray (dry ablation). In order to identify dominant ablation mechanisms, transient acoustic waves were compared to ablation thresholds and the volume of material removed. The ablation profile and depth were measured using optical coherence tomography (OCT). Irregular surface modification, charring and peripheral cracks were associated with dry ablation, whereas craters for spray samples were relatively clean without thermal damage. In spite of a 60% higher ablation threshold for spray associated irradiations owing to water absorption, acoustic peak pressures were six times higher and ablation volume was up to a factor of 2 larger compared to dry ablation. The enhanced pressure and ablation performance of the spray-assisted process was the result of rapid water vaporization, material ejection with recoil stress, interstitial water explosion and possibly liquid-jet formation. With water cooling and abrasive/disruptive mechanical effects, the spray ablation can be a safe and efficient modality for dental treatment.

Effects of nozzle type and spray angle on spray deposition in ivy pot plants.

Science.gov (United States)

Foqué, Dieter; Nuyttens, David

2011-02-01

Fewer plant protection products are now authorised for use in ornamental growings. Frequent spraying with the same product or a suboptimal technique can lead to resistance in pests and diseases. Better application techniques could improve the sustainable use of the plant protection products still available. Spray boom systems--instead of the still predominantly used spray guns--might improve crop protection management in greenhouses considerably. The effect of nozzle type, spray pressure and spray angle on spray deposition and coverage in ivy pot plants was studied, with a focus on crop penetration and spraying the bottom side of the leaves in this dense crop. The experiments showed a significant and important effect of collector position on deposition and coverage in the plant. Although spray deposition and coverage on the bottom side of the leaves are generally low, they could be improved 3.0-4.9-fold using the appropriate application technique. When using a spray boom in a dense crop, the nozzle choice, spray pressure and spray angle should be well considered. The hollow-cone, the air-inclusion flat-fan and the standard flat-fan nozzle with an inclined spray angle performed best because of the effect of swirling droplets, droplets with a high momentum and droplet direction respectively. Copyright © 2010 Society of Chemical Industry.

Plasma-sprayed tantalum/alumina cermets

International Nuclear Information System (INIS)

Kramer, C.M.

1977-12-01

Cermets of tantalum and alumina were fabricated by plasma spraying, with the amount of alumina varied from 0 to 65 percent (by volume). Each of four compositions was then measured for tensile strength, elastic modulus, and coefficient of thermal expansion. In general, strength and strain to failure decreased with increasing alumina content: 62 MPa for 100 percent Ta to 19 MPa for 35 v percent Ta. A maximum of 0.1 percent strain was observed for the sprayed 100 percent Ta specimens. The coefficient of thermal expansion measured for the pure Ta was 6.2 (10 -6 )/K

INFLUENCE OF TECHNOLOGICAL MODES OF MAGNETIC-ELECTRIC GRINDING ON MICROSTRUCTURE OF GAS-THERMAL SPRAYED NI–CR–B–SI-COATINGS

Directory of Open Access Journals (Sweden)

N. V. Spiridonov

2009-01-01

Full Text Available Influence of technological modes of magnetic-electric grinding on structural changes in a surface layer of gas-thermal sprayed coatings is investigated in the paper. The paper presents optimum modes of  coating roughing and finishing processes.

Thermal spraying of polyethylene-based polymers: Processing and characterization

Science.gov (United States)

Otterson, David Mark

This research explores the development of a flame-spray process map as it relates to polymers. This work provides a more complete understanding of the thermal history of the coating material from injection, to deposition and finally to cooling. This was accomplished through precise control of the processing conditions during deposition. Mass flow meters were used to monitor air and fuel flows as they were systematically changed, while temperatures were simultaneously monitored along the length of the flame. A process model was then implemented that incorporated this information along with measured particle velocities, particle size distribution, the polymer's melting temperature and its enthalpy of melting. This computational model was then used to develop a process map that described particle softening, melting and decomposition phenomena as a function of particle size and standoff distance. It demonstrated that changes in particle size caused significant variations in particle states achieved in-flight. A series of experiments were used to determine the range of spray parameters within which a cohesive coating without visible signs of degradation could be sprayed. These results provided additional information that complimented the computational processing map. The boundaries established by these results were the basis for a Statistical Design of Experiments that tested the effects that subtle processing changes had on coating properties. A series of processing maps were developed that combined the computational and the experimental results to describe the manner in which processing parameters interact to determine the degree of melting, polymer degradation and coating porosity. Strong interactions between standoff distance and traverse rate can cause the polymer to degrade and form pores in the coating. A clear picture of the manner in which particle size and standoff distance interact to determine particle melting was provided by combining the computational

Re-emission and thermal desorption of deuterium from plasma sprayed tungsten coatings for application in ASDEX-upgrade

International Nuclear Information System (INIS)

Garcia-Rosales, C.; Franzen, P.; Plank, H.; Roth, J.; Gauthier, E.

1996-01-01

The trapping and release of deuterium implanted with an energy of 100 eV in wrought and in plasma sprayed tungsten of different manufacture and structure has been investigated by means of re-emission as well as thermal and isothermal desorption spectroscopy. The experimental data for wrought tungsten are compared with model calculations with the PIDAT code in order to estimate the parameters governing diffusion, surface recombination and trapping in tungsten. The amount of retained deuterium in tungsten is of the same order of magnitude as in graphite for the implantation parameters used in this work. The mobile hydrogen concentration in tungsten during the implantation is of the same order of magnitude than the trapped one, being released after the termination of the implantation. The fraction of deuterium trapped to defects increases strongly with the porosity of the samples. The temperature needed for the release of the trapped deuterium (∝600 K) are considerably lower than for graphite, due to the smaller trapping energy (≤1.5 eV). (orig.)

Thermal decomposition study of uranyl nitrate and cerium hydroxide in a spray dryer

International Nuclear Information System (INIS)

Silva Wildhagen, G.R. da.

1993-05-01

A study, in a spray dryer system based on drying and thermal decomposition of uranyl nitrate solutions aiming the production of uranium trioxide adequate for the use in posterior steps of reduction and hydro fluorination in nuclear fuel cycle; and cerium hydroxide suspensions for the production of cerium oxide with high surface area is presented. Thus, the project and construction of a countercurrent spray dryer was elaborated for capacity of 10 Kg U O 3 /h and 3,5 k Ce O 2 /h. The methodology used in these experiments consisted in the analysis of several parameters (concentration and flow rate of the feed, atomization pressure and inlet temperature of the dryer) over the physical and chemical properties of the products. Using the obtained results, with the help of a mathematical model, it was developed the project of a continuous pilot unity for the production of uranium trioxide or cerium oxide, with capacity of 20 Kg U O 3 /h or 10 Kg Ce O 2 /h, respectively. (author)

In-Swath Spray Deposition Characteristics of a Low Drift Nozzle for Low Volume Aerial Application - Preliminary Results.

Science.gov (United States)

CP flat-fan nozzles with selectable tips were evaluated for droplet spectra and coverage using water sensitive papers placed in the spray swath. This study used low application volumes (1, 2, and 3 GPA) at a certain spray application height as measured precisely by laser mounted in the aircraft. No...

Applicability of fan spray nozzles to stripping insoluble gases from viscous liquids

International Nuclear Information System (INIS)

Tseng, H.H.; Johnson, E.F.

1983-08-01

Fan spray nozzle stripping appears to be a practical technique for separating dilute volatile solutes from nonvolatile solvents. In particular this technique can be used to strip molecular tritium and tritium fluoride at extremely small concentration (in the parts per million range) from molten salts used as blanket materials in a fusion reactor. Under adjusted operating conditions of the fan spray as it leaves the nozzle, a high percentage of the theoretically maximum achievable stripping would take place from the expanding sheet of the fan spray as it leaves the nozzle and before it breaks up. Although the only available experimental data are for aqueous solutions, a new theoretical analysis of the fan spray sheet demonstrates the applicability of this technique to nonaqueous liquids. The equation derived from this analysis relates the theoretically achievable mass transfer efficiency to the properties of the liquid flowing through the fan spray nozzle and to the operating conditions of the nozzle. Any fluid with viscosity higher than or equal to that of water would be expected to follow this equation as long as a fan-shaped sheet is formed under the operating conditions of the nozzle

Spray-coatable negative photoresist for high topography MEMS applications

International Nuclear Information System (INIS)

Arnold, Markus; Haas, Sven; Schwenzer, Falk; Schwenzer, Gunther; Reuter, Danny; Geßner, Thomas; Voigt, Anja; Gruetzner, Gabi

2017-01-01

In microsystem technology, the lithographical processing of substrates with a topography is very important. Interconnecting lines, which are routed over sloped topography sidewalls from the top of the protecting wafer to the contact pads of the device wafer, are one example of patterning over a topography. For structuring such circuit paths, a photolithography process, and therefore a process for homogeneous photoresist coating, is required. The most flexible and advantageous way of depositing a homogeneous photoresist film over structures with high topography steps is spray-coating. As a pattern transfer process for circuit paths in cavities, the lift-off process is widely used. A negative resist, like ma-N (MRT) or AZnLOF (AZ) is favoured for lift-off processes due to the existing negative angle of the sidewalls. Only a few sprayable negative photoresists are commercially available. In this paper, the development of a novel negative resist spray-coating based on a commercially available single-layer lift-off resist for spin-coating, especially for the patterning of structures inside the cavity and on the cavity wall, is presented. A variety of parameters influences the spray-coating process, and therefore the patterning results. Besides the spray-coating tool and the parameters, the composition of the resist solution itself also influences the coating results. For homogeneous resist coverage over the topography of the substrate, different solvent combinations for diluting the resist solution, different chuck temperatures during the coating process, and also the softbake conditions, are all investigated. The solvent formulations and the process conditions are optimized with respect to the homogeneity of the resist coverage on the top edge of the cavities. Finally, the developed spray-coating process, the resist material and the process stability are demonstrated by the following applications: (i) lift-off, (ii) electroplating, (iii) the wet and (iv) the dry

Comparison between alkali heat treatment and sprayed hydroxyapatite coating on thermally-sprayed rough Ti surface in rabbit model: Effects on bone-bonding ability and osteoconductivity.

Science.gov (United States)

Kawai, Toshiyuki; Takemoto, Mitsuru; Fujibayashi, Shunsuke; Tanaka, Masashi; Akiyama, Haruhiko; Nakamura, Takashi; Matsuda, Shuichi

2015-07-01

In this study, we investigated the effect of different surface treatments (hydroxyapatite (HA) coating, alkali heat treatment, and no treatment) on the ability of bone to bond to a rough arc-sprayed Ti metal surface, using rabbit models. The bone-to-implant contacts for untreated, HA-coated, and alkali heat-treated implants were 21.2%, 72.1%, and 33.8% at 4 weeks, 21.8%, 70.9%, and 30.0% at 8 weeks, and 16.3%, 70.2%, and 29.9% at 16 weeks, respectively (n = 8). HA -coated implants showed significantly higher bone-to-implant contacts than the untreated and alkali heat-treated implants at all the time point, whereas alkali heat-treated implants showed significantly higher bone-to-implant contacts than untreated implants at 4 and 16 weeks. The failure loads in a mechanical test for untreated, HA coated, alkali heat-treated plates were 65.4 N, 70.7 N, and 90.8 N at 4 weeks, 76.1 N, 64.7 N, and 104.8 N at 8 weeks and 88.7 N, 92.6 N, and 118.5 N at 16 weeks, respectively (n = 8). The alkali heat-treated plates showed significantly higher failure loads than HA-coated plates at 8 and 16 weeks. The difference between HA-coated plates and untreated plates were not statistically significant at any time point. Thus HA coating, although it enables high bone-to-implant contact, may not enhance the bone-bonding properties of thermally-sprayed rough Ti metal surfaces. In contrast, alkali heat treatment can be successfully applied to thermally-sprayed Ti metal to enhance both bone-to-implant contact and bone-bonding strength. © 2014 Wiley Periodicals, Inc.

Drift curves from spray applications on commom bean crop

Directory of Open Access Journals (Sweden)

Mariana Rodrigues Bueno

Full Text Available ABSTRACT In order to avoid the occurrence of drift in pesticide applications, it is fundamental to know the behavior of sprayed droplets. This study aimed to determine drift curves in pesticide applications on common bean crop under brazilian weather conditions, using different nozzle types and compared them with the "German" and "Dutch" drift prediction models. The experiment was conducted in Uberlândia, Minas Gerais/Brazil, in completely randomized design with ten replications and 4 x 20 split-plot arrangement in space. Drift deposited on collectors located over ground level was resulted by 150 L ha-1 carrier volume applications through four nozzle types (XR 11002 (fine droplets; AIXR 11002 (coarse droplets; TT 11002 (medium droplets; TTI 11002 (extremely coarse droplets, collected in 20 downwind distances, parallel to the crop line outside the target area, spaced by 2.5 m. The tracer rhodamine B was added to the spray to be quantified by fluorimetry. Drift prediction models adjusted by exponential functions were obtained considering the 90th percentile for XR, TT, AIXR and TTI nozzles. It is suggested to use the estimated drift models from this study for each nozzle type in drift prediction evaluations on bean crops under brazilian weather conditions.

Optimized functionally graded La2Zr2O7/8YSZ thermal barrier coatings fabricated by suspension plasma spraying

International Nuclear Information System (INIS)

Wang, Chaohui; Wang, You; Fan, Shan; You, Yuan; Wang, Liang; Yang, Changlong; Sun, Xiaoguang; Li, Xuewei

2015-01-01

In this paper, an optimized functionally graded coating (OFGC) was successfully fabricated by suspension plasma spraying (SPS) with feedstocks of the suspension of nanoparticles. La 2 Zr 2 O 7 /8YSZ OFGC with gradual compositional variation along the through-thickness direction is proposed to mitigate spallation and crack formation owing to the high residual stresses caused by frequent thermal cycling for TBCs. The single ceramic layer coatings (SCLC) of LZ and double ceramic layer coatings (DCLC) of LZ/8YSZ were fabricated by SPS as comparison. The phase composition and microstructure of the SCLC, OFGC and DCLC were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM) and Energy Dispersive Spectrometer (EDS). Moreover, the thermal cycling tests were carried out to evaluate their thermal shock behavior. Changes in weight and morphology of specimens were analyzed during thermal cycling tests. The results showed that OFGC has extended lifetime compared with SCLC and DCLC. The failure of DCLC with clear interface between different ceramic layers occurred via delamination mode, as a result of crack initiation and propagation generated by thermal mismatch between LZ and 8YSZ. While the failure of OFGC occurred in thermally grown oxide (TGO) layers, indicating that the gradual compositional variation avoided thermal stress concentration in the top ceramic layers. - Highlights: • Optimized functionally graded coatings and double ceramic layer coatings were deposited by suspension plasma spray. • The graded area of OFGC is continuously changed from inner 8YSZ to outer La 2 Zr 2 O 7 (LZ). • The OFGC shows a more extended thermal cycling life than the LZ SCLC and LZ/8YSZ DCLC. • Various failure mechanisms were proposed to explain thermal cycling behavior

Electroform/Plasma-Spray Laminates for X-Ray Optics

Science.gov (United States)

Ulmer, Melville P.; Graham, Michael; Vaynman, Semyon

2007-01-01

Electroform/plasma-spray laminates have shown promise as lightweight, strong, low-thermal-expansion components for xray optics. The basic idea is to exploit both (1) the well-established art of fabrication of optical components by replication and (2) plasma spraying as a means of reinforcing a thin replica optic with one or more backing layer(s) having tailorable thermomechanical properties. In x-ray optics as in other applications, replication reduces the time and cost of fabrication because grinding and polishing can be limited to a few thick masters, from which many lightweight replicas can thereafter be made. The first step in the fabrication of a component of the type in question is to make a replica optic by electroforming a thin layer of nickel on a master. Through proper control of the electroforming process conditions, it is possible to minimize residual stress and, hence, to minimize distortion in the replica. Next, a powder comprising ceramic particles coated with a metal compatible with the electroformed nickel is plasma-sprayed onto the backside of the nickel replica. Then through several repetitions and variations of the preceding steps or perhaps a small compressive stress, alternating layers of electroformed nickel and plasma-sprayed metal-coated ceramic powder are deposited. The thicknesses of the layers and the composition of the metal-coated ceramic powder are chosen to optimize the strength, areal mass density, and toughness of the finished component. An important benefit of using both electroforming and plasma spraying is the possibility of balancing stresses to a minimum level, which could be zero or perhaps a small net compressive stress designed to enhance the function of the component in its intended application.

Plasma sprayed samarium--cobalt permanent magnets

International Nuclear Information System (INIS)

Willson, M.C.; Janowiecki, R.J.

1975-01-01

Samarium--cobalt permanent magnets were fabricated by arc plasma spraying. This process involves the injection of relatively coarse powder particles into a high-temperature gas for melting and spraying onto a substrate. The technique is being investigated as an economical method for fabricating cobalt--rare earth magnets for advanced traveling wave tubes and cross-field amplifiers. Plasma spraying permits deposition of material at high rates over large areas with optional direct bonding to the substrate, and offers the ability to fabricate magnets in a variety of shapes and sizes. Isotropic magnets were produced with high coercivity and good reproducibility in magnetic properties. Post-spray thermal treatments were used to enhance the magnetic properties of sprayed deposits. Samarium--cobalt magnets, sprayed from samarium-rich powder and subjected to post-spray heat treatment, displayed energy products in excess of 9 million gauss-oersteds and coercive forces of approximately 6000 oersteds. Bar magnet arrays were constructed by depositing magnets on ceramic substrates. (auth)

Plasma sprayed samarium--cobalt permanent magnets

International Nuclear Information System (INIS)

Willson, M.C.; Janowiecki, R.J.

1975-01-01

Samarium--Co permanent magnets were fabricated by arc plasma spraying. This process involves the injection of relatively coarse powder particles into a high temperature gas for melting and spraying onto a substrate. The technique is being investigated as an economical method for fabricating Co--rare earth magnets for advanced traveling wave tubes and cross-field amplifiers. Plasma spraying permits deposition of material at high rates over large areas with optional direct bonding to the substrate, and offers the ability to fabricate magnets in a variety of shapes and sizes. Isotropic magnets were produced with high coercivity and good reproducibility in magnetic properties. Post-spray thermal treatments were used to enhance the magnetic properties of sprayed deposits. Samarium--Co magnets, sprayed from Sm-rich powder and subjected to post-spray heat treatment, displayed energy products in excess of 9 million G-Oe and coercive forces of approximately 6000 Oe. Bar magnet arrays were constructed by depositing magnets on ceramic substrates

Effects caused by thermal shocks in plasma sprayed protective coatings from materials based on Al2O3

International Nuclear Information System (INIS)

Gorski, L.; Wolski, T.; Gostynski, D.

1996-01-01

Plasma sprayed coatings from the materials based on Al 2 O 3 with addition of NiO and TiO 2 have been studied. Thermal shock resistance of these coatings has been tested on special experimental arrangement in the stream of hot and cold gases. Changes in coating microstructure has been determined by light microscopy methods. Phase transition caused by the experiments are revealed by X-ray diffraction methods. The resistance for thermal fatigue processes depends on used coatings materials. (author). 21 refs, 21 figs, 1 tab

Thermo-mechanical modeling of laser treatment on titanium cold-spray coatings

Science.gov (United States)

Paradiso, V.; Rubino, F.; Tucci, F.; Astarita, A.; Carlone, P.

2018-05-01

Titanium coatings are very attractive to several industrial fields, especially aeronautics, due to the enhanced corrosion resistance and wear properties as well as improved compatibility with carbon fiber reinforced plastic (CFRP) materials. Cold sprayed titanium coatings, among the others deposition processes, are finding a widespread use in high performance applications, whereas post-deposition treatments are often used to modify the microstructure of the cold-sprayed layer. Laser treatments allow one to noticeably increase the superficial properties of titanium coatings when the process parameters are properly set. On the other hand, the high heat input required to melt titanium particles may result in excessive temperature increase even in the substrate. This paper introduces a thermo-mechanical model to simulate the laser treatment effects on a cold sprayed titanium coating as well as the aluminium substrate. The proposed thermo-mechanical finite element model considers the transient temperature field due to the laser source and applied boundary conditions using them as input loads for the subsequent stress-strain analysis. Numerical outcomes highlighted the relevance of thermal gradients and thermally induced stresses and strains in promoting the damage of the coating.

Thermal performance experiments on ultimate heat sinks, spray ponds, and cooling ponds

International Nuclear Information System (INIS)

Hadlock, R.K.

1976-12-01

A program of measurement on a Battelle-Northwest (BNW) spray pond has been completed to prove an integrated instrumentation system for application in future field experiments. The measurement programs in the field will produce data of relevance to the design and understanding of performance for ultimate heat sinks as components of emergency core cooling systems. In the absence of active emergency cooling systems, the data will be obtained on analog systems--prime candidates among these are the naturally-occurring hot ponds at Yellowstone National Park and man-made hot cooling ponds at Savannah River National Laboratory as well as spray ponds at various industrial facilities. The proof experiment has provided data that not only illustrate the effectiveness of the instrumentation system but also display interesting site-specific heat transfer processes. The data to be obtained in the field will also be site specific but must be of generic applicability in modeling for design and performance purposes. The integrated instrumentation system will evolve, through modest modifications and substantial supplementation, to provide the requisite data for the more demanding situation of work in and about hot water

Electrostatic application of antimicrobial sprays to sanitize food handling and processing surfaces for enhanced food safety

International Nuclear Information System (INIS)

Lyons, Shawn M; Harrison, Mark A; Law, S Edward

2011-01-01

Human illnesses and deaths caused by foodborne pathogens (e.g., Salmonella enterica, Listeria monocytogenes, Escherichia coli O157:H7, etc.) are of increasing concern globally in maintaining safe food supplies. At various stages of the food production, processing and supply chain antimicrobial agents are required to sanitize contact surfaces. Additionally, during outbreaks of contagious pathogenic microorganisms (e.g., H1N1 influenza), public health requires timely decontamination of extensive surfaces within public schools, mass transit systems, etc. Prior publications verify effectiveness of air-assisted, induction-charged (AAIC) electrostatic spraying of various chemical and biological agents to protect on-farm production of food crops...typically doubling droplet deposition efficiency with concomitant increases in biological control efficacy. Within a biosafety facility this present work evaluated the AAIC electrostatic-spraying process for application of antimicrobial liquids onto various pathogen-inoculated food processing and handling surfaces as a food safety intervention strategy. Fluoroanalysis of AAIC electrostatic sprays (-7.2 mC/kg charge-to-mass ratio) showed significantly greater (p<0.05) mass of tracer active ingredient (A.I.) deposited onto target surfaces at various orientations as compared both to a similar uncharged spray nozzle (0 mC/kg) and to a conventional hydraulic-atomizing nozzle. Per unit mass of A.I. dispensed toward targets, for example, A.I. mass deposited by AAIC electrostatic sprays onto difficult to coat backsides was 6.1-times greater than for similar uncharged sprays and 29.0-times greater than for conventional hydraulic-nozzle sprays. Even at the 56% reduction in peracetic acid sanitizer A.I. dispensed by AAIC electrostatic spray applications, they achieved equal or greater CFU population reductions of Salmonella on most target orientations and materials as compared to uncharged sprays and conventional full-rate hydraulic

Electrostatic application of antimicrobial sprays to sanitize food handling and processing surfaces for enhanced food safety

Energy Technology Data Exchange (ETDEWEB)

Lyons, Shawn M; Harrison, Mark A [Food Science and Technology Department, University of Georgia, Athens, GA, 30602-2610 (United States); Law, S Edward, E-mail: edlaw@engr.uga.edu [Biological and Agricultural Engineering Department, Applied Electrostatics Laboratory www.ael.engr.uga.edu, University of Georgia, Athens, GA, 30602-4435 (United States)

2011-06-23

Human illnesses and deaths caused by foodborne pathogens (e.g., Salmonella enterica, Listeria monocytogenes, Escherichia coli O157:H7, etc.) are of increasing concern globally in maintaining safe food supplies. At various stages of the food production, processing and supply chain antimicrobial agents are required to sanitize contact surfaces. Additionally, during outbreaks of contagious pathogenic microorganisms (e.g., H1N1 influenza), public health requires timely decontamination of extensive surfaces within public schools, mass transit systems, etc. Prior publications verify effectiveness of air-assisted, induction-charged (AAIC) electrostatic spraying of various chemical and biological agents to protect on-farm production of food crops...typically doubling droplet deposition efficiency with concomitant increases in biological control efficacy. Within a biosafety facility this present work evaluated the AAIC electrostatic-spraying process for application of antimicrobial liquids onto various pathogen-inoculated food processing and handling surfaces as a food safety intervention strategy. Fluoroanalysis of AAIC electrostatic sprays (-7.2 mC/kg charge-to-mass ratio) showed significantly greater (p<0.05) mass of tracer active ingredient (A.I.) deposited onto target surfaces at various orientations as compared both to a similar uncharged spray nozzle (0 mC/kg) and to a conventional hydraulic-atomizing nozzle. Per unit mass of A.I. dispensed toward targets, for example, A.I. mass deposited by AAIC electrostatic sprays onto difficult to coat backsides was 6.1-times greater than for similar uncharged sprays and 29.0-times greater than for conventional hydraulic-nozzle sprays. Even at the 56% reduction in peracetic acid sanitizer A.I. dispensed by AAIC electrostatic spray applications, they achieved equal or greater CFU population reductions of Salmonella on most target orientations and materials as compared to uncharged sprays and conventional full-rate hydraulic

Spray cast Al-Si base alloys for stiffness and fatigue strength requirements

International Nuclear Information System (INIS)

Courbiere, M.; Mocellin, A.

1993-01-01

Hypereutectic AlSiFe spray-cast alloys exhibit properties similar to those of metal-matrix composite (MMC's) : high Young's modulus and a low coefficient of thermal expansion. These physical properties can be adjusted by changing the Si content of the alloy. The refinement of the microstructure is produced by formation of a large amount of nuclei in the spray. Consolidation done by extrusion (bars, tubes or profiles) and/or forging leads to high mechanical properties, especially very good dynamic properties. High fatigue properties coupled with high modulus, good high temperature behaviour and low thermal expansion, allow their use for applications in the automotive industry. In opposition to MMC's, these materials present the advantage of easy recycling and easy machinability as it is the case for the conventional AlSi alloys. The low oxygen content allows quality joining with conventional arc welding techniques. (orig.)

Molybdenum disilicide composites produced by plasma spraying

International Nuclear Information System (INIS)

Castro, R.G.; Hollis, K.J.; Kung, H.H.; Bartlett, A.H.

1998-01-01

The intermetallic compound, molybdenum disilicide (MoSi 2 ) is being considered for high temperature structural applications because of its high melting point and superior oxidation resistance at elevated temperatures. The lack of high temperature strength, creep resistance and low temperature ductility has hindered its progress for structural applications. Plasma spraying of coatings and structural components of MoSi 2 -based composites offers an exciting processing alternative to conventional powder processing methods due to superior flexibility and the ability to tailor properties. Laminate, discontinuous and in situ reinforced composites have been produced with secondary reinforcements of Ta, Al 2 O 3 , SiC, Si 3 N 4 and Mo 5 Si 3 . Laminate composites, in particular, have been shown to improve the damage tolerance of MoSi 2 during high temperature melting operations. A review of research which as been performed at Los Alamos National Laboratory on plasma spraying of MoSi 2 -based composites to improve low temperature fracture toughness, thermal shock resistance, high temperature strength and creep resistance will be discussed

Thermal barrier coatings: Coating methods, performance, and heat engine applications. (Latest citations from the EI Compendex*plus database). Published Search

Energy Technology Data Exchange (ETDEWEB)

NONE

1997-02-01

The bibliography contains citations concerning conference proceedings on coating methods, performance evaluations, and applications of thermal barrier coatings as protective coatings for heat engine components against high temperature corrosions and chemical erosions. The developments of thermal barrier coating techniques for high performance and reliable gas turbines, diesel engines, jet engines, and internal combustion engines are presented. Topics include plasma sprayed coating methods, yttria stabilized zirconia coatings, coating life models, coating failure and durability, thermal shock and cycling, and acoustic emission analysis of coatings. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

Thermal barrier coatings: Coating methods, performance, and heat engine applications. (Latest citations from the EI Compendex*plus database). Published Search

Energy Technology Data Exchange (ETDEWEB)

NONE

1995-11-01

The bibliography contains citations concerning conference proceedings on coating methods, performance evaluations, and applications of thermal barrier coatings as protective coatings for heat engine components against high temperature corrosions and chemical erosions. The developments of thermal barrier coating techniques for high performance and reliable gas turbines, diesel engines, jet engines, and internal combustion engines are presented. Topics include plasma sprayed coating methods, yttria stabilized zirconia coatings, coating life models, coating failure and durability, thermal shock and cycling, and acoustic emission analysis of coatings. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

Babbitt Casting and Babbitt Spraying Processes Case Study

OpenAIRE

M. Jalali Azizpour; S.Norouzi H. Mohammadi Majd

2011-01-01

In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis s...

DURABILITY AND TRIBOLOGICAL PROPERTIES OF THERMALLY SPRAYED WC CERMET COATING IN LUBRICATED ROLLING WITH SLIDING CONTACT

Directory of Open Access Journals (Sweden)

Mohammad Ali

2010-09-01

Full Text Available Durability and tribological properties of thermally sprayed WC-Cr-Ni cermet coating were investigated experimentally in lubricated rolling with sliding contact conditions. By means of the high energy type flame spraying (Hi-HVOF method, the coating was formed onto the axially ground and circumferentially ground roller specimens made of a thermally refined carbon steel. In the experiments, the WC cermet coated steel roller was mated with the carburized hardened steel roller without coating in line contact condition. The coated roller was mated with the smooth non-coated roller under a contact pressure of 1.0 or 1.2 GPa, and it was mated with the rough non-coated roller under a contact pressure of 0.6 or 0.8 GPa. As a result, it was found that in general, the coating on the circumferentially ground substrate shows a lower durability compared with that on the axially ground substrate and this difference appears more distinctly for the higher contact pressure for both smooth mating surface and rough mating surface. It was also found that there are significant differences in the tribological properties of WC cermet coating depending on the contact pressure. In addition, depending on the smooth or rough mating surface, remarkable differences in the tribological properties were found.

Effects of insecticide spray application on insect pest infestation and ...

African Journals Online (AJOL)

Field studies were conducted during the 2008 - 2009 cropping season to determine the minimal insecticide application which can reduce cowpea yield losses on the field due to insect pest infestations in the Transkei region of South Africa. Treatments consisted of five cowpea varieties and four regimes of insecticide spray ...

Layered growth with bottom-spray granulation for spray deposition of drug.

Science.gov (United States)

Er, Dawn Z L; Liew, Celine V; Heng, Paul W S

2009-07-30

The gap in scientific knowledge on bottom-spray fluidized bed granulation has emphasized the need for more studies in this area. This paper comparatively studied the applicability of a modified bottom-spray process and the conventional top-spray process for the spray deposition of a micronized drug during granulation. The differences in circulation pattern, mode of growth and resultant granule properties between the two processes were highlighted. The more ordered and consistent circulation pattern of particles in a bottom-spray fluidized bed was observed to give rise to layered granule growth. This resulted in better drug content uniformity among the granule batches and within a granule batch. The processes' sensitivities to wetting and feed material characteristics were also compared and found to differ markedly. Less robustness to differing process conditions was observed for the top-spray process. The resultant bottom-spray granules formed were observed to be less porous, more spherical and had good flow properties. The bottom-spray technique can thus be potentially applied for the spray deposition of drug during granulation and was observed to be a good alternative to the conventional technique for preparing granules.

Replacement of Chromium Electroplating on C-2, E-2, P-3 and C-130 Propeller Hub Components Using HVOF Thermal Spray Coatings

National Research Council Canada - National Science Library

Sartwell, Bruce

2004-01-01

.... This document constitutes the final report on a project to qualify high-velocity oxygen-fuel (HVOF) thermal spray coatings as a replacement for hard chrome plating on propeller hub components from various military aircraft...

Constrained sintering of an air-plasma-sprayed thermal barrier coating

International Nuclear Information System (INIS)

Cocks, A.C.F.; Fleck, N.A.

2010-01-01

A micromechanical model is presented for the constrained sintering of an air-plasma-sprayed, thermal barrier coating upon a thick superalloy substrate. The coating comprises random splats with intervening penny-shaped cracks. The crack faces make contact at asperities, which progressively sinter in-service by interfacial diffusion, accommodated by bulk creep. Diffusion is driven by the reduction in interfacial energy at the developing contacts and by the local asperity contact stress. At elevated operating temperature, both sintering and creep strains accumulate within the plane of the coating. The sensitivities of sintering rate and microstructure evolution rate to the kinetic parameters and thermodynamic driving forces are explored. It is demonstrated that the sintering response is governed by three independent timescales, as dictated by the material and geometric properties of the coating. Finally, the role of substrate constraint is assessed by comparing the rate of constrained sintering with that for free sintering.

Application of persulfate-oxidation foam spraying as a bioremediation pretreatment for diesel oil-contaminated soil.

Science.gov (United States)

Bajagain, Rishikesh; Lee, Sojin; Jeong, Seung-Woo

2018-05-15

This study investigated a persulfate-bioaugmentation serial foam spraying technique to remove total petroleum hydrocarbons (TPHs) present in diesel-contaminated unsaturated soil. Feeding of remedial agents by foam spraying increased the infiltration/unsaturated hydraulic conductivity of reagents into the unsaturated soil. Persulfate mixed with a surfactant solution infiltrated the soil faster than peroxide, resulting in relatively even soil moisture content. Persulfate had a higher soil infiltration tendency, which would facilitate its distribution over a wide soil area, thereby enhancing subsequent biodegradation efficiency. Nearly 80% of soil-TPHs were degraded by combined persulfate-bioaugmentation foam spraying, while bioaugmentation foam spraying alone removed 52%. TPH fraction analysis revealed that the removal rate for the biodegradation recalcitrant fraction (C 18 to C 22 ) in deeper soil regions was higher for persulfate-bioaugmentation serial foam application than for peroxide-bioaugmentation foam application. Persulfate-foam spraying may be superior to peroxide for TPH removal even at a low concentration (50 mN) because persulfate-foam is more permeable, persistent, and does not change soil pH in the subsurface. Although the number of soil microbes declines by oxidation pretreatment, bioaugmentation-foam alters the microbial population exponentially. Copyright © 2018 Elsevier Ltd. All rights reserved.

Comparison of performance coatings thermally sprayed subject to testing adhesive wear

International Nuclear Information System (INIS)

Marangoni, G.F.; Arnt, A.B.C.; Rocha, M.R. da

2014-01-01

In this work, the microstructural changes and wear resistance adhesive coatings obtained from powders thermally sprayed by high velocity oxy-fuel (HVOF) were evaluated. Based coatings chrome-nickel and tungsten-cobalt are applied in conditions subject to intense wear especially abrasive. With the aim of evaluate the performance of these coatings under conditions of adhesive wear, these coatings samples were tested by the standard ASTM G99. As test parameters were used: Tungsten carbide pin (SAE 52100) with 6 mm diameter, normal load of 50N and a tangential velocity of 0.5 m / s. The worn surfaces of the coatings were characterized by optical and scanning electron microscopy and X-ray diffraction. Results indicate that the performance front wear is related to the conditions of adhesion and uniformity of the coating applied. (author)

Erosion resistance and adhesion of composite metal/ceramic coatings produced by plasma spraying

OpenAIRE

Ramm , D.; Hutchings , I.; Clyne , T.

1993-01-01

Ceramic coatings can exhibit greater erosion resistance than most metallic coatings. Such coatings are conveniently produced by thermal spraying. Unfortunately, thermally sprayed ceramic coatings often exhibit poor adhesion, partly as a consequence of the development of residual stresses during spraying and subsequent cooling. Composite coatings have been studied using aluminium/alumina deposits on steel substrates. The incorporation of ceramics within a ductile matrix has potential for sharp...

Effect of Suspension Plasma-Sprayed YSZ Columnar Microstructure and Bond Coat Surface Preparation on Thermal Barrier Coating Properties

Science.gov (United States)

Bernard, Benjamin; Quet, Aurélie; Bianchi, Luc; Schick, Vincent; Joulia, Aurélien; Malié, André; Rémy, Benjamin

2017-08-01

Suspension plasma spraying (SPS) is identified as promising for the enhancement of thermal barrier coating (TBC) systems used in gas turbines. Particularly, the emerging columnar microstructure enabled by the SPS process is likely to bring about an interesting TBC lifetime. At the same time, the SPS process opens the way to a decrease in thermal conductivity, one of the main issues for the next generation of gas turbines, compared to the state-of-the-art deposition technique, so-called electron beam physical vapor deposition (EB-PVD). In this paper, yttria-stabilized zirconia (YSZ) coatings presenting columnar structures, performed using both SPS and EB-PVD processes, were studied. Depending on the columnar microstructure readily adaptable in the SPS process, low thermal conductivities can be obtained. At 1100 °C, a decrease from 1.3 W m-1 K-1 for EB-PVD YSZ coatings to about 0.7 W m-1 K-1 for SPS coatings was shown. The higher content of porosity in the case of SPS coatings increases the thermal resistance through the thickness and decreases thermal conductivity. The lifetime of SPS YSZ coatings was studied by isothermal cyclic tests, showing equivalent or even higher performances compared to EB-PVD ones. Tests were performed using classical bond coats used for EB-PVD TBC coatings. Thermal cyclic fatigue performance of the best SPS coating reached 1000 cycles to failure on AM1 substrates with a β-(Ni,Pt)Al bond coat. Tests were also performed on AM1 substrates with a Pt-diffused γ-Ni/γ'-Ni3Al bond coat for which more than 2000 cycles to failure were observed for columnar SPS YSZ coatings. The high thermal compliance offered by both the columnar structure and the porosity allowed the reaching of a high lifetime, promising for a TBC application.

Aspects of industrial production of solid electrolyte fuel cells (SOFC) by thermal spraying technology; Aspekte industrieller Fertigung von Festelektrolyt-Brennstoffzellen (SOFC) mittels thermischer Beschichtungsverfahren

Energy Technology Data Exchange (ETDEWEB)

Weckmann, Hannes

2010-07-01

The present thesis deals with measures to optimize the large-volume production of Solid Oxide Fuel Cells (SOFC) based on thermal spraying technology. Based on the well-established Vacuum Plasma Spraying (VPS) at DLR the potential of alternative thermal spraying techniques as well as alternative base materials was investigated in order to deposit SOFC-anode, electrolyte and insulating layers. Production costs, reproducibility and long-term stability of the production process as well as the fuel cell performance were major target criteria. Depending on the parameter set applied when using the cost efficient Atmospheric Plasma Spraying (APS) in combination with Nickel-Graphite as base material a significant improvement of gas permeability and electrical conductivity was achieved in comparison to the VPS sprayed reference anode. The power density of a fuel cell with an APS-Nickel-Graphite anode (184 mW/cm{sup 2}) was slightly better than the performance with a VPS reference anode (159 mW/cm{sup 2}). In comparison to the VPS process, ceramic electrolyte layers of fully stabilized Zirconia (YSZ) with significantly higher gas tightness could be demonstrated when high energy processes such as Low Pressure Plasma Spraying (LPPS). Thin-film Low Pressure Plasma Spraying (LPPS-Thin-film) and High Velocity Oxy Fuel Spraying (HVOF) were applied. The power density of a fuel cell equipped with an HVOF electrolyte was significantly improved to 234 mW/cm{sup 2} as compared to 187 mW/cm{sup 2} with the VPS sprayed reference cell. Further improvement of the power density was achieved with an LPPS-electrolyte (273 mW/cm{sup 2}). HVOF and VPS sprayed layers of pure Spinel in composite with metallic active braze (equivalent to the sealing between individual layers in the fuel cell stack) could exceed the demanded charge transfer resistance of >1 k{omega}cm{sup 2} at 800 C operating temperature only in few cases. When blended base powder of Spinel and Magnesia in combination with the VPS

An evaluation of the electric arc spray and (HPPS) processes for the manufacturing of high power plasma spraying MCrAIY coatings

Science.gov (United States)

Sacriste, D.; Goubot, N.; Dhers, J.; Ducos, M.; Vardelle, A.

2001-06-01

The high power plasma torch (PlazJet) can be used to spray refractory ceramics with high spray rates and deposition efficiency. It can provide dense and hard coating with high bond strengths. When manufacturing thermal barrier coatings, the PlazJet gun is well adapted to spraying the ceramic top coat but not the MCrAIY materials that are used as bond coat. Arc spraying can compete with plasma spraying for metallic coatings since cored wires can be used to spray alloys and composites. In addition, the high production rate of arc spraying enables a significant decrease in coating cost. This paper discusses the performances of the PlazJet gun, and a twin-wire are spray system, and compares the properties and cost of MCrAIY coatings made with these two processes. For arc spraying, the use of air or nitrogen as atomizing gas is also investigated.

Higher Temperature Thermal Barrier Coatings with the Combined Use of Yttrium Aluminum Garnet and the Solution Precursor Plasma Spray Process

Science.gov (United States)

Gell, Maurice; Wang, Jiwen; Kumar, Rishi; Roth, Jeffery; Jiang, Chen; Jordan, Eric H.

2018-04-01

Gas-turbine engines are widely used in transportation, energy and defense industries. The increasing demand for more efficient gas turbines requires higher turbine operating temperatures. For more than 40 years, yttria-stabilized zirconia (YSZ) has been the dominant thermal barrier coating (TBC) due to its outstanding material properties. However, the practical use of YSZ-based TBCs is limited to approximately 1200 °C. Developing new, higher temperature TBCs has proven challenging to satisfy the multiple property requirements of a durable TBC. In this study, an advanced TBC has been developed by using the solution precursor plasma spray (SPPS) process that generates unique engineered microstructures with the higher temperature yttrium aluminum garnet (YAG) to produce a TBC that can meet and exceed the major performance standards of state-of-the-art air plasma sprayed YSZ, including: phase stability, sintering resistance, CMAS resistance, thermal cycle durability, thermal conductivity and erosion resistance. The temperature improvement for hot section gas turbine materials (superalloys & TBCs) has been at the rate of about 50 °C per decade over the last 50 years. In contrast, SPPS YAG TBCs offer the near-term potential of a > 200 °C improvement in temperature capability.

Higher Temperature Thermal Barrier Coatings with the Combined Use of Yttrium Aluminum Garnet and the Solution Precursor Plasma Spray Process

Science.gov (United States)

Gell, Maurice; Wang, Jiwen; Kumar, Rishi; Roth, Jeffery; Jiang, Chen; Jordan, Eric H.

2018-02-01

Gas-turbine engines are widely used in transportation, energy and defense industries. The increasing demand for more efficient gas turbines requires higher turbine operating temperatures. For more than 40 years, yttria-stabilized zirconia (YSZ) has been the dominant thermal barrier coating (TBC) due to its outstanding material properties. However, the practical use of YSZ-based TBCs is limited to approximately 1200 °C. Developing new, higher temperature TBCs has proven challenging to satisfy the multiple property requirements of a durable TBC. In this study, an advanced TBC has been developed by using the solution precursor plasma spray (SPPS) process that generates unique engineered microstructures with the higher temperature yttrium aluminum garnet (YAG) to produce a TBC that can meet and exceed the major performance standards of state-of-the-art air plasma sprayed YSZ, including: phase stability, sintering resistance, CMAS resistance, thermal cycle durability, thermal conductivity and erosion resistance. The temperature improvement for hot section gas turbine materials (superalloys & TBCs) has been at the rate of about 50 °C per decade over the last 50 years. In contrast, SPPS YAG TBCs offer the near-term potential of a > 200 °C improvement in temperature capability.

Thermal interaction between WC-Co coating and steel substrate in process of HVOF spraying

International Nuclear Information System (INIS)

Guilemany, J.M.; Sobolev, V.V.; Nutting, J.; Dong, Z.; Calero, J.A.

1994-01-01

The WC-Co powders can be used to produce good adhesive and wear resistant HVOF thermal spray coatings on steel and light alloys substrates. In order to understand the properties of this kind of coating, the phases which are present in the coatings and structure changes during post heat treatments have been investigated. Although the coating properties depend very much on the structure developed in the substrate-coating interfacial region it has not been yet investigated in detail. The present study is devoted to the experimental and theoretical analysis of this interfacial region. The structure characterization has been performed mainly through the use of transmission electron microscopy. To provide a theoretical investigation a realistic prediction model of the process has been developed and on its base the mathematical simulation of the substrate-coating thermal interaction has been undertaken

Droplets and sprays

CERN Document Server

Sazhin, Sergei

2014-01-01

Providing a clear and systematic description of droplets and spray dynamic models, this book maximises reader insight into the underlying physics of the processes involved, outlines the development of new physical and mathematical models, and broadens understanding of interactions between the complex physical processes which take place in sprays. Complementing approaches based on the direct application of computational fluid dynamics (CFD), Droplets and Sprays treats both theoretical and practical aspects of internal combustion engine process such as the direct injection of liquid fuel, subcritical heating and evaporation. Includes case studies that illustrate the approaches relevance to automotive applications,  it is also anticipated that the described models can find use in other areas such as in medicine and environmental science.

Application of Atmospheric Plasma-Sprayed Ferrite Layers for Particle Accelerators

CERN Document Server

Caspers, F; Federmann, S; Taborelli, M; Schulz, C; Bobzin, K; Wu, J

2013-01-01

A common problem in all kinds of cavity-like structures in particle accelerators is the occurrence of RF-resonances. Typically, ferrite plates attached to the walls of such structures as diagnostic devices, kickers or collimators, are used to dampen those undesired modes. However, the heat transfer rate from these plates to the walls is rather limited. Brazing ferrite plates to the walls is not possible in most cases due to the different thermal expansion coefficients. To overcome those limitations, atmospheric plasma spraying techniques have been investigated. Ferrite layers with a thickness from 50 μm to about 300 μm can be deposited on metallic surfaces like stainless steel exhibiting good thermal contact and still reasonable absorption properties. In this paper the technological aspects of plasma deposition are discussed and results of specifically developed RF loss measurement procedures for such thin magnetically lossy layers on metal are presented.

Electrical characteristics and preparation of (Ba0.5Sr0.5)TiO3 films by spray pyrolysis and rapid thermal annealing

International Nuclear Information System (INIS)

Koo, Horngshow; Ku, Hongkou; Kawai, Tomoji; Chen Mi

2007-01-01

Functional films of (Ba 0.5 Sr 0.5 )TiO 3 on Pt (1000 A)/Ti (100 A)/SiO 2 (2000 A)/Si substrates are prepared by spray pyrolysis and subsequently rapid thermal annealing. Barium nitrate, strontium nitrate and titanium isopropoxide are used as starting materials with ethylene glycol as solvent. For (Ba 0.5 Sr 0.5 )TiO 3 functional thin film, thermal characteristics of the precursor powder scratched from as-sprayed films show a remarkable peak around 300-400degC and 57.7% weight loss up to 1000degC. The as-sprayed precursor film with coffee-like color and amorphous-like phase is transformed into the resultant film with white, crystalline perovskite phase and characteristic peaks (110) and (100). The resultant films show correspondent increases of dielectric constant, leakage current and dissipation factor with increasing annealing temperatures. The dielectric constant is 264 and tangent loss is 0.21 in the resultant films annealed at 750degC for 5 min while leakage current density is 1.5x10 -6 A/cm 2 in the film annealed at 550degC for 5 min. (author)

New generation of plasma-sprayed mullite coatings on silicon carbide

Science.gov (United States)

Lee, Kang N.; Miller, Robert A.; Jacobson, Nathan S.

1995-01-01

Mullite is promising as a protective coating for silicon-based ceramics in aggressive high-temperature environments. Conventionally plasma-sprayed mullite on SiC tends to crack and debond on thermal cycling. It is shown that this behavior is due to the presence of amorphous mullite in the conventionally sprayed mullite. Heating the SiC substrate during the plasma spraying eliminated the amorphous phase and produced coatings with dramatically improved properties. The new coating exhibits excellent adherence and crack resistance under thermal cycling between room temperature and 1000 to 1400 C. Preliminary tests showed good resistance to Na2CO3-induced hot corrosion.

Application of pulse combustion technology in spray drying process

Directory of Open Access Journals (Sweden)

I. Zbicinski

2000-12-01

Full Text Available The paper presents development of valved pulse combustor designed for application in drying process and drying tests performed in a specially built installation. Laser technique was applied to investigate the flow field and structure of dispersed phase during pulse combustion spray drying process. PDA technique was used to determine initial atomization parameters as well as particle size distribution, velocity of the particles, mass concentration of liquid phase in the cross section of spray stream, etc., in the drying chamber during drying tests. Water was used to estimate the level of evaporation and 5 and 10% solutions of sodium chloride to carry out drying tests. The Computational Fluid Dynamics technique was used to perform theoretical predictions of time-dependent velocity, temperature distribution and particle trajectories in the drying chamber. Satisfactory agreement between calculations and experimental results was found in certain regions of the drying chamber.

Evaluation of spray application methods for navel orangeworm control in almonds.

Science.gov (United States)

Markle, James C; Niederholzer, Franz Ja; Zalom, Frank G

2016-12-01

Gear Up/Throttle Down (GUTD) and Inward Only strategies represent potential alternatives to conventional airblast applications to reduce spray drift. This study evaluates Inward Only and a modified version of GUTD in almonds, the largest US tree crop, at the recommended hull split treatment timing for control of navel orangeworm (NOW), the key almond insect pest. Conventional treatment produced the most drift (15.6% of total bifenthrin load), while the GUTD and Inward Only treatments produced only 7.6 and 9.7% respectively. For all methods, 92-94% of the drift was found in the first 15.2 m downwind of the orchard. NOW control was lower for the Inward Only treatment compared with the GUTD and conventional treatments. NOW control was consistently lower at 4.88 m height relative to 2.44 m in all treatments, reflecting the reduced deposition higher in the tree canopy recorded in deposition samples. While Inward Only treatments reduced spray drift relative to the conventional application method, poorer control of NOW, the key insect pest of almonds, in the Inward Only treatment would likely limit its voluntary use by growers. However, GUTD holds promise for use at the hull split treatment timing to address spray drift. © 2016 Society of Chemical Industry. © 2016 Society of Chemical Industry.

The development of beryllium plasma spray technology for the International Thermonuclear Experimental Reactor (ITER)

International Nuclear Information System (INIS)

Castro, R.G.; Elliott, K.E.; Hollis, K.J.; Watson, R.D.

1999-01-01

Over the past five years, four international parties, which include the European Communities, Japan, the Russian Federation and the United States, have been collaborating on the design and development of the International Thermonuclear Experimental Reactor (ITER), the next generation magnetic fusion energy device. During the ITER Engineering Design Activity (EDA), beryllium plasma spray technology was investigated by Los Alamos National Laboratory as a method for fabricating and repairing and the beryllium first wall surface of the ITER tokamak. Significant progress has been made in developing beryllium plasma spraying technology for this application. Information will be presented on the research performed to improve the thermal properties of plasma sprayed beryllium coatings and a method that was developed for cleaning and preparing the surface of beryllium prior to depositing plasma sprayed beryllium coatings. Results of high heat flux testing of the beryllium coatings using electron beam simulated ITER conditions will also be presented

Microstructure, Tensile Adhesion Strength and Thermal Shock Resistance of TBCs with Different Flame-Sprayed Bond Coat Materials Onto BMI Polyimide Matrix Composite

Science.gov (United States)

Abedi, H. R.; Salehi, M.; Shafyei, A.

2017-10-01

In this study, thermal barrier coatings (TBCs) composed of different bond coats (Zn, Al, Cu-8Al and Cu-6Sn) with mullite top coats were flame-sprayed and air-plasma-sprayed, respectively, onto bismaleimide matrix composites. These polyimide matrix composites are of interest to replace PMR-15, due to concerns about the toxicity of the MDA monomer from which PMR-15 is made. The results showed that pores and cracks appeared at the bond coat/substrate interface for the Al-bonded TBC because of its high thermal conductivity and diffusivity resulting in transferring of high heat flux and temperature to the polymeric substrate during top coat deposition. The other TBC systems due to the lower conductivity and diffusivity of bonding layers could decrease the adverse thermal effect on the polymer substrate during top coat deposition and exhibited adhesive bond coat/substrate interfaces. The tensile adhesion test showed that the adhesion strength of the coatings to the substrate is inversely proportional to the level of residual stress in the coatings. However, the adhesion strength of Al bond-coated sample decreased strongly after mullite top coat deposition due to thermal damage at the bond coat/substrate interface. TBC system with the Cu-6Sn bond coat exhibited the best thermal shock resistance, while Al-bonded TBC showed the lowest. It was inferred that thermal mismatch stresses and oxidation of the bond coats were the main factors causing failure in the thermal shock test.

Spray deposition using impulse atomization technique

International Nuclear Information System (INIS)

Ellendt, N.; Schmidt, R.; Knabe, J.; Henein, H.; Uhlenwinkel, V.

2004-01-01

A novel technique, impulse atomization, has been used for spray deposition. This single fluid atomization technique leads to different spray characteristics and impact conditions of the droplets compared to gas atomization technique which is the common technique used for spray deposition. Deposition experiments with a Cu-6Sn alloy were conducted to evaluate the appropriateness of impulse atomization to produce dense material. Based on these experiments, a model has been developed to simulate the thermal history and the local solidification rates of the deposited material. A numerical study shows how different cooling conditions affect the solidification rate of the material

Implementation and Development of the Incremental Hole Drilling Method for the Measurement of Residual Stress in Thermal Spray Coatings

Science.gov (United States)

Valente, T.; Bartuli, C.; Sebastiani, M.; Loreto, A.

2005-12-01

The experimental measurement of residual stresses originating within thick coatings deposited by thermal spray on solid substrates plays a role of fundamental relevance in the preliminary stages of coating design and process parameters optimization. The hole-drilling method is a versatile and widely used technique for the experimental determination of residual stress in the most superficial layers of a solid body. The consolidated procedure, however, can only be implemented for metallic bulk materials or for homogeneous, linear elastic, and isotropic materials. The main objective of the present investigation was to adapt the experimental method to the measurement of stress fields built up in ceramic coatings/metallic bonding layers structures manufactured by plasma spray deposition. A finite element calculation procedure was implemented to identify the calibration coefficients necessary to take into account the elastic modulus discontinuities that characterize the layered structure through its thickness. Experimental adjustments were then proposed to overcome problems related to the low thermal conductivity of the coatings. The number of calculation steps and experimental drilling steps were finally optimized.

Measurement of the non-thermal properties in a low-pressure spraying plasma

International Nuclear Information System (INIS)

Jung, Yong Ho; Chung, Kyu Sun

2002-01-01

The non-thermal properties of a low-pressure spraying plasma have been characterized by using optical emission spectroscopy and single probes installed in a fast scanning probe system. A two-temperature model of the electrons is introduced to explain their non-isothermal properties, which are measured using single probes. The excitation temperatures of the atomic and the ionic lines are calculated from measurements of the emission intensities of Ar (I) and Ar (II), and those temperatures can be explained by using a local thermodynamic equilibrium (LTE) or a non-local thermodynamic equilibrium (non-LTE) model. In order to deduce more reasonable values (excitation temperatures), we introduce a multi-thermodynamic equilibrium (MTE) model, which gives different temperatures, depending upon the atomic excitation states

Thermal Spray Deposition, Phase Stability and Mechanical Properties of La2Zr2O7/LaAlO3 Coatings

Science.gov (United States)

Lozano-Mandujano, D.; Poblano-Salas, C. A.; Ruiz-Luna, H.; Esparza-Esparza, B.; Giraldo-Betancur, A. L.; Alvarado-Orozco, J. M.; Trápaga-Martínez, L. G.; Muñoz-Saldaña, J.

2017-08-01

This paper deals with the deposition of La2Zr2O7 (LZO) and LaAlO3 (LAO) mixtures by air plasma spray (APS). The raw material for thermal spray, single phase LZO and LAO in a 70:30 mol.% ratio mixture was prepared from commercial metallic oxides by high-energy ball milling (HEBM) and high-temperature solid-state reaction. The HEBM synthesis route, followed by a spray-drying process, successfully produced spherical agglomerates with adequate size distribution and powder-flow properties for feeding an APS system. The as-sprayed coating consisted mainly of a crystalline LZO matrix and partially crystalline LAO, which resulted from the high cooling rate experienced by the molten particles as they impact the substrate. The coatings were annealed at 1100 °C to promote recrystallization of the LAO phase. The reduced elastic modulus and hardness, measured by nanoindentation, increased from 124.1 to 174.7 GPa and from 11.3 to 14.4 GPa, respectively, after the annealing treatment. These values are higher than those reported for YSZ coatings; however, the fracture toughness ( K IC) of the annealed coating was only 1.04 MPa m0.5.

Corrosion resistance and characterization of metallic coatings deposited by thermal spray on carbon steel

International Nuclear Information System (INIS)

Sá Brito, V.R.S.; Bastos, I.N.; Costa, H.R.M.

2012-01-01

Highlights: ► Five combinations of metallic coatings and intermediate bonds were deposited on carbon steels. ► High strength was reached in adhesion tests. ► Epoxy sealing of coatings improves corrosion resistance. -- Abstract: Carbon steels are not resistant to corrosion and several methods are used in surface engineering to protect them from aggressive environments such as marine. The main objective of this work is the evaluation of mechanical and metallurgical properties of five metallic coatings produced by thermal spray on carbon steel. Five chemical compositions were tested in order to give a large panel of possibility. Coatings were characterized by several methods to result in a screening of their performance. At first, the assessment of microstructural morphology by optical microscopy (OM) and by scanning electron microscopy (SEM) was made. OM and SEM results showed uniformity of deposited layer, low amount of oxides and porosity. The physical properties of coatings were also evaluated by microhardness measurement, adhesion and porosity quantification. The corrosion resistance was analyzed in salt spray and electrochemical polarization tests. In the polarization test, as well as in the salt spray, all sealed conditions presented low corrosion. A new intermediate 78.3Ni20Cr1.4Si0.3Fe alloy was studied in order to reduce pores and microcracks that are frequently found in ordinary 95Ni5Al alloy. Based on the performed characterizations, the findings suggested that the FeCrCo deposition, with an epoxy sealing, is suitable to be used as an efficient coating of carbon steel in aggressive marine environments.

Development & characterization of alumina coating by atmospheric plasma spraying

Science.gov (United States)

Sebastian, Jobin; Scaria, Abyson; Kurian, Don George

2018-03-01

Ceramic coatings are applied on metals to prevent them from oxidation and corrosion at room as well as elevated temperatures. The service environment, mechanisms of protection, chemical and mechanical compatibility, application method, control of coating quality and ability of the coating to be repaired are the factors that need to be considered while selecting the required coating. The coatings based on oxide materials provides high degree of thermal insulation and protection against oxidation at high temperatures for the underlying substrate materials. These coatings are usually applied by the flame or plasma spraying methods. The surface cleanliness needs to be ensured before spraying. Abrasive blasting can be used to provide the required surface roughness for good adhesion between the substrate and the coating. A pre bond coat like Nickel Chromium can be applied on to the substrate material before spraying the oxide coating to avoid chances of poor adhesion between the oxide coating and the metallic substrate. Plasma spraying produces oxide coatings of greater density, higher hardness, and smooth surface finish than that of the flame spraying process Inert gas is often used for generation of plasma gas so as to avoid the oxidation of the substrate material. The work focuses to develop, characterize and optimize the parameters used in Al2O3 coating on transition stainless steel substrate material for minimizing the wear rate and maximizing the leak tightness using plasma spray process. The experiment is designed using Taguchi’s L9 orthogonal array. The parameters that are to be optimized are plasma voltage, spraying distance and the cooling jet pressure. The characterization techniques includes micro-hardness and porosity tests followed by Grey relational analysis of the results.

Effect of spray volume on the deposition, viability and infectivity of entomopathogenic nematodes in a foliar spray on vegetables.

Science.gov (United States)

Brusselman, Eva; Beck, Bert; Pollet, Sabien; Temmerman, Femke; Spanoghe, Pieter; Moens, Maurice; Nuyttens, David

2012-10-01

Spray volume can influence the amount of free water on the leaf surface and subsequently the ability of entomopathogenic nematodes (EPNs) to move. In this study, an investigation was made of the effect of spray volume (548, 730 and 1095 L ha(-1) ) on the deposition, viability and infectivity of EPNs against Galleria mellonella on savoy cabbage, cauliflower and leek. Increasing spray volume decreased nematode deposition on 7.1 cm2 leek leaf discs at a 15° angle with the spray nozzle. Although the number of living nematodes observed on leek after 240 min of exposure was not significantly different between the low-volume application (548 L ha(-1) ) and the high-volume application (1095 L ha(-1) ), a greater infectivity was obtained in the latter application. The higher number of droplets deposited on the leek discs in the high-volume application may have stimulated nematode movement. No significant effect of spray volume was observed on the relative deposition of Steinernema carpocapsae on the bottom side of cauliflower and savoy cabbage leaf discs. In spite of the low S. carpocapsae deposition on the bottom side of the savoy cabbage discs, high infectivity was obtained against G. mellonella. Using the lowest spray volume on savoy cabbage, infectivity decreased with increasing exposure time, while infectivity was not affected by exposure time when a spray volume of 730 L ha(-1) or more was used. Spray volume is an important application parameter, as it affects nematode infectivity. Future research should investigate the effect of spray volume in the field and its influence on the effect of adjuvants. Copyright © 2012 Society of Chemical Industry.

Pesticide residues in individual versus composite samples of apples after fine or coarse spray quality application

DEFF Research Database (Denmark)

Poulsen, Mette E.; Wenneker, Marcel; Withagen, Jacques

2012-01-01

. None of the results for the pesticides residues measured in individual apples exceeded the EU Maximum Residue Levels (MRLs). However, there was a large variation in the residues levels in the apples, with levels from 0.01 to 1.4 mg kg−1 for captan, the pesticide with the highest variation, and from 0.......01 to 0.2 mg kg−1 for pyraclostrobin, the pesticide with the lowest variation. Residues of fenoxycarb and indoxacarb were only found in a few apples, probably due to the early application time of these two compounds. The evaluation of the effect of spray quality did not show any major difference between......In this study, field trials on fine and coarse spray quality application of pesticides on apples were performed. The main objectives were to study the variation of pesticide residue levels in individual fruits versus composite samples, and the effect of standard fine spray quality application...

Simulation of the coating film appearance for spray application

OpenAIRE

Seeler, Fabian; Hager, Christian; Schneider, Matthias; Tiedje, Oliver

2015-01-01

The coating film topography depends on the substrate structure, the application parameters and the coating material’s levelling properties. Substrates consisting of several materials with different surface structures and differently inclined areas make a homogenous coating film structure difficult. By means of simulations, the paint film structure is intended to be controlled so that the theoretical optimum is reached and the experimental effort can be reduced. The focus is on spray applicati...

Field evaluation of a self-propelled sprayer and effects of the application rate on spray deposition and losses to the ground in greenhouse tomato crops.

Science.gov (United States)

Sánchez-Hermosilla, Julián; Rincón, Víctor J; Páez, Francisco; Agüera, Francisco; Carvajal, Fernando

2011-08-01

In the greenhouses of south-eastern Spain, plant protection products are applied using mainly sprayers at high pressures and high volumes. This results in major losses on the ground and less than uniform spray deposition on the canopy. Recently, self-propelled vehicles equipped with vertical spray booms have appeared on the market. In this study, deposition on the canopy and the losses to the ground at different spray volumes have been compared, using a self-propelled vehicle with vertical spray booms versus a gun sprayer. Three different spray volumes have been tested with a boom sprayer, and two with a spray gun. The vehicle with the vertical spray boom gave similar depositions to those made with the gun, but at lower application volumes. Also, the distribution of the vertical spray boom was more uniform, with lower losses to the ground. The vertical spray booms used in tomato crops improve the application of plant protection products with respect to the spray gun, reducing the application volumes and the environmental risks of soil pollution. Copyright © 2011 Society of Chemical Industry.

Industrial application of model predictive control to a milk powder spray drying plant

DEFF Research Database (Denmark)

Petersen, Lars Norbert; Poulsen, Niels Kjølstad; Niemann, Hans Henrik

2016-01-01

In this paper, we present our first results from an industrial application of model predictive control (MPC) with real-time steady-state target optimization (RTO) for control of an industrial spray dryer that produces enriched milk powder. The MPC algorithm is based on a continuous-time transfer...... provides significantly better control of the residual moisture content, increases the throughput and decreases the energy consumption compared to conventional PI-control. The MPC operates the spray dryer closer to the residual moisture constraint of the powder product. Thus, the same amount of feed...

Strontium Zirconate TBC Sprayed by a High Feed-Rate Water-Stabilized Plasma Torch

Science.gov (United States)

Ctibor, P.; Nevrla, B.; Cizek, J.; Lukac, F.

2017-12-01

A novel thermal barrier coating (TBC) material, strontium zirconate SrZrO3, was sprayed by a high feed-rate water-stabilized plasma torch WSP 500. Stainless steel coupons were used as substrates. Coatings with a thickness of about 1.2 mm were produced, whereas the substrates were preheated over 450 °C. The torch worked at 150 kW power and was able to spray SrZrO3 with a high spray rate over 10 kg per hour. Microstructure and microhardness, phase composition, adhesion, thermal conductivity and thermal expansion were evaluated. The coating has low thermal conductivity under 1 W/m K in the interval from room temperature up to 1200 °C. Its crystallite size is slightly over 400 nm and thermal expansion 12.3 µm K-1 in the similar temperature range.

Cold sprayed WO3 and TiO2 electrodes for photoelectrochemical water and methanol oxidation in renewable energy applications.

Science.gov (United States)

Haisch, Christoph; Schneider, Jenny; Fleisch, Manuel; Gutzmann, Henning; Klassen, Thomas; Bahnemann, Detlef W

2017-10-03

Films prepared by cold spray have potential applications as photoanodes in electrochemical water splitting and waste water purification. In the present study cold sprayed photoelectrodes produced with WO 3 (active under visible light illumination) and TiO 2 (active under UV illumination) on titanium metal substrates were investigated as photoanodes for the oxidation of water and methanol, respectively. Methanol was chosen as organic model pollutant in acidic electrolytes. Main advantages of the cold sprayed photoelectrodes are the improved metal-semiconductor junctions and the superior mechanical stability. Additionally, the cold spray method can be utilized as a large-scale electrode fabrication technique for photoelectrochemical applications. Incident photon to current efficiencies reveal that cold sprayed TiO 2 /WO 3 photoanodes exhibit the best photoelectrochemical properties with regard to the water and methanol oxidation reactions in comparison with the benchmark photocatalyst Aeroxide TiO 2 P25 due to more efficient harvesting of the total solar light irradiation related to their smaller band gap energies.

Spray Deposition and Drift Characteristics of a Low Drift Nozzle for Aerial Application at Different Application Altitudes

Science.gov (United States)

A complex interaction of controllable and uncontrollable factors is involved in aerial application of crop production and protection materials. Although it is difficult to completely characterize spray deposition and drift, these important factors can be estimated with appropriate sampling protocol ...

Influence of spray parameters on the microstructure and mechanical properties of gas-tunnel plasma sprayed hydroxyapatite coatings

International Nuclear Information System (INIS)

Morks, M.F.; Kobayashi, Akira

2007-01-01

For biomedical applications, hydroxyapatite (HA) coatings were deposited on 304 stainless steel substrate by using a gas tunnel type plasma spraying process. The influences of spraying distances and plasma arc currents on the microstructure, hardness and adhesion properties of HA coatings were investigated. Microstructure observation by SEM showed that HA coatings sprayed at low plasma power have a porous structure and poor hardness. HA coatings sprayed at high plasma power and short spraying distance are characterized by good adhesion and low porosity with dense structure. Hardness increased for HA coatings sprayed at shorter spraying distance and higher plasma power, mainly due to the formation of dense coatings

Improving the biocontrol potential of entomopathogenic nematodes against Mamestra brassicae: effect of spray application technique, adjuvants and an attractant.

Science.gov (United States)

Beck, Bert; Brusselman, Eva; Nuyttens, David; Moens, Maurice; Temmerman, Femke; Pollet, Sabien; Van Weyenberg, Stephanie; Spanoghe, Pieter

2014-01-01

Steinernema carpocapsae Weiser, an entomopathogenic nematode (EPN), is a potential biological control agent for the cabbage moth (Mamestra brassicae L.). This research aimed to identify a suitable spray application technique, and to determine whether yeast extract added to an EPN spray has an attracting and/or a feeding stimulant effect on M. brassicae. The biological control capabilities of EPN against this pest were examined in the field. Good coverage of the underside of cauliflower leaves, the habitat of young instar larvae (L1-L4) of M. brassicae was obtained using different spray boom configurations with vertical extensions that carried underleaf spraying nozzles. One of the configurations was selected for field testing with an EPN spray. Brewer's yeast extract stimulated larval feeding on leaves, and increased the mortality of these larvae when exposed to EPN. The field trial showed that a spray application with S. carpocapsae, Addit and xanthan gum can effectively lower the numbers of cabbage heads damaged by M. brassicae. Brewer's yeast extract did not significantly increase this field performance of EPN. Steinernema carpocapsae, applied with an appropriate spray technique, can be used within biological control schemes as part of a resistance management programme for Bt. © 2013 Society of Chemical Industry.

Improved Thermally Grown Oxide Scale in Air Plasma Sprayed NiCrAlY/Nano-YSZ Coatings

International Nuclear Information System (INIS)

Daroonparvar, M.; Yajid, M.A.M.; Yusof, N.M.; Hussain, M.S.

2013-01-01

Oxidation has been considered as one of the principal disruptive factors in thermal barrier coating systems during service. So, oxidation behavior of thermal barrier coating (TBC) systems with nano structured and micro structured YSZ coatings was investigated at 1000 degree c for 24 h, 48 h, and 120 h. Air plasma sprayed nano-YSZ coating exhibited a tri modal structure. Microstructural characterization also demonstrated an improved thermally grown oxide scale containing lower spinels in nano-TBC system after 120 h of oxidation. This phenomenon is mainly related to the unique structure of the nano-YSZ coating, which acted as a strong barrier for oxygen diffusion into the TBC system at elevated temperatures. Nearly continues but thinner Al 2 O 3 layer formation at the NiCrAlY/nano-YSZ interface was seen, due to lower oxygen infiltration into the system. Under this condition, spinels formation and growth on the Al 2 O 3 oxide scale were diminished in nano-TBC system compared to normal TBC system.

Experiment and numerical analysis of the NPP pressurizer auxiliary spray line submitted to large thermal shocks

International Nuclear Information System (INIS)

Couterot, C.; Geyer, P.; Proix, J.M.

1994-03-01

The pressurizer auxiliary spray line of PWR nuclear power plants may be submitted to severe temperature transients during upset conditions: a 325 deg C cold thermal shock in one second is followed by a 200 deg C hot thermal shock. For such transients, the RCC-M French design code rules that prevent the ratcheting deformation hazard are not respected for the components with thickness transition. Consequently, Electricite de France has realized twenty thermal cycles under pressure on a representative mock-up. During these tests, many temperature, strain and diametral variations were measured. No significant ratcheting deformation was detected on all components, except on the 6'' x 2'' x 6'' T-piece, where a weak progressive diameter increase was observed during a few cycles. Moreover, computations of a 2'' socket welding were made with the non linear kinematic hardening Chaboche model which also showed a weak progressive deformation behaviour. (authors). 7 figs., 7 refs

Fabrication of High-Temperature Heat Exchangers by Plasma Spraying Exterior Skins on Nickel Foams

Science.gov (United States)

Hafeez, P.; Yugeswaran, S.; Chandra, S.; Mostaghimi, J.; Coyle, T. W.

2016-06-01

Thermal-sprayed heat exchangers were tested at high temperatures (750 °C), and their performances were compared to the foam heat exchangers made by brazing Inconel sheets to their surface. Nickel foil was brazed to the exterior surface of 10-mm-thick layers of 10 and 40 PPI nickel foam. A plasma torch was used to spray an Inconel coating on the surface of the foil. A burner test rig was built to produce hot combustion gases that flowed over exposed face of the heat exchanger. Cooling air flowed through the foam heat exchanger at rates of up to 200 SLPM. Surface temperature and air inlet/exit temperature were measured. Heat transfer to air flowing through the foam was significantly higher for the thermally sprayed heat exchangers than for the brazed heat exchangers. On an average, thermally sprayed heat exchangers show 36% higher heat transfer than conventionally brazed foam heat exchangers. At low flow rates, the convective resistance is large (~4 × 10-2 m2 K/W), and the effect of thermal contact resistance is negligible. At higher flow rates, the convective resistance decreases (~2 × 10-3 m2 K/W), and the lower contact resistance of the thermally sprayed heat exchanger provides better performance than the brazed heat exchangers.

Modification of Bonding Strength Test of WC HVOF Thermal Spray Coating on Rocket Nozzle

Directory of Open Access Journals (Sweden)

Bondan Sofyan

2010-10-01

Full Text Available One way to reduce structural weight of RX-100 rocket is by modifying the nozzle material and processing. Nozzle is the main target in weight reduction due to the fact that it contributes 30 % to the total weight of the structur. An alternative for this is by substitution of massive graphite, which is currently used as thermal protector in the nozzle, with thin layer of HVOF (High Velocity Oxy-Fuel thermal spray layer. This paper presents the characterization of nozzle base material as well as the modification of bonding strength test, by designing additional jig to facilitate testing processes while maintaining level of test accuracy. The results showed that the material used for  RX-100 rocket nozzle is confirmed to be S45C steel. Modification of the bonding strength test was conducted by utilizing chains, which improve test flexibility and maintains level of accuracy of the test.

Effect of whey protein isolate and β-cyclodextrin wall systems on stability of microencapsulated vanillin by spray-freeze drying method.

Science.gov (United States)

Hundre, Swetank Y; Karthik, P; Anandharamakrishnan, C

2015-05-01

Vanillin flavour is highly volatile in nature and due to that application in food incorporation is limited; hence microencapsulation of vanillin is an ideal technique to increase its stability and functionality. In this study, vanillin was microencapsulated for the first time by non-thermal spray-freeze-drying (SFD) technique and its stability was compared with other conventional techniques such as spray drying (SD) and freeze-drying (FD). Different wall materials like β-cyclodextrin (β-cyd), whey protein isolate (WPI) and combinations of these wall materials (β-cyd + WPI) were used to encapsulate vanillin. SFD microencapsulated vanillin with WPI showed spherical shape with numerous fine pores on the surface, which in turn exhibited good rehydration ability. On the other hand, SD powder depicted spherical shape without pores and FD encapsulated powder yielded larger particle sizes with flaky structure. FTIR analysis confirmed that there was no interaction between vanillin and wall materials. Moreover, spray-freeze-dried vanillin + WPI sample exhibited better thermal stability than spray dried and freeze-dried microencapsulated samples. Copyright © 2014 Elsevier Ltd. All rights reserved.

Corrosion performance of atmospheric plasma sprayed alumina coatings on AZ31B magnesium alloy under immersion environment

Directory of Open Access Journals (Sweden)

D. Thirumalaikumarasamy

2014-12-01

Full Text Available Plasma sprayed ceramic coatings are successfully used in many industrial applications, where high wear and corrosion resistance with thermal insulation are required. The alumina powders were plasma sprayed on AZ31B magnesium alloy with three different plasma spraying parameters. In the present work, the influence of plasma spray parameters on the corrosion behavior of the coatings was investigated. The corrosion behavior of the coated samples was evaluated by immersion corrosion test in 3.5 wt% NaCl solution. Empirical relationship was established to predict the corrosion rate of plasma sprayed alumina coatings by incorporating process parameters. The experiments were conducted based on a three factor, five-level, central composite rotatable design matrix. The developed relationship can be effectively used to predict the corrosion rate of alumina coatings at 95% confidence level. The results indicate that the input power has the greatest influence on corrosion rate, followed by stand-off distance and powder feed rate.

Thermal Cameras and Applications

DEFF Research Database (Denmark)

Gade, Rikke; Moeslund, Thomas B.

2014-01-01

Thermal cameras are passive sensors that capture the infrared radiation emitted by all objects with a temperature above absolute zero. This type of camera was originally developed as a surveillance and night vision tool for the military, but recently the price has dropped, significantly opening up...... a broader field of applications. Deploying this type of sensor in vision systems eliminates the illumination problems of normal greyscale and RGB cameras. This survey provides an overview of the current applications of thermal cameras. Applications include animals, agriculture, buildings, gas detection......, industrial, and military applications, as well as detection, tracking, and recognition of humans. Moreover, this survey describes the nature of thermal radiation and the technology of thermal cameras....

Development of Process for Plasma Spray:Case Study for Molybdenum

Czech Academy of Sciences Publication Activity Database

Sampath, S.; Jiang, X.; Kulkarni, A.; Matějíček, Jiří; Gilmore, D. L.; Neiser, R. A.

2003-01-01

Roč. 348, 1-2 (2003), s. 54-66 ISSN 0921-5093 Grant - others:NSF(US) DMR9632570 Institutional research plan: CEZ:AV0Z2043910 Keywords : process maps, plasma spray, thermal spray Subject RIV: JG - Metallurgy Impact factor: 1.365, year: 2003

Optimized functionally graded La{sub 2}Zr{sub 2}O{sub 7}/8YSZ thermal barrier coatings fabricated by suspension plasma spraying

Energy Technology Data Exchange (ETDEWEB)

Wang, Chaohui [Laboratory of Nano Surface Engineering, School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China); College of Materials Science and Engineering, Qiqihar University, Qiqihar 161006 (China); Wang, You, E-mail: wangyou@hit.edu.cn [Laboratory of Nano Surface Engineering, School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China); Fan, Shan; You, Yuan [College of Materials Science and Engineering, Qiqihar University, Qiqihar 161006 (China); Wang, Liang [Key Laboratory of Inorganic Coating Materials, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 201899 (China); Yang, Changlong [College of Materials Science and Engineering, Qiqihar University, Qiqihar 161006 (China); Sun, Xiaoguang [National Engineering Research Center for High-speed EMU, CSR Qingdao Sifang Co. Ltd., Qingdao 266111 (China); Li, Xuewei [Laboratory of Nano Surface Engineering, School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China)

2015-11-15

In this paper, an optimized functionally graded coating (OFGC) was successfully fabricated by suspension plasma spraying (SPS) with feedstocks of the suspension of nanoparticles. La{sub 2}Zr{sub 2}O{sub 7}/8YSZ OFGC with gradual compositional variation along the through-thickness direction is proposed to mitigate spallation and crack formation owing to the high residual stresses caused by frequent thermal cycling for TBCs. The single ceramic layer coatings (SCLC) of LZ and double ceramic layer coatings (DCLC) of LZ/8YSZ were fabricated by SPS as comparison. The phase composition and microstructure of the SCLC, OFGC and DCLC were characterized by X-ray diffraction (XRD), scanning electron microscope (SEM) and Energy Dispersive Spectrometer (EDS). Moreover, the thermal cycling tests were carried out to evaluate their thermal shock behavior. Changes in weight and morphology of specimens were analyzed during thermal cycling tests. The results showed that OFGC has extended lifetime compared with SCLC and DCLC. The failure of DCLC with clear interface between different ceramic layers occurred via delamination mode, as a result of crack initiation and propagation generated by thermal mismatch between LZ and 8YSZ. While the failure of OFGC occurred in thermally grown oxide (TGO) layers, indicating that the gradual compositional variation avoided thermal stress concentration in the top ceramic layers. - Highlights: • Optimized functionally graded coatings and double ceramic layer coatings were deposited by suspension plasma spray. • The graded area of OFGC is continuously changed from inner 8YSZ to outer La{sub 2}Zr{sub 2}O{sub 7} (LZ). • The OFGC shows a more extended thermal cycling life than the LZ SCLC and LZ/8YSZ DCLC. • Various failure mechanisms were proposed to explain thermal cycling behavior.

Study of different biocomposite coatings on Ti alloy by a subsonic thermal spraying technique

Energy Technology Data Exchange (ETDEWEB)

Li Muqin [Provincial Key Laboratory of Biomaterials, Jiamusi University, Heilongjiang Province, 154007 (China); Zhang Rui [College of Stomatology, Jiamusi University, Heilongjiang Province, 154003 (China); Wang Jianping [College of Stomatology, Jiamusi University, Heilongjiang Province, 154003 (China); Yang Shiqin [State Key Laboratory Advanced Welding Production Technology, Harbin Institute of Technology, 150001 (China)

2007-03-01

A subsonic thermal spraying technique (STS) was used to make different biocomposite coatings on titanium alloys for preparing three kinds of implants: 8Ti2G, HA and 8H2B, respectively. The implants were embedded in a region of jaw of dogs whose teeth were pulled out three months previously. The dogs, in two groups, were killed 30 days and 90 days, respectively, after they were operated on. Osteointegration between the implants and host bone was investigated by x-ray, histology and the SEM technique. The results showed that the three kinds of coatings all exhibited good biocompatibility and synostosis, but their osteointegration capability showed a difference and decreased in the sequence of 8H2B, HA and 8Ti2G. The activity of coating, which promoted the reactions between implants and bone tissue, was further increased by the addition of bioglass in the 8H2B coating. Subsequently, chemical bonding was formed, and the osteointegration strength was increased. The study provided a new approach to prepare biocomposite coatings. The 8H2B implants, which formed an integral functional biocomposite coating on Ti alloys, showed a better osteointegration capability with bioactivity and pore gradient variation. A theoretical base was provided for the biocomposite coating application.

Characterization of plasma sprayed beryllium ITER first wall mockups

Energy Technology Data Exchange (ETDEWEB)

Castro, R.G.; Vaidya, R.U.; Hollis, K.J. [Los Alamos National Lab., NM (United States). Material Science and Technology Div.

1998-01-01

ITER first wall beryllium mockups, which were fabricated by vacuum plasma spraying the beryllium armor, have survived 3000 thermal fatigue cycles at 1 MW/m{sup 2} without damage during high heat flux testing at the Plasma Materials Test Facility at Sandia National Laboratory in New Mexico. The thermal and mechanical properties of the plasma sprayed beryllium armor have been characterized. Results are reported on the chemical composition of the beryllium armor in the as-deposited condition, the through thickness and normal to the through thickness thermal conductivity and thermal expansion, the four-point bend flexure strength and edge-notch fracture toughness of the beryllium armor, the bond strength between the beryllium armor and the underlying heat sink material, and ultrasonic C-scans of the Be/heat sink interface. (author)

Characterization of Plasma Sprayed Beryllium ITER First Wall Mockups

International Nuclear Information System (INIS)

Castro, Richard G.; Vaidya, Rajendra U.; Hollis, Kendall J.

1997-10-01

ITER first wall beryllium mockups, which were fabricated by vacuum plasma spraying the beryllium armor, have survived 3000 thermal fatigue cycles at 1 MW/sq m without damage during high heat flux testing at the Plasma Materials Test Facility at Sandia National Laboratory in New Mexico. The thermal and mechanical properties of the plasma sprayed beryllium armor have been characterized. Results are reported on the chemical composition of the beryllium armor in the as-deposited condition, the through thickness and normal to the through thickness thermal conductivity and thermal expansion, the four-point bend flexure strength and edge-notch fracture toughness of the beryllium armor, the bond strength between the beryllium armor and the underlying heat sink material, and ultrasonic C-scans of the Be/heat sink interface

Thermal management for LED applications

CERN Document Server

Poppe, András

2014-01-01

Thermal Management for LED Applications provides state-of-the-art information on recent developments in thermal management as it relates to LEDs and LED-based systems and their applications. Coverage begins with an overview of the basics of thermal management including thermal design for LEDs, thermal characterization and testing of LEDs, and issues related to failure mechanisms and reliability and performance in harsh environments. Advances and recent developments in thermal management round out the book with discussions on advances in TIMs (thermal interface materials) for LED applications, advances in forced convection cooling of LEDs, and advances in heat sinks for LED assemblies. This book also: Presents a comprehensive overview of the basics of thermal management as it relates to LEDs and LED-based systems Discusses both design and thermal management considerations when manufacturing LEDs and LED-based systems Covers reliability and performance of LEDs in harsh environments Has a hands-on applications a...

Role of process conditions on the microstructure, stoichiometry and functional performance of atmospheric plasma sprayed La(Sr)MnO3 coatings

Science.gov (United States)

Han, Su Jung; Chen, Yikai; Sampath, Sanjay

2014-08-01

Strontium doped lanthanum manganite (LSM) perovskite coatings were produced via atmospheric plasma spray technique to examine their applicability as electrically conductive coatings to protect chromium-poisoning of cathode side metallic interconnects in solid oxide fuel cells. Various plasma spray process conditions were manipulated including plasma power, total gas flow and content of H2 in the plasma gas in order to understand their effects on coating properties as well as efficacy as a protectant against Cr-poisoning. In-flight temperatures and velocities of spray particles were monitored for the various plasma spray conditions enabling assessment of thermal and kinetic energies of LSM particles. As anticipated, coating density improves with increasing thermal and/or kinetic energies of the LSM particles. However, the LSM particles also experienced significant phase decomposition at higher thermal exposure and longer residence time conditions. Due to preferential loss of oxygen and manganese, La2O3 phase is also formed under certain processing regimes. The resultant mixed-phase coating is ineffective both from electrical transport and as a protective coating for the metallic interconnect. Concomitantly, coatings with limited decomposition show excellent conductivity and protection characteristics demonstrating the need for mechanism driven process optimization for these functional oxide coatings.

Synthesis of free-standing carbon nanohybrid by directly growing carbon nanotubes on air-sprayed graphene oxide paper and its application in supercapacitor

International Nuclear Information System (INIS)

Wei, Li; Jiang, Wenchao; Yuan, Yang; Goh, Kunli; Yu, Dingshan; Wang, Liang; Chen, Yuan

2015-01-01

We report the synthesis of a free-standing two dimensional carbon nanotube (CNT)-reduced graphene oxide (rGO) hybrid by directly growing CNTs on air-sprayed GO paper. As a result of the good integration between CNTs and thermally reduced GO film during chemical vapor deposition, excellent electrical conductivity (2.6×10 4 S/m), mechanical flexibility (electrical resistance only increases 1.1% after bent to 90° for 500 times) and a relatively large surface area (335.3 m 2 /g) are achieved. Two-electrode supercapacitor assembled using the CNT–rGO hybrids in ionic liquid electrolyte (1-ethyl-3-methylimidazolium tetrafluoroborate) shows excellent stability upon 500 bending cycles with the gravimetric energy density measuring 23.7 Wh/kg and a power density of 2.0 kW/kg. Furthermore, it shows an impedance phase angle of −64.4° at a frequency of 120 Hz, suggesting good potentials for 120 Hz alternating current line filtering applications. - Graphical abstract: Flexible and highly conductive carbon nanotube-reduced graphene oxide nanohybrid. - Highlights: • Direct growth of carbon nanotubes by chemical vapor deposition on air-sprayed graphene oxide paper. • Two-dimensional carbon nanohybrid with excellent conductivity and mechanical flexibility. • Supercapacitor with excellent performance stability upon mechanical deformation for flexible electronics applications. • Supercapacitor with high impedance phase angle for 120 Hz alternating current line filtering applications

Characteristics and Thermal Efficiency of a Non-transferred DC Plasma Spraying Torch Under Low Pressure

International Nuclear Information System (INIS)

Bao Shicong; Ye Minyou; Zhang Xiaodong; Guo Wenkang; Xu Ping

2008-01-01

Current-voltage (I-V) characteristics of a non-transferred DC arc plasma spray torch operated in argon at vacuum are reported. The arc voltage is of negative characteristics for a current below 200 A, flat for a current between 200 A to 250 A and positive for a current beyond 250 A. The voltage increases slowly with the increase in carrier gas of arc. The rate of change in voltage with currents is about 3∼4 V/100 A at a gas flow rate of about 1∼1.5 V/10 standard liter per minute (slpm). The I-V characteristics of the DC plasma torch are of a shape of hyperbola. Arc power increases with the argon flow rate, and the thermal efficiency of the torch acts in a similar way. The thermal efficiency of the non-transferred DC plasmatron is about 65∼78%. (low temperature plasma)

Corrosion characteristics of thermal sprayed coating of stainless alloys in chloride solution; Taishoku gokin yosha himaku no enkabutsu yoekichu ni okeru fushoku tokusei

Energy Technology Data Exchange (ETDEWEB)

Suzuki, T. [Ajinomoto Co. Inc., Tokyo (Japan); Ishikawa, K. [Tokyo Metallikon Co. Ltd., Tokyo (Japan); Kitamura, Y. [Kitamura Technical Consultant Office, Kanagawa (Japan)

1994-12-15

With an objective to develop a thermal sprayed coating of environment interruption type that can be sprayed at sites, electrochemical discussions, SEM observation, and EPMA surface analysis were performed on corrosion characteristics in chloride solution of coatings of SUS 304, 316 and Hastelloy C thermally sprayed onto test pieces made of structural steel SS400, as well as the effect of improvement in corrosion resistance by means of a coating reforming treatment. The following conclusions were obtained: the degradation in corrosion resistance of the coatings is attributable to increase in anodic solubility due to appearance of innumerable crevices as a result of deposited particles forming porous structure and due to drop of Cr content in the matrix caused by generation of oxides on the surface of the crevices, by which the corrosion progresses in the form of crevice corrosion; and denseness of the passive coating is lost on the surface of the deposited particles, accelerating the cathodic reaction. A suitable means that could be used practically in chloride solution would be a method to use a material with less crevice susceptibility such as Hastelloy C as a base material, and seal the crevice structure with epoxy resin, etc. 7 refs., 10 figs., 3 tabs.

Improved Metallography Of Thermal-Barrier Coatings

Science.gov (United States)

Brindley, William J.; Leonhardt, Todd A.

1991-01-01

New technique for preparation of metallographic samples makes interpretation of images of pores and microcracks more reliable. Involves use of vacuum epoxy infiltration and interference-film coating to reduce uncertainty. Developed for inspection of plasma-sprayed ceramic thermal-barrier coatings on metals but applicable to other porous, translucent materials, including many important ceramics.

Low-Temperature Preparation of Tungsten Oxide Anode Buffer Layer via Ultrasonic Spray Pyrolysis Method for Large-Area Organic Solar Cells.

Science.gov (United States)

Ji, Ran; Zheng, Ding; Zhou, Chang; Cheng, Jiang; Yu, Junsheng; Li, Lu

2017-07-18

Tungsten oxide (WO₃) is prepared by a low-temperature ultrasonic spray pyrolysis method in air atmosphere, and it is used as an anode buffer layer (ABL) for organic solar cells (OSCs). The properties of the WO₃ transition metal oxide material as well as the mechanism of ultrasonic spray pyrolysis processes are investigated. The results show that the ultrasonic spray pyrolysized WO₃ ABL exhibits low roughness, matched energy level, and high conductivity, which results in high charge transport efficiency and suppressive recombination in OSCs. As a result, compared to the OSCs based on vacuum thermal evaporated WO₃, a higher power conversion efficiency of 3.63% is reached with low-temperature ultrasonic spray pyrolysized WO₃ ABL. Furthermore, the mostly spray-coated OSCs with large area was fabricated, which has a power conversion efficiency of ~1%. This work significantly enhances our understanding of the preparation and application of low temperature-processed WO₃, and highlights the potential of large area, all spray coated OSCs for sustainable commercial fabrication.

Measuring Spray Droplet Size from Agricultural Nozzles Using Laser Diffraction

Science.gov (United States)

Fritz, Bradley K.; Hoffmann, W. Clint

2016-01-01

When making an application of any crop protection material such as an herbicide or pesticide, the applicator uses a variety of skills and information to make an application so that the material reaches the target site (i.e., plant). Information critical in this process is the droplet size that a particular spray nozzle, spray pressure, and spray solution combination generates, as droplet size greatly influences product efficacy and how the spray moves through the environment. Researchers and product manufacturers commonly use laser diffraction equipment to measure the spray droplet size in laboratory wind tunnels. The work presented here describes methods used in making spray droplet size measurements with laser diffraction equipment for both ground and aerial application scenarios that can be used to ensure inter- and intra-laboratory precision while minimizing sampling bias associated with laser diffraction systems. Maintaining critical measurement distances and concurrent airflow throughout the testing process is key to this precision. Real time data quality analysis is also critical to preventing excess variation in the data or extraneous inclusion of erroneous data. Some limitations of this method include atypical spray nozzles, spray solutions or application conditions that result in spray streams that do not fully atomize within the measurement distances discussed. Successful adaption of this method can provide a highly efficient method for evaluation of the performance of agrochemical spray application nozzles under a variety of operational settings. Also discussed are potential experimental design considerations that can be included to enhance functionality of the data collected. PMID:27684589

Impact of probing volume from different mechanical measurement methods on elastic properties of thermally sprayed Ni-based coatings on a mesoscopic scale

Czech Academy of Sciences Publication Activity Database

Margadant, N.; Neuenschwander, J.; Stauss, S.; Kaps, H.; Kulkarni, A.; Matějíček, Jiří; Rössler, G.

2006-01-01

Roč. 200, č. 8 (2006), s. 2805-2820 ISSN 0257-8972 Grant - others:Evropská unie Eureka 1973 “Thermetcoat” (EU) Institutional research plan: CEZ:AV0Z20430508 Keywords : Elastic Pro perties * Defects * Thermal spraying * Nickel alloy Subject RIV: JG - Metallurgy Impact factor: 1.559, year: 2006

Current Progress in Solution Precursor Plasma Spraying of Cermets: A Review

Directory of Open Access Journals (Sweden)

Romnick Unabia

2018-06-01

Full Text Available Ceramic and metal composites, known also as cermets, may considerably improve many material properties with regards to that of initial components. Hence, cermets are frequently applied in many technological fields. Among many processes which can be employed for cermet manufacturing, thermal spraying is one of the most frequently used. Conventional plasma spraying of powders is a popular and cost-effective manufacturing process. One of its most recent innovations, called solution precursor plasma spraying (SPPS, is an emerging coating deposition method which uses homogeneously mixed solution precursors as a feedstock. The technique enables a single-step deposition avoiding the powder preparation procedures. The nanostructured coatings developed by SPPS increasingly find a place in the field of surface engineering. The present review shows the recent progress in the fabrication of cermets using SPPS. The influence of starting solution precursors, such as their chemistry, concentration, and solvents used, to the micro-structural characteristics of cermet coatings is discussed. The effect of the operational plasma spray process parameters such as solution injection mode to the deposition process and coatings’ microstructure is also presented. Moreover, the advantages of the SPPS process and its drawbacks compared to the conventional powder plasma spraying process are discussed. Finally, some applications of SPPS cermet coatings are presented to understand the potential of the process.

Thermal Conductivity and Water Vapor Stability of Ceramic HfO2-Based Coating Materials

Science.gov (United States)

Zhu, Dong-Ming; Fox, Dennis S.; Bansal, Narottam P.; Miller, Robert A.

2004-01-01

HfO2-Y2O3 and La2Zr2O7 are candidate thermal/environmental barrier coating materials for gas turbine ceramic matrix composite (CMC) combustor liner applications because of their relatively low thermal conductivity and high temperature capability. In this paper, thermal conductivity and high temperature phase stability of plasma-sprayed coatings and/or hot-pressed HfO2-5mol%Y2O3, HfO2-15mol%Y2O3 and La2Zr2O7 were evaluated at temperatures up to 1700 C using a steady-state laser heat-flux technique. Sintering behavior of the plasma-sprayed coatings was determined by monitoring the thermal conductivity increases during a 20-hour test period at various temperatures. Durability and failure mechanisms of the HfO2-Y2O3 and La2Zr2O7 coatings on mullite/SiC Hexoloy or CMC substrates were investigated at 1650 C under thermal gradient cyclic conditions. Coating design and testing issues for the 1650 C thermal/environmental barrier coating applications will also be discussed.

Study of thermal and electrical parameters of workpieces during spray coating by electrolytic plasma jet

International Nuclear Information System (INIS)

Khafizov, A A; Shakirov, Yu I; Valiev, R A; Valiev, R I; Khafizova, G M

2016-01-01

In this paper the results are presented of thermal and electrical parameters of products in the system bottom layer - intermediate layer when applying protective coatings of ferromagnetic powder by plasma spray produced in an electric discharge with a liquid cathode, on steel samples. Temperature distribution and gradients in coating and intermediate coating were examined. Detailed descriptions of spray coating with ferromagnetic powder by plasma jet obtained in electrical discharge with liquid cathode and the apparatus for obtaining thereof is provided. Problem has been solved by using of Fourier analysis. Initial data for calculations is provided. Results of numerical analysis are provided as temporal functions of temperature in contiguity between coating and intermediate coating as well as temporal function of the value Q=q-φ; where q is density of heat current directed to the free surface of intermediate coating, φ is density of heat current in contiguity between coating and intermediate coating. The analysis of data given shows that in the systems of contact heat exchange bottom layer-intermediate layer with close values of the thermophysical characteristics of constituting materials is observed a slow increase of the temperature of the contact as a function of time. (paper)

Protection of 310l Stainless Steel from Wear at Elevated Temperatures using Conicraly Thermal Spray Coatings with and without Sic Addition

Science.gov (United States)

Zhang, Yan; Zhang, Tao; Li, Kaiyang; Li, Dongyang

2017-10-01

Due to its high oxidation resistance, 310L stainless steel is often used for thermal facilities working at high-temperatures. However, the steel may fail prematurely at elevated temperatures when encounter surface mechanical attacks such as wear. Thermal spray coatings have been demonstrated to be effective in protecting the steel from wear at elevated temperatures. In this study, we investigated the effectiveness of high velocity oxy-fuel(HVOF) spraying CoNiCrAlY/SiC coatings in resisting wear of 310L stainless steel at elevated temperature using a pin-on-disc wear tester. In order to further improve the performance of the coating, 5%SiC was added to the coating. It was demonstrated that the CoNiCrAlY/SiC coating after heat treatment markedly suppressed wear. However, the added SiC particles did not show benefits to the wear resistance of the coating. Microstructures of CoNiCrAlY coatings with and without the SiC addition were characterized in order to understand the mechanism responsible for the observed phenomena.

Characterization of spray deposition and drift from a low drift nozzle for aerial application at different application altitudes

Science.gov (United States)

A complex interaction of controllable and uncontrollable factors is involved in aerial application of crop production and protection materials. Although it is difficult to completely characterize spray deposition and drift, these important factors can be estimated with appropriate sampling protocol ...

Evaluation of mechanical properties of Aluminum-Copper cold sprayed and alloy 625 wire arc sprayed coatings

Science.gov (United States)

Bashirzadeh, Milad

This study examines microstructural-based mechanical properties of Al-Cu composite deposited by cold spraying and wire arc sprayed nickel-based alloy 625 coating using numerical modeling and experimental techniques. The microhardness and elastic modulus of samples were determined using the Knoop hardness technique. Hardness in both transverse and longitudinal directions on the sample cross-sections has been measured. An image-based finite element simulation algorithm was employed to determine the mechanical properties through an inverse analysis. In addition mechanical tests including, tensile, bending, and nano-indentation tests were performed on alloy 625 wire arc sprayed samples. Overall, results from the experimental tests are in relatively good agreement for deposited Al-Cu composites and alloy 625 coating. However, results obtained from numerical simulation are significantly higher in value than experimentally obtained results. Examination and comparison of the results are strong indications of the influence of microstructure characteristics on the mechanical properties of thermally spray deposited coatings.

Method and Apparatus for Thermal Spraying of Metal Coatings Using Pulsejet Resonant Pulsed Combustion

Science.gov (United States)

Paxson, Daniel E. (Inventor)

2014-01-01

An apparatus and method for thermal spraying a metal coating on a substrate is accomplished with a modified pulsejet and optionally an ejector to assist in preventing oxidation. Metal such as Aluminum or Magnesium may be used. A pulsejet is first initiated by applying fuel, air, and a spark. Metal is inserted continuously in a high volume of metal into a combustion chamber of the pulsejet. The combustion is thereafter controlled resonantly at high frequency and the metal is heated to a molten state. The metal is then transported from the combustion chamber into a tailpipe of said pulsejet and is expelled therefrom at high velocity and deposited on a target substrate.

Residual stress measurements of 2-phase sprayed coating layer

International Nuclear Information System (INIS)

Nishida, Masayuki; Hanabusa, Takao

1997-01-01

In a series of the already reported single phase metal and ceramic melt sprayed films, on two phase melt sprayed films, their stress and thermal stress changes due to their bending load are tried to test. In order to prepare two phase state, austenitic stainless steel wire is used by a laser melt spraying method. In this method, CO 2 laser is used for a thermal source, and proceeding direction of its laser is selected to cross melt spraying direction. As a result, the following facts can be elucidated. The stress values at α- and γ-phase in the stainless steel film are linearly responsive to the bending load, and the stress change in α-phase is smaller than that in γ-phase. In a heat and cool cycle, α-phase shows a trend of extension with increasing temperature but γ-phase shows a trend of compression inversely. And, stress behavior at α- and γ-phases in the stainless steel film does not agree with a mixing rule in common two-phase materials. (G.K.)

Tailoring a High Temperature Corrosion Resistant FeNiCrAl for Oxy-Combustion Application by Thermal Spray Coating and HIP

Directory of Open Access Journals (Sweden)

Jarkko Metsäjoki

2015-10-01

Full Text Available Oxy-fuel combustion combined with CCS (carbon capture and storage aims to decrease CO2 emissions in energy production using fossil fuels. Oxygen firing changes power plant boiler conditions compared to conventional firing. Higher material temperatures and harsher and more variable environmental conditions cause new degradation processes that are inadequately understood at the moment. In this study, an Fe-Ni-Cr-Al alloy was developed based on thermodynamic simulations. The chosen composition was manufactured as powder by gas atomization. The powder was sieved into two fractions: The finer was used to produce thermal spray coatings by high velocity oxy-fuel (HVOF and the coarser to manufacture bulk specimens by hot isostatic pressing (HIP. The high temperature corrosion properties of the manufactured FeNiCrAl coating and bulk material were tested in laboratory conditions simulating oxy-combustion. The manufacturing methods and the results of high temperature corrosion performance are presented. The corrosion performance of the coating was on average between the bulk steel references Sanicro 25 and TP347HFG.

Assessment of properties thermal sprayed coatings realised using cermet blend powder

Directory of Open Access Journals (Sweden)

J. Brezinová

2014-10-01

Full Text Available The article deals with the assessment of selected properties of plasma sprayed coatings based on ZrSiO4 doped with different volume fractions of metal dopant (Ni. Mixed powders are cermet blends. Aim of the work consists of verificating the possibility to replace the application of Ni interlayer by adding Ni directly to the ceramic powder and apply them together in a single technological operation. The coatings were studied from point of view of their structure, porosity, adhesion of the coatings in relation to the volume of dopant added and wear resistance. The best properties reached composite coating doped with 12 % Ni.

Parameter Studies on High-Velocity Oxy-Fuel Spraying of CoNiCrAlY Coatings Used in the Aeronautical Industry

Directory of Open Access Journals (Sweden)

J. A. Cabral-Miramontes

2014-01-01

Full Text Available The thermal spraying process is a surface treatment which does not adversely affect the base metal on which it is performed. The coatings obtained by HVOF thermal spray are employed in aeronautics, aerospace, and power generation industries. Alloys and coatings designed to resist oxidizing environments at high temperatures should be able to develop a surface oxide layer, which is thermodynamically stable, slowly growing, and adherent. MCrAlY type (M = Co, Ni or combination of both coatings are used in wear and corrosion applications but also provide protection against high temperature oxidation and corrosion attack in molten salts. In this investigation, CoNiCrAlY coatings were produced employing a HVOF DJH 2700 gun. The work presented here focuses on the influences of process parameters of a gas-drive HVOF system on the microstructure, adherence, wear, and oxygen content of CoNiCrAlY. The results showed that spray distance significantly affects the properties of CoNiCrAlY coatings.

CONCHAS-SPRAY, Reactive Flows with Fuel Sprays

International Nuclear Information System (INIS)

Cloutman, L.D.; Dukowicz, J.K.; Ramshaw, J.D.; Amsden, A.A.

2001-01-01

Description of program or function: CONCHAS-SPRAY solves the equations of transient, multicomponent, chemically reactive fluid dynamics, together with those for the dynamics of an evaporating liquid spray. The program was developed with applications to internal combustion engines in mind. The formulation is spatially two-dimensional, and encompasses both planar and axisymmetric geometries. In the latter case, the flow is permitted to swirl about the axis of symmetry. CONCHAS-SPRAY is a time-marching, finite- difference program that uses a partially implicit numerical scheme. Spatial differences are formed with respect to a generalized two- dimensional mesh of arbitrary quadrilaterals whose corner locations are specified functions of time. This feature allows a Lagrangian, Eulerian, or mixed description, and is particularly useful for representing curved or moving boundary surfaces. Arbitrary numbers of species and chemical reactions are allowed. The latter are subdivided into kinetic and equilibrium reactions, which are treated by different algorithms. A turbulent law-of-the-wall boundary layer option is provided. CONCHAS-SPRAY calls a number of LANL system subroutines to display graphic or numerical information on microfiche. These routines are not included, but are described in the reference report. Several routines called from LINPACK and SLATEC1.0 are included

Thermophysical properties of YSZ and YCeSZ suspension plasma sprayed coatings having different microstructures

Czech Academy of Sciences Publication Activity Database

Sokołowski, P.; Björklund, S.; Mušálek, Radek; Candidato, Jr., R.T.; Pawłowski, L.; Nait-Ali, B.; Smith, D.

2017-01-01

Roč. 318, May (2017), s. 28-38 ISSN 0257-8972. [International Meeting on Thermal Spraying (RIPT)/7./. Limoges, 09.12.2015-11.12.2015] R&D Projects: GA ČR GA15-12145S Institutional support: RVO:61389021 Keywords : Thermal Barrier Coatings (TBC) * Suspension Plasma Spraying * Thermal conductivity * Specific heat * Thermal dilatation * Response function method Subject RIV: JK - Corrosion ; Surface Treatment of Materials OBOR OECD: Coating and films Impact factor: 2.589, year: 2016 http://www.sciencedirect.com/science/article/pii/S0257897217302086

Spray structure of a pressure-swirl atomizer for combustion applications

Directory of Open Access Journals (Sweden)

Jicha Miroslav

2012-04-01

Full Text Available In the present work, global as well as spatially resolved parameters of a spray produced by a pressure-swirl atomizer are obtained. Small pressure-swirl atomizer for aircraft combustion chambers was run on a newly designed test bench with Jet A-1 kerosene type aviation fuel. The atomizer was tested in four regimes based on typical operation conditions of the engine. Spray characteristics were studied using two optical measurement systems, Particle Image velocimetry (PIV and Phase-Doppler Particle Analyzer (P/DPA. The results obtained with P/DPA include information about Sauter Mean Diameter of droplets and spray velocity profiles in one plane perpendicular to the spray axis. Velocity magnitudes of droplets in an axial section of the spray were obtained using PIV. The experimental outputs also show a good confirmation of velocity profiles obtained with both instruments in the test plane. These data together will elucidate impact of the spray quality on the whole combustion process, its efficiency and exhaust gas emissions.

Spray structure of a pressure-swirl atomizer for combustion applications

Science.gov (United States)

Durdina, Lukas; Jedelsky, Jan; Jicha, Miroslav

2012-04-01

In the present work, global as well as spatially resolved parameters of a spray produced by a pressure-swirl atomizer are obtained. Small pressure-swirl atomizer for aircraft combustion chambers was run on a newly designed test bench with Jet A-1 kerosene type aviation fuel. The atomizer was tested in four regimes based on typical operation conditions of the engine. Spray characteristics were studied using two optical measurement systems, Particle Image velocimetry (PIV) and Phase-Doppler Particle Analyzer (P/DPA). The results obtained with P/DPA include information about Sauter Mean Diameter of droplets and spray velocity profiles in one plane perpendicular to the spray axis. Velocity magnitudes of droplets in an axial section of the spray were obtained using PIV. The experimental outputs also show a good confirmation of velocity profiles obtained with both instruments in the test plane. These data together will elucidate impact of the spray quality on the whole combustion process, its efficiency and exhaust gas emissions.

Automated Plasma Spray (APS) process feasibility study: Plasma spray process development and evaluation

Science.gov (United States)

Fetheroff, C. W.; Derkacs, T.; Matay, I. M.

1979-01-01

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal-barrier coatings to aircraft gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical blade positioner incorporating two interlaced six-degree-of-freedom assemblies; a noncoherent optical metrology subsystem; a microprocessor-based adaptive system controller; and commercial plasma spray equipment. Over fifty JT9D first stage turbine blades specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary specimens achieved an overall coating thickness uniformity of + or - 53 micrometers, much better than is achievable manually. Factors limiting this performance were identified and process modifications were initiated accordingly. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were initiated. One of the preliminary evaluation specimens was subjected to a torch test and metallographic evaluation.

Production of nanocrystalline cermet thermal spray powders for wear resistant coatings by high-energy milling

International Nuclear Information System (INIS)

Eigen, N.; Klassen, T.; Aust, E.; Bormann, R.; Gaertner, F.

2003-01-01

TiC-Ni based nanocrystalline cermet powders for thermal spraying were produced by high-energy milling. Milling experiments were performed in an attrition mill and a vibration mill in kilogram scale, and powder morphologies and microstructures were characterized using scanning electron microscopy, X-ray diffraction, and laser scattering for particle size analysis. Milling time and powder input were optimized with respect to the desired microstructure and particle sizes, and the results using both types of mill were compared. Powders with homogeneously dispersed hard phase particles below 300 nm could be produced in both mills. Additional processes for the refinement of powder morphology and particle size distribution are discussed

Numerical analysis of partially molten splat during thermal spray process using the finite element method

Science.gov (United States)

Zirari, M.; Abdellah El-Hadj, A.; Bacha, N.

2010-03-01

A finite element method is used to simulate the deposition of the thermal spray coating process. A set of governing equations is solving by a volume of fluid method. For the solidification phenomenon, we use the specific heat method (SHM). We begin by comparing the present model with experimental and numerical model available in the literature. In this study, completely molten or semi-molten aluminum particle impacts a H13 tool steel substrate is considered. Next we investigate the effect of inclination of impact of a partially molten particle on flat substrate. It was found that the melting state of the particle has great effects on the morphologies of the splat.

High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

Science.gov (United States)

Harder, Bryan James; Zhu, Dongming; Schmitt, Michael P.; Wolfe, Douglas E.

2014-01-01

Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

Preparation of MMC structures consisting of carbonfibre/aluminium prepregs by using the high velocity flame spraying; Herstellen von Halbzeugen aus kohlenstoffaserverstaerkten Aluminiumprepregs mit dem Hochgeschwindigkeitsflammspritzen

Energy Technology Data Exchange (ETDEWEB)

Wielage, B.; Rahm, J. [Lehrstuhl fuer Verbundwerkstoffe, TU Chemnitz-Zwickau, Chemnitz (Germany)

1994-12-01

The application of the thermal spraying process is a new way to produce carbon fibre reinforced Al-Matrix composites. Spreaded fibre rovings are enveloped in the matrix material with high velocity flame spraying. The advantage of the thermal spraying process is based in the low times for contacting between carbon fibres and liquid matrix material. Chemical reactions on the interface fibre/matrix, which are caused the decreasing of the fibre tensile strange, can be excluded. The thermal sprayed prepregs are compressed to MMC by hot pressing process. This longfibre reinforced composites are used to increase for instance casted components of motors. The aim of this research is the estimation of possibility to applicate the high velocity flame process for prepreg manufacturing. (orig.) [Deutsch] Die Anwendung des thermischen Spritzens zur Herstellung C/langfaserverstaerkter Al-Matrix Verbundwerkstoffe mittels Prepregtechnik beschreitet einen neuartigen Verfahrensweg. Zu Fasergelegen aufgespreizte Rovings werden durch Flamm- oder Hochgeschwindigkeitsflammspritzen mit dem Matrixmetall eingehuellt. Der Vorteil des thermischen Spritzens liegt in den geringen Kontaktzeiten der C-Fasern mit dem schmelzfluessigen Matrixmetall. Chemische Reaktionen zwischen Fasern und der Matrix, die zur Karbidbildung und Reduzierung der Verbundfestigkeit fuehren, koennen auch beim Verwenden von C-Fasern ohne Barriereschicht weitgehend ausgeschlossen werden. Die so hergestellten Prepregs koennen z.B. durch Heisspressen zu MMC kompaktiert werden, und als Halbzeuge (Inserts) Gussbauteile in hochbelasteten Bereichen partiell verstaerken. Die im Rahmen der Veroeffentlichung dargestellten Untersuchungen haben die kritische Beurteilung der Ergebnisse des HVOF-Spritzverfahrens zur Herstellung von C/Faser/Aluminiumprepregs zum Ziel. (orig.)

Fine Sprays for Disinfection within Healthcare

Directory of Open Access Journals (Sweden)

G Nasr

2016-09-01

Full Text Available Problems exist worldwide with Hospital Acquired Infections (HAI's. The Spray Research Group (SRG have been working with relevant industries in developing a product which can provide a delivery system for treatment chemicals for surfaces, including the design and testing of a novel Spill-Return Atomiser (SRA for this purpose. A comprehensive description of this atomiser has already been given. This paper reports on a new application of this atomiser and discusses the problem of spray coating for disinfection that has been considered very little in previous work. The related spray coating performance tests in developing the product are thus provided. The experimental work includes determining the required spray duration and the coverage area produced by different sprays, including the analysis of the effects of atomiser positions, configurations, and the required number of atomisers. Comparison is made with the efficacy of an ultrasonic gas atomiser that is currently used for this purpose. The investigation has found that the utilisation of fine sprays (10μm>D32>25μm at high liquid pressure (<12MPa and low flow rates (<0.3 l/min is suitable for surface disinfection in healthcare applications (i.e. MRSA, VRSA etc.

Stainless steel coatings produced through atmospheric plasma spraying study of in flight powder behavior and coating structure

International Nuclear Information System (INIS)

Denoirjean, A.; Denoirjean, P.; Fauchais, P.; Labbe, J.C.; Khan, A.A.

2005-01-01

The Stainless Steel coatings deposited through Atmospheric Plasma Spraying over mild steel surface present an interest from commercial point of view, especially for the applications where corrosion resistance or inertness towards severe environment is required. Atmospheric Plasma Spraying is fast and relatively less expensive choice as compared to Vacuum Plasma Spraying, the only limitation being the extremely reactive nature of metallic powders used. A study of the behaviour of metallic powders within an Atmospheric Plasma Jet is presented in view of better understanding and eventual improvement in coating properties. Metallic powder particles show very interesting features when individual particles are collected after passing them through a DC Blown Arc Thermal Plasma Jet under Atmospheric Pressure. The spraying was carried out under air which makes the significance of these results even more interesting from the industrial point of view. Proper control of Spraying Parameters can help produce Stainless Steel coatings of reasonably low porosity and a typical lamellar microstructure. The results of SEM, AFM and XRD are discussed. A strange oxidation phenomenon under highly non equilibrium conditions is observed. (author)

High-Performance Corrosion-Resistant Materials: Iron-Based Amorphous-Metal Thermal-Spray Coatings

International Nuclear Information System (INIS)

Farmer, J C; Haslam, J J; Wong, F; Ji, X; Day, S D; Branagan, D J; Marshall, M C; Meacham, B E; Buffa, E J; Blue, C A; Rivard, J K; Beardsley, M B; Weaver, D T; Aprigliano, L F; Kohler, L; Bayles, R; Lemieux, E J; Wolejsza, T M; Martin, F J; Yang, N; Lucadamo, G; Perepezko, J H; Hildal, K; Kaufman, L; Heuer, A H; Ernst, F; Michal, G M; Kahn, H; Lavernia, E J

2004-01-01

The multi-institutional High Performance Corrosion Resistant Materials (HPCRM) Team is cosponsored by the Defense Advanced Projects Agency (DARPA) Defense Science Office (DSO) and the Department of Energy (DOE) Office of Civilian Radioactive Waste Management (OCRWM), and has developed new corrosion-resistant, iron-based amorphous metals that can be applied as coatings with advanced thermal spray technology. Two compositions have corrosion resistance superior to wrought nickel-based Alloy C-22 (UNS No. N06022) in very aggressive environments, including concentrated calcium-chloride brines at elevated temperature. Corrosion costs the Department of Defense billions of dollars every year, with an immense quantity of material in various structures undergoing corrosion. For example, in addition to fluid and seawater piping, ballast tanks, and propulsions systems, approximately 345 million square feet of structure aboard naval ships and crafts require costly corrosion control measures. The use of advanced corrosion-resistant materials to prevent the continuous degradation of this massive surface area would be extremely beneficial. The Fe-based corrosion-resistant, amorphous-metal coatings under development may prove of importance for applications on ships. Such coatings could be used as an ''integral drip shield'' on spent fuel containers, as well as protective coatings that could be applied over welds, thereby preventing exposure to environments that might cause stress corrosion cracking. In the future, such new high-performance iron-based materials could be substituted for more-expensive nickel-based alloys, thereby enabling a reduction in the $58-billion life cycle cost for the long-term storage of the Nation's spent nuclear fuel by tens of percent

Development of a model for spray evaporation based on droplet analysis

KAUST Repository

Chen, Q.

2016-08-20

Extreme flash evaporation occurs when superheated liquid is sprayed into a low pressure zone. This method has high potential to improve the performance of thermally-driven desalination plants. To enable a more in-depth understanding on flash evaporation of a superheated feed water spray, a theoretical model has been developed with key considerations given to droplet motion and droplet size distribution. The model has been validated against 14 experimental data sets from literature sources to within 12% discrepancy. This model is capable of accurately predicting the water productivity and thermal efficiency of existing spray evaporator under specific operating conditions. Employing this model, the effect of several design parameters on system performance was investigated. Key results revealed that smaller droplet enabled faster evaporation process while higher initial droplet velocity promoted water productivity. Thermal utilization marginally changes with the degree of superheat, which renders a quick design calculation of the brine temperature without the need for iterations. © 2016 Elsevier B.V.

Development of a model for spray evaporation based on droplet analysis

KAUST Repository

Chen, Q.; Thu, K.; Bui, T.D.; Li, Y.; Ng, Kim Choon; Chua, K.J.

2016-01-01

Extreme flash evaporation occurs when superheated liquid is sprayed into a low pressure zone. This method has high potential to improve the performance of thermally-driven desalination plants. To enable a more in-depth understanding on flash evaporation of a superheated feed water spray, a theoretical model has been developed with key considerations given to droplet motion and droplet size distribution. The model has been validated against 14 experimental data sets from literature sources to within 12% discrepancy. This model is capable of accurately predicting the water productivity and thermal efficiency of existing spray evaporator under specific operating conditions. Employing this model, the effect of several design parameters on system performance was investigated. Key results revealed that smaller droplet enabled faster evaporation process while higher initial droplet velocity promoted water productivity. Thermal utilization marginally changes with the degree of superheat, which renders a quick design calculation of the brine temperature without the need for iterations. © 2016 Elsevier B.V.

Comparative characteristic and erosion behavior of NiCr coatings deposited by various high-velocity oxyfuel spray processes

Science.gov (United States)

Sidhu, Hazoor Singh; Sidhu, Buta Singh; Prakash, S.

2006-12-01

The purpose of this study is to analyze and compare the mechanical properties and microstructure details at the interface of high-velocity oxyfuel (HVOF)-sprayed NiCr-coated boiler tube steels, namely ASTM-SA-210 grade A1, ASTM-SA213-T-11, and ASTM-SA213-T-22. Coatings were developed by two different techniques, and in these techniques liquefied petroleum gas was used as the fuel gas. First, the coatings were characterized by metallographic, scanning electron microscopy/energy-dispersive x-ray analysis, x-ray diffraction, surface roughness, and microhardness, and then were subjected to erosion testing. An attempt has been made to describe the transformations taking place during thermal spraying. It is concluded that the HVOF wire spraying process offers a technically viable and cost-effective alternative to HVOF powder spraying process for applications in an energy generation power plant with a point view of life enhancement and to minimize the tube failures because it gives a coating having better resistance to erosion.

Thin Spray-on Liner - a potential application. Demonstrated at a longwall installation on Dendrobium mine

Energy Technology Data Exchange (ETDEWEB)

Byrnes, Roger [BHP Billiton, NSW (Australia). Dendrobium Mine; Martin, Philip [BASF AG Australia (Australia). BASF-CC Australia Ltd' s

2008-08-21

The paper describes a potential application of a Thin Spray-on Liner, on a longwall installation in Australia. The BHPBilliton mine, Dendrobium, is a relatively new mine in the Southern New South Wales coalfields, near to Wollongong. Normal installation and start-up operations for a new longwall face is to completely rock bolt and mesh the face. The operations use plastic/glassfibre cutable rock bolts, with steel/plastic mesh to prevent spalling. The biggest problem on face start up is the sheets of steel or plastic mesh getting wrapped around the shearer disc, which requires time consuming additional work removing the mesh. BASF Construction Chemicals Australia Pty Ltd's Underground Construction group, (UGC), proposed the use of Masterseal 845A, a fast sprayable cementitious/polymer membrane material that could be trialed and used to replace the steel mesh, as a surface support in unison with the conventional cutable rock bolts. The application took 12 h spraying to cover the 240 m long face line which averaged about 3.3 m high. The product was sprayed between 3.5 m to 4 mm thick, and according to the mine operators was at least three times quicker than mesh installation, not withstanding the savings in transport of the awkward bundles of mesh. In conclusion the Thin Spray-on Liner (TSL) performed adequately and achieved it's objective in this installation at Dendrobium mine. (orig.)

Effect of Microstructure on the Thermal Conductivity of Plasma Sprayed Y2O3 Stabilized Zirconia (8% YSZ

Directory of Open Access Journals (Sweden)

Ningning Hu

2017-11-01

Full Text Available In this paper, the effect of microstructure on the thermal conductivity of plasma-sprayed Y2O3 stabilized ZrO2 (YSZ thermal barrier coatings (TBCs is investigated. Nine freestanding samples deposited on aluminum alloys are studied. Cross-section morphology such as pores, cracks, m-phase content, grain boundary density of the coated samples are examined by scanning electron microscopy (SEM and electron back-scattered diffraction (EBSD. Multiple linear regressions are used to develop quantitative models that describe the relationship between the particle parameters, m-phase content and features of the microstructure such as porosity, crack-porosity, and the length density of small and big angle-cracks. Moreover, the relationship between the microstructure and thermal conductivity is investigated. Results reveal that the thermal conductivity of the coating is mainly determined by the microstructure and grain boundary density at room temperature (25 °C, and by the length density of big-angle-crack, monoclinic phase content and grain boundary density at high temperature (1200 °C.

Macro controlling of copper oxide deposition processes and spray mode by using home-made fully computerized spray pyrolysis system

Science.gov (United States)

Essa, Mohammed Sh.; Chiad, Bahaa T.; Shafeeq, Omer Sh.

2017-09-01

Thin Films of Copper Oxide (CuO) absorption layer have been deposited using home-made Fully Computerized Spray Pyrolysis Deposition system FCSPD on glass substrates, at the nozzle to substrate distance equal to 20,35 cm, and computerized spray mode (continues spray, macro-control spray). The substrate temperature has been kept at 450 °c with the optional user can enter temperature tolerance values ± 5 °C. Also that fixed molar concentration of 0.1 M, and 2D platform speed or deposition platform speed of 4mm/s. more than 1000 instruction program code, and specific design of graphical user interface GUI to fully control the deposition process and real-time monitoring and controlling the deposition temperature at every 200 ms. The changing in the temperature has been recorded during deposition processes, in addition to all deposition parameters. The films have been characterized to evaluate the thermal distribution over the X, Y movable hot plate, the structure and optical energy gap, thermal and temperature distribution exhibited a good and uniform distribution over 20 cm2 hot plate area, X-ray diffraction (XRD) measurement revealed that the films are polycrystalline in nature and can be assigned to monoclinic CuO structure. Optical band gap varies from 1.5-1.66 eV depending on deposition parameter.

Quality characteristic of spray-drying egg white powders.

Science.gov (United States)

Ma, Shuang; Zhao, Songning; Zhang, Yan; Yu, Yiding; Liu, Jingbo; Xu, Menglei

2013-10-01

Spray drying is a useful method for developing egg process and utilization. The objective of this study was to evaluate effects on spray drying condition of egg white. The optimized conditions were spraying flow 22 mL/min, feeding temperature 39.8 °C and inlet-air temperature 178.2 °C. Results of sulfydryl (SH) groups measurement indicated conformation structure have changed resulting in protein molecule occur S-S crosslinking phenomenon when heating. It led to free SH content decreased during spray drying process. There was almost no change of differential scanning calorimetry between fresh egg white and spray-drying egg white powder (EWP). For a given protein, the apparent SH reactivity is in turn influenced by the physico-chemical characteristics of the reactant. The phenomenon illustrated the thermal denaturation of these proteins was unrelated to their free SH contents. Color measurement was used to study browning level. EWP in optimized conditions revealed insignificant brown stain. Swelling capacity and scanning electron micrograph both proved well quality characteristic of spray-drying EWP. Results suggested spray drying under the optimized conditions present suitable and alternative method for egg processing industrial implementation. Egg food industrialization needs new drying method to extend shelf-life. The purpose of the study was to provide optimal process of healthy and nutritional instant spray-drying EWP and study quality characteristic of spray-drying EWP.

Low-Temperature Preparation of Tungsten Oxide Anode Buffer Layer via Ultrasonic Spray Pyrolysis Method for Large-Area Organic Solar Cells

Directory of Open Access Journals (Sweden)

Ran Ji

2017-07-01

Full Text Available Tungsten oxide (WO3 is prepared by a low-temperature ultrasonic spray pyrolysis method in air atmosphere, and it is used as an anode buffer layer (ABL for organic solar cells (OSCs. The properties of the WO3 transition metal oxide material as well as the mechanism of ultrasonic spray pyrolysis processes are investigated. The results show that the ultrasonic spray pyrolysized WO3 ABL exhibits low roughness, matched energy level, and high conductivity, which results in high charge transport efficiency and suppressive recombination in OSCs. As a result, compared to the OSCs based on vacuum thermal evaporated WO3, a higher power conversion efficiency of 3.63% is reached with low-temperature ultrasonic spray pyrolysized WO3 ABL. Furthermore, the mostly spray-coated OSCs with large area was fabricated, which has a power conversion efficiency of ~1%. This work significantly enhances our understanding of the preparation and application of low temperature-processed WO3, and highlights the potential of large area, all spray coated OSCs for sustainable commercial fabrication.

Role of thermal spray processing method on the microstructure, residual stress and properties of coatings:an integrated study for Ni-5wt.% Al bond coats

Czech Academy of Sciences Publication Activity Database

Sampath, S.; Jiang, X.; Matějíček, Jiří; Prchlík, L.; Kulkarni, A.; Vaidya, A.

2004-01-01

Roč. 364, 1-2 (2004), s. 216-231 ISSN 0921-5093 Grant - others:NSF(US) DMR9632570 Institutional research plan: CEZ:AV0Z2043910 Keywords : bond coats, thermal spraying, microstructure Subject RIV: JG - Metallurgy Impact factor: 1.445, year: 2004

Porosity and wear resistance of flame sprayed tungsten carbide coatings

Science.gov (United States)

Winarto, Winarto; Sofyan, Nofrijon; Rooscote, Didi

2017-06-01

Thermal-sprayed coatings offer practical and economical solutions for corrosion and wear protection of components or tools. To improve the coating properties, heat treatment such as preheat is applied. The selection of coating and substrate materials is a key factor in improving the quality of the coating morphology after the heat treatment. This paper presents the experimental results regarding the effect of preheat temperatures, i.e. 200°C, 300°C and 400°C, on porosity and wear resistance of tungsten carbide (WC) coating sprayed by flame thermal coating. The powders and coatings morphology were analyzed by a Field Emission Scanning Electron Microscope equipped with Energy Dispersive Spectrometry (FE-SEM/EDS), whereas the phase identification was performed by X-Ray diffraction technique (XRD). In order to evaluate the quality of the flame spray obtained coatings, the porosity, micro-hardness and wear rate of the specimens was determined. The results showed that WC coating gives a higher surface hardness from 1391 HVN up to 1541 HVN compared to that of the non-coating. Moreover, the wear rate increased from 0.072 mm3/min. to 0.082 mm3/min. when preheat temperature was increased. Preheat on H13 steel substrate can reduce the percentage of porosity level from 10.24 % to 3.94% on the thermal spray coatings.

Microstructure formation and corrosion behaviour in HVOF-sprayed Inconel 625 coatings

International Nuclear Information System (INIS)

Zhang, D.; Harris, S.J.; McCartney, D.G.

2003-01-01

The nickel-based alloy Inconel 625 was thermally sprayed by two different variants of the high velocity oxy-fuel process. In this study, coatings deposited by a liquid-fuelled gun were compared with those produced by a gas-fuelled system; in general, the former generates higher particle velocities but lower particle temperatures. Investigations into the microstructural evolution of the coatings, using scanning electron microscopy and X-ray diffraction, are presented along with results on their aqueous corrosion behaviour, obtained from salt spray and potentiodynamic tests. It is inferred from coating microstructures that, during spraying, powder particles generally comprised three separate zones as follows: fully melted regions; partially melted zones; and an unmelted core. However, the relative proportions formed in an individual powder particle depended on its size, trajectory through the gun, the gas dynamics (velocity/temperature) of the thermal spray gun and the type of gun employed. Cr 2 O 3 was the principal oxide phase formed during spraying and the quantity appeared to be directly related to the degree to which particles were melted. The salt spray test provides a sensitive means of determining the presence of interconnected porosity in coatings and those produced with the liquid-fuelled gun exhibited reduced interconnected porosity and increased corrosion resistance compared with deposits obtained from the gas-fuelled system. In addition, potentiodynamic tests revealed that passive current densities are 10-20 times lower in liquid-fuel coatings than in those sprayed with the gas-fuelled gun

Application of Constrained Linear MPC to a Spray Dryer

DEFF Research Database (Denmark)

Petersen, Lars Norbert; Poulsen, Niels Kjølstad; Niemann, Hans Henrik

2014-01-01

In this paper we develop a linear model predictive control (MPC) algorithm for control of a two stage spray dryer. The states are estimated by a stationary Kalman filter. A non-linear first-principle engineering model is developed to simulate the spray drying process. The model is validated against...... experimental data and able to precisely predict the temperatures, the air humidity and the residual moisture in the dryer. The MPC controls these variables to the target and reject disturbances. Spray drying is a cost-effective method to evaporate water from liquid foods and produces a free flowing powder...

Application of a topical vapocoolant spray decreases pain at the site of initial intradermal anaesthetic injection during ultrasound-guided breast needle biopsy

International Nuclear Information System (INIS)

Collado-Mesa, F.; Net, J.M.; Arheart, K.; Klevos, G.A.; Yepes, M.M.

2015-01-01

Aim: To assess whether the application of a topical vapocoolant spray immediately prior to initial intradermal anaesthetic injection during ultrasound-guided breast biopsy decreases pain at the site of the initial injection. Materials and methods: In this institutional review board-approved, Health Insurance Portability and Accountability Act (HIPAA)-compliant study, 50 women aged 49.1 ± 1.6 years (mean ± standard error) were recruited and provided written informed consent. Participants served as their own controls and were blinded as to whether a topical vapocoolant spray or a placebo was used immediately prior to the initial local anaesthetic injection at two separate biopsy sites. With the exception of the application of vapocoolant or placebo, the entire ultrasound-guided procedure was performed according to a routine protocol. Participants recorded pain at initial injection site on a visual analogue scale. General linear mixed models for repeated measures analysis of variance and a 0.05 significance level were used. Results: Application of topical vapocoolant spray was shown to significantly decrease pain at the site of initial intradermal anaesthetic injection as compared to placebo (p<0.001). Treatment effect was independent of age of the subject, race/ethnicity, operator, type of biopsy device, and histopathology result. No complications from vapocoolant spray use were reported. Conclusion: Application of a topical vapocoolant spray immediately prior to initial intradermal anaesthetic injection during ultrasound-guided breast biopsy significantly decreases pain at the site of the initial injection and could contribute to improve the patient's overall procedural experience. -- Highlights: •Topical vapocoolant spray decreased pain at site of initial anesthetic injection (

spray use were reported

Production of Babbitt Coatings by High Velocity Oxygen Fuel (HVOF) Spraying

Science.gov (United States)

Nascimento, A. R. C.; Ettouil, F. B.; Moreau, C.; Savoie, S.; Schulz, R.

2017-10-01

This work presents HVOF as an alternative means to produce dense Babbitt coatings by thermal spray. A radial injection setup and low fuel flow rates were used to minimize heat transfer to the low melting point alloy. In-flight particle diagnostic systems were used to correlate spray parameters with the changes in particle velocity and thermal radiation intensity. The use of particles with larger diameters resulted in higher deposition efficiencies. It was shown that HVOF Babbitt coatings combine a dense structure and a fine distribution of intermetallic phases when compared to more traditional babbitting techniques.

Corrosion Resistance of a Cast-Iron Material Coated With a Ceramic Layer Using Thermal Spray Method

Science.gov (United States)

Florea, C. D.; Bejinariu, C.; Munteanu, C.; Istrate, B.; Toma, S. L.; Alexandru, A.; Cimpoesu, R.

2018-06-01

Cast-iron 250 used for breake systems present many corrosion signs after a mean usage time based on the environment conditions they work. In order to improve them corrosion resistance we propose to cover the active part of the material using a ceramic material. The deposition process is an industrial deposition system based on thermal spraying that can cover high surfaces in low time. In this articol we analyze the influence of a ceramic layer (40-50 µm) on the corrosion resistance of FC250 cast iron. The results were analyzed using scanning electron microscopy (SEM), X-ray energy dispersive (EDS) and linear and cyclic potentiometry.

Effects of isothermal treatment on microstructure and scratch test behavior of plasma sprayed zirconia coatings

Directory of Open Access Journals (Sweden)

Veloso Guilherme

2004-01-01

Full Text Available The increase of the petroleum cost in the last decades revitalized the interest for lighter and more economic vehicles. Simultaneously, the demand for safe and unpolluted transports grows. The application of thermal barriers coatings (TBC on combustion chamber and on flat surface of pistons reduces the thermal losses of the engines, resulting in higher temperatures in the combustion chamber. This fact contributes to the improvement of the thermal efficiency (performance and for the reduction of incomplete combustion. Supported on these initial ideas, thermal barriers coatings constituted by CaO partially stabilized zirconia were produced and their microstructure examined. This coating still presents some drawbacks associated with thermal stresses and permeability to oxidizing gases, which will, eventually, lead to failure of the TBC by spallation. The failure may, in general, be associated to one of three factors: oxide growth at the ceramic-metal interface, formed during thermal cycling; stress build-up due to thermal cycling; and metal-oxide interface segregation, mainly of S. However, it is also relevant to understand the behavior of TBC's under isothermal oxidation. Therefore, this paper investigates the effect of oxidation on the adherence of thermal sprayed coatings. The adherence was measured by linear scratching tests, widely used for thin coatings. Plasma sprayed calcia partially stabilized zirconia was used as TBC and Ni-5%Al as bond coat, with Al substrates. Coated samples were submitted to heat treatments at 500 °C, for 50 h. The microstructures were examined by optical light microscopy, X-ray diffraction, profilometry and SEM.

Suspension thermal spraying of hydroxyapatite: microstructure and in vitro behaviour.

Science.gov (United States)

Bolelli, Giovanni; Bellucci, Devis; Cannillo, Valeria; Lusvarghi, Luca; Sola, Antonella; Stiegler, Nico; Müller, Philipp; Killinger, Andreas; Gadow, Rainer; Altomare, Lina; De Nardo, Luigi

2014-01-01

In cementless fixation of metallic prostheses, bony ingrowth onto the implant surface is often promoted by osteoconductive plasma-sprayed hydroxyapatite coatings. The present work explores the use of the innovative High Velocity Suspension Flame Spraying (HVSFS) process to coat Ti substrates with thin homogeneous hydroxyapatite coatings. The HVSFS hydroxyapatite coatings studied were dense, 27-37μm thick, with some transverse microcracks. Lamellae were sintered together and nearly unidentifiable, unlike conventional plasma-sprayed hydroxyapatite. Crystallinities of 10%-70% were obtained, depending on the deposition parameters and the use of a TiO2 bond coat. The average hardness of layers with low (hydroxyapatite, with a Weibull modulus of ≈3.3. During soaking in simulated body fluid, glassy coatings were progressively resorbed and replaced by a new, precipitated hydroxyapatite layer, whereas coatings with 70% crystallinity were stable up to 14days of immersion. The interpretation of the precipitation behaviour was also assisted by surface charge assessments, performed through Z-potential measurements. During in vitro tests, HA coatings showed no cytotoxicity towards the SAOS-2 osteoblast cell line, and surface cell proliferation was comparable with proliferation on reference polystyrene culture plates. © 2013.

Experimental Comparison of the Tribological Properties of Selected Surfaces Created by Thermal Spraying Technology

Directory of Open Access Journals (Sweden)

František Tóth

2016-01-01

Full Text Available The scientific article titled “Experimental comparison of the tribological properties of selected surfaces created by thermal spraying technology” deals with the surface condition of selected pairs working within the mixed friction before and after experimental tests. Based on the chosen methodology, the experimental tests were performed on the Tribotestor M’06 testing machine. The ecological oil MOGUL HEES 46 (manufactured by Paramo was used as a lubricant. The tests were performed on selected material pairs. The first friction element was a shaft of steel 14 220. The second friction element was a steel plate of steel 11 373 with a friction surface created by two materials, i.e. CuSn10 and NP 40. The results are statistically elaborated and illustrated in figures and tables.

High thermal conductivity materials for thermal management applications

Science.gov (United States)

Broido, David A.; Reinecke, Thomas L.; Lindsay, Lucas R.

2018-05-29

High thermal conductivity materials and methods of their use for thermal management applications are provided. In some embodiments, a device comprises a heat generating unit (304) and a thermally conductive unit (306, 308, 310) in thermal communication with the heat generating unit (304) for conducting heat generated by the heat generating unit (304) away from the heat generating unit (304), the thermally conductive unit (306, 308, 310) comprising a thermally conductive compound, alloy or composite thereof. The thermally conductive compound may include Boron Arsenide, Boron Antimonide, Germanium Carbide and Beryllium Selenide.

Tungsten/copper composite deposits produced by a cold spray

International Nuclear Information System (INIS)

Kang, Hyun-Ki; Kang, Suk Bong

2003-01-01

An agglomerated tungsten/copper composite powder was both cold sprayed and plasma sprayed onto a mild steel substrate for electronic package applications. Most pores resulting from the spraying were found in the vicinity of the tungsten-rich regions of the final product. The levels of porosity varied with the amount of tungsten present. No copper oxidation was found at the cold-sprayed deposit, but relatively high copper oxidation was observed at the plasma-sprayed deposit

Properties of arc-sprayed coatings from Fe-based cored wires for high-temperature applications

Science.gov (United States)

Korobov, Yu. S.; Nevezhin, S. V.; Filiрpov, M. A.; Makarov, A. V.; Malygina, I. Yu.; Fantozzi, D.; Milanti, A.; Koivuluoto, H.; Vuoristo, P.

2017-12-01

Equipment of a thermal power plant is subjected to high temperature oxidation and wear. This raises operating costs through frequent repair of worn parts and high metal consumption. The paper proposes a possible solution to this problem through arc spraying of protective coatings. Cored wires of the Fe-Cr-C basic alloying system are used as a feedstock. Additional alloying by Al, B, Si, Ti and Y allows one to create wear- and heat-resistant coatings, which are an attractive substitute of more expensive Co- and Ni-based materials.

SPRAY FOAM IN ACCESSIBLE SPACES:BEST PRACTICES AND CASE STUDIES FOR RETROFIT IN MIXED-HUMID CLIMATE

Energy Technology Data Exchange (ETDEWEB)

Christian, Jeffrey E [ORNL; Gant, Kathy [Oak Ridge National Laboratory (ORNL)

2013-12-01

Heating and cooling the house is one of the homeowners major expenses. Reducing these costs, saving energy, and creating a healthier, more comfortable indoor environment are good reasons to consider improving the building thermal envelope. Improvements usually consider increasing the amount of insulation, reducing the infiltration of outside air, and controlling moisture in existing buildings. This report describes the use of spray foam materials to insulate, seal, and control moisture. This discussion is limited to treating areas that are accessible. What is accessible, however, can vary depending on the type of renovation. If the building has been gutted or exterior surfaces removed, there are more options. This report will look at areas to consider for spray foam application and discuss the types of spray foams available and their uses. A number of case studies are presented to show the effectiveness of this retrofit in existing houses based on performance data.

Mitigating Localized Corrosion Using Thermally Sprayed Aluminum (TSA) Coatings on Welded 25% Cr Superduplex Stainless Steel

Science.gov (United States)

Paul, S.; Lu, Q.; Harvey, M. D. F.

2015-04-01

Thermally sprayed aluminum (TSA) coating has been increasingly used for the protection of carbon steel offshore structures, topside equipment, and flowlines/pipelines exposed to both marine atmospheres and seawater immersion conditions. In this paper, the effectiveness of TSA coatings in preventing localized corrosion, such as pitting and crevice corrosion of 25% Cr superduplex stainless steel (SDSS) in subsea applications, has been investigated. Welded 25% Cr SDSS (coated and uncoated) with and without defects, and surfaces coated with epoxy paint were also examined. Pitting and crevice corrosion tests, on welded 25% Cr SDSS specimens with and without TSA/epoxy coatings, were conducted in recirculated, aerated, and synthetic seawater at 90 °C for 90 days. The tests were carried out at both the free corrosion potentials and an applied cathodic potential of -1100 mV saturated calomel electrode. The acidity (pH) of the test solution was monitored daily and adjusted to between pH 7.5 and 8.1, using dilute HCl solution or dilute NaOH, depending on the pH of the solution measured during the test. The test results demonstrated that TSA prevented pitting and crevice corrosion of 25% Cr SDSS in artificial seawater at 90 °C, even when 10-mm-diameter coating defect exposing the underlying steel was present.

Physical chemistry of WC-12 %Co coatings deposited by thermal spraying at different standoff distances

Energy Technology Data Exchange (ETDEWEB)

Afzal, Muhammad; Ahmed, Furqan; Anwar, Muhammad Yousaf; Ali, Liaqat; Ajmal, Muhammad [Univ. of Engineering and Technology, Metallurgical and Materials Engineering, Lahore (Pakistan); Khan, Aamer Nusair [Institute of Industrial and Control System, Rawalpindi (Pakistan)

2015-09-15

In the present research, WC-12 %Co cermet coatings were deposited on AISI-321 stainless steel substrate using air plasma spraying. During the deposition process, the standoff distance was varied from 80 to 130 mm with 10 mm increments. Other parameters such as current, voltage, time, carrier gas flow rate and powder feed rate etc. were kept constant. The objective was to study the effects of spraying distance on the microstructure of as-sprayed coatings. The microscopic analyses revealed that the band of spraying distance ranging from 90 to 100 mm was the threshold distance for optimum results, provided that all the other spraying parameters were kept constant. In this range of threshold distance, minimum percentages of porosity and defects were observed. Further, the formation of different phases, at six spraying distances, was studied using X-ray diffraction, and the phase analysis was correlated with hardness results.

Modification of vacuum plasma sprayed tungsten coating on reduced activation ferritic/martensitic steels by friction stir processing

International Nuclear Information System (INIS)

Tanigawa, Hiroyasu; Ozawa, Kazumi; Morisada, Yoshiaki; Noh, Sanghoon; Fujii, Hidetoshi

2015-01-01

Highlights: • Friction stir processing (FSP) was applied on vacuum plasma spray (VPS) W to improve its low thermal conductivity and weakness due to high porosity. • FSP can achieve significant improvement both in mechanical and thermal properties of VPS-W coating. • It was indicated that the double pass FSP at 600 rpm/50 mm/min/2 ton on VPS-W show the most dense microstructure and hardest mechanical property. • Hardness test over FSPed VPS-W layer revealed that the hardness of W becomes higher than that of bulk W. • The thermal conductivity of double pass FSPed VPS-W was about 80% of bulk W at 200 °C, and it becomes equivalent to that of bulk W over 800 °C. - Abstract: Tungsten (W) is the primary candidate material as a plasma facing material in fusion devices, as for its high melting temperature, good thermal conductivity and low sputtering rate, and vacuum plasma spray (VPS) technique is preferred as it is applicable for large area without brittle interlayer, but the thermal conductivity of W layer is very poor, and easy to detach, mainly caused by its porous structure. W Friction stir processing (FSP) was applied on VPS-W to improve these poor properties, and it was suggested that FSP can contribute to significant improvement in both mechanical and thermal properties of the VPS-W coating.

Spray casting project final report

International Nuclear Information System (INIS)

Churnetski, S.R.; Thompson, J.E.

1996-08-01

Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step

Mikrostruktur dan Karakterisasi Sifat Mekanik Lapisan Cr3C2-NiAl-Al2O3 Hasil Deposisi Dengan Menggunakan High Velocity Oxygen Fuel Thermal Spray Coating

Directory of Open Access Journals (Sweden)

Edy Riyanto

2012-03-01

Full Text Available Surface coating processing of industrial component with thermal spray coatings have been applied in many industrial fields. Ceramic matrix composite coating which consists of Cr3C2-Al2O3-NiAl had been carried out to obtain layers of material that has superior mechanical properties to enhance component performance. Deposition of CMC with High Velocity Oxygen Fuel (HVOF thermal spray coating has been employed. This study aims to determine the effect of powder particle size on the microstructure, surface roughness and hardness of the layer, by varying the NiAl powder particle size. Test results show NiAl powder particle size has an influence on the mechanical properties of CMC coating. Hardness of coating increases and surface roughness values of coating decrease with smaller NiAl particle size.  

Two intelligent spraying systems developed for tree crop production

Science.gov (United States)

Precision pesticide application technologies are needed to achieve efficient and effective spray deposition on target areas and minimize off-target losses. Two variable-rate intelligent sprayers were developed as an introduction of new generation sprayers for tree crop applications. The first spraye...

Analysis of inadvertent containment spray actuation for NPP Krsko

International Nuclear Information System (INIS)

Grgic, D.; Spalj, S.; Fancev, T.

2000-01-01

Refueling Water Storage Tank (RWST) supplies borated water to the Chemical and Volume Control System, Emergency Core Cooling System and Containment Spray System. In the analyses of the containment external pressure the spray temperature is assumed to be equal to the RWST lower temperature limit. This value ensures that the design negative containment pressure will not be exceeded in the event of inadvertent actuation of the Containment Spray. For NPP Kriko the negative containment pressure has to be kept below 0.1 kp/cm2 to avoid the loss of containment integrity. This paper pursuents the analysis of Inadvertent Containment Spray Actuation in order to check the influence of change in RWST water temperature on containment negative pressure. GOTHIC computer code was used for calculation of containment thermal hydraulic behavior during this accident. (author)

Beclomethasone Nasal Spray

Science.gov (United States)

... class of medications called corticosteroids. It works by blocking the release of certain natural substances that cause ... your thumb. Point the applicator away from your face. If you are using the spray for the ...

Flunisolide Nasal Spray

Science.gov (United States)

... class of medications called corticosteroids. It works by blocking the release of certain natural substances that cause ... your thumb. Point the applicator away from your face. If you are using the spray for the ...

Suspension thermal spraying of hydroxyapatite: Microstructure and in vitro behaviour

Energy Technology Data Exchange (ETDEWEB)

Bolelli, Giovanni, E-mail: giovanni.bolelli@unimore.it [Department of Engineering “Enzo Ferrari”, Università di Modena e Reggio Emilia, Via Vignolese 905, 41125 Modena, MO (Italy); Bellucci, Devis; Cannillo, Valeria; Lusvarghi, Luca; Sola, Antonella [Department of Engineering “Enzo Ferrari”, Università di Modena e Reggio Emilia, Via Vignolese 905, 41125 Modena, MO (Italy); Stiegler, Nico; Müller, Philipp; Killinger, Andreas; Gadow, Rainer [Institute for Manufacturing Technologies of Ceramic Components and Composites (IMTCCC), Universität Stuttgart, Allmandring 7b, 70569 Stuttgart (Germany); Altomare, Lina; De Nardo, Luigi [Dipartimento di Chimica, Materiali e Ingegneria Chimica “G. Natta”, Politecnico di Milano, Via Mancinelli 7, I-20131 Milano (Italy)

2014-01-01

In cementless fixation of metallic prostheses, bony ingrowth onto the implant surface is often promoted by osteoconductive plasma-sprayed hydroxyapatite coatings. The present work explores the use of the innovative High Velocity Suspension Flame Spraying (HVSFS) process to coat Ti substrates with thin homogeneous hydroxyapatite coatings. The HVSFS hydroxyapatite coatings studied were dense, 27–37 μm thick, with some transverse microcracks. Lamellae were sintered together and nearly unidentifiable, unlike conventional plasma-sprayed hydroxyapatite. Crystallinities of 10%–70% were obtained, depending on the deposition parameters and the use of a TiO{sub 2} bond coat. The average hardness of layers with low (< 24%) and high (70%) crystallinity was ≈ 3.5 GPa and ≈ 4.5 GPa respectively. The distributions of hardness values, all characterised by Weibull modulus in the 5–7 range, were narrower than that of conventional plasma-sprayed hydroxyapatite, with a Weibull modulus of ≈ 3.3. During soaking in simulated body fluid, glassy coatings were progressively resorbed and replaced by a new, precipitated hydroxyapatite layer, whereas coatings with 70% crystallinity were stable up to 14 days of immersion. The interpretation of the precipitation behaviour was also assisted by surface charge assessments, performed through Z-potential measurements. During in vitro tests, HA coatings showed no cytotoxicity towards the SAOS-2 osteoblast cell line, and surface cell proliferation was comparable with proliferation on reference polystyrene culture plates. - Highlights: • Thin, dense HA layers were originated by HVSFS deposition of molten agglomerates of ≈ 1 μm. • Tensile adhesion strength of HVSFS HA onto Ti well above the threshold of ISO 13779-2 • Crystallinity (10–70%) is determined by system temperature during deposition. • Crystallinity controls the reactivity during immersion in simulated body fluid. • SAOS-2 osteoblast-like cells adhered well and

Modeling of droplet dynamic and thermal behaviour during spray ...

Indian Academy of Sciences (India)

Modeling Studies Volume 26 Issue 3 April 2003 pp 355-364 ... Mathematical modeling of supersonic gas atomization for spray forming has been investigated. ... Department of Mechanical Engineering, M.S. Ramaiah Institute of Technology, Bangalore 560 054, India; Department of Mechanical Engineering, University ...

Nanoparticles by spray drying using innovative new technology: the Büchi nano spray dryer B-90.

Science.gov (United States)

Li, Xiang; Anton, Nicolas; Arpagaus, Cordin; Belleteix, Fabrice; Vandamme, Thierry F

2010-10-15

Spray drying technology is widely known and used to transform liquids (solutions, emulsions, suspension, slurries, pastes or even melts) into solid powders. Its main applications are found in the food, chemical and materials industries to enhance ingredient conservation, particle properties, powder handling and storage etc. However, spray drying can also be used for specific applications in the formulation of pharmaceuticals for drug delivery (e.g. particles for pulmonary delivery). Büchi is a reference in the development of spray drying technology, notably for laboratory scale devices. This study presents the Nano Spray Dryer B-90, a revolutionary new sprayer developed by Büchi, use of which can lower the size of the produced dried particles by an order of magnitude attaining submicron sizes. In this paper, results are presented with a panel of five representative polymeric wall materials (arabic gum, whey protein, polyvinyl alcohol, modified starch, and maltodextrin) and the potentials to encapsulate nano-emulsions, or to formulate nano-crystals (e.g. from furosemide) are also shown. Copyright © 2010 Elsevier B.V. All rights reserved.

Analysis of LOFT pressurizer spray and surge nozzles to include a 4500F step transient

International Nuclear Information System (INIS)

Nitzel, M.E.

1978-01-01

This report presents the analysis of the LOFT pressurizer spray and surge nozzles to include a 450 0 F step thermal transient. Previous analysis performed under subcontract by Basic Technology Incorporated was utilized where applicable. The SAASIII finite element computer program was used to determine stress distributions in the nozzles due to the step transient. Computer results were then incorporated in the necessary additional calculations to ascertain that stress limitations were not exceeded. The results of the analysis indicate that both the spray and surge nozzles will be within stress allowables prescribed by subsubarticle NB-3220 of the 1974 edition of the ASME Boiler and Pressure Vessel Code when subjected to currently known design, normal operating, upset, emergency, and faulted condition loads

Suspension Flame Spray Construction of Polyimide-Copper Layers for Marine Antifouling Applications

Science.gov (United States)

Liu, Yi; Xu, Xiaomin; Suo, Xinkun; Gong, Yongfeng; Li, Hua

2018-01-01

Individual capsule-like polyimide splats have been fabricated by suspension flame spray, and the polyimide splat exhibits hollow structure with an inner pore and a tiny hole on its top surface. Enwrapping of 200-1000-nm copper particles inside the splats is accomplished during the deposition for constrained release of copper for antifouling performances. Antifouling testing of the coatings by 24-h exposure to Escherichia coli-containing artificial seawater shows that the Cu-doped splat already prohibits effectively attachment of the bacteria. The prohibited adhesion of bacteria obviously impedes formation and further development of bacterial biofilm. This capsulated splat with releasing and loading of copper biocides results in dual-functional structures bearing both release-killing and contact-killing mechanisms. The suspension flame spray route and the encapsulated structure of the polyimide-Cu coatings would open a new window for designing and constructing marine antifouling layers for long-term applications.

Feasibility of suspension spraying of yttria-stabilized zirconia with water-stabilized plasma torch

Czech Academy of Sciences Publication Activity Database

Mušálek, Radek; Bertolissi, Gabriele; Medřický, J.; Kotlan, Jiří; Pala, Zdeněk; Curry, N.

2015-01-01

Roč. 268, April (2015), s. 58-62 ISSN 0257-8972. [Rencontres Internationales de la Projection Thermique/6./. Limoges, 11.12.2013-13.12.2013] R&D Projects: GA ČR(CZ) GPP108/12/P552 Institutional support: RVO:61389021 Keywords : Thermal spray coating * Suspension spray ing * Thermal barrier coating * Water-stabilized plasma * High enthalpy plasma Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 2.139, year: 2015 http://www.sciencedirect.com/science/article/pii/S025789721400680X

Polymeric materials for solar thermal applications

CERN Document Server

Köhl, Michael; Papillon, Philippe; Wallner, Gernot M; Saile, Sandrin

2012-01-01

Bridging the gap between basic science and technological applications, this is the first book devoted to polymers for solar thermal applications.Clearly divided into three major parts, the contributions are written by experts on solar thermal applications and polymer scientists alike. The first part explains the fundamentals of solar thermal energy especially for representatives of the plastics industry and researchers. Part two then goes on to provide introductory information on polymeric materials and processing for solar thermal experts. The third part combines both of these fields, dis

Wear and microstructural characteristics of spray atomized zircon sand reinforced LM13 alloy

Energy Technology Data Exchange (ETDEWEB)

Kaur, K.; Pandey, O.P. [School of Physics and Materials Science, Thapar University Patiala, Punjab (India)

2010-07-15

The requirement of the high performance light weight materials demands the development of varieties of materials within the economical range to get it commercialized. Light weight aluminium alloys are used in several structural applications like automotive, aerospace, defense industry and other fields of engineering. The ceramic particle reinforced aluminium metal matrix composites (AMCs) have emerged as a suitable candidate for commercial applications. A variety of processing routes have been adopted to manufacture AMCs. In the present work LM13 alloy reinforced with zircon sand is formed via spray forming. During experimentation a self prepared convergent-divergent nozzle is used for inert gas atomization of the melt which is subsequently deposited on copper substrate placed vertically below the atomizer. The zircon sand particles are injected in the atomization zone by external injectors aligned perpendicular to the gas atomization axis. Zircon sand has been found to have new promising economical commercial candidate due to its easy availability and good mechanical properties like high hardness, high modulus of elasticity and good thermal stability. The microhardness of cast alloy and spray formed composite shows that the spray formed zircon sand reinforced composite has higher hardness. Also the lower wear rate has been observed in case of the zircon sand reinforced AMC as compared to LM13 alloy. This behaviour is further analyzed in light of microstructural features of the spray deposited composite using optical and scanning electron microscope (SEM). A comparative study of this material (LM13/Zircon sand) with the parent alloy (LM13) is presented in this work. (Abstract Copyright [2010], Wiley Periodicals, Inc.)

Oxidation and thermal shock behavior of thermal barrier coated 18/10CrNi alloy with coating modifications

Energy Technology Data Exchange (ETDEWEB)

Guergen, Selim [Vocational School of Transportation, Anadolu University, Eskisehir (Turkmenistan); Diltemiz, Seyid Fehmi [Turkish Air Force1st Air Supply and Maintenance Center Command, Eskisehir (Turkmenistan); Kushan, Melih Cemal [Dept. of Mechanical Engineering, Eskisehir Osmangazi University, Eskisehir (Turkmenistan)

2017-01-15

In this study, substrates of 18/10CrNi alloy plates were initially sprayed with a Ni-21Cr-10Al-1Y bond coat and then with an yttria stabilized zirconia top coat by plasma spraying. Subsequently, plasma-sprayed Thermal barrier coatings (TBCs) were treated with two different modification methods, namely, vacuum heat treatment and laser glazing. The effects of modifications on the oxidation and thermal shock behavior of the coatings were evaluated. The effect of coat thickness on the bond strength of the coats was also investigated. Results showed enhancement of the oxidation resistance and thermal shock resistance of TBCs following modifications. Although vacuum heat treatment and laser glazing exhibited comparable results as per oxidation resistance, the former generated the best improvement in the thermal shock resistance of the TBCs. Bond strength also decreased as coat thickness increased.

Effects of variations in coating materials and process conditions on the thermal cycle properties of NiCrAlY/YSZ thermal barrier coatings

Energy Technology Data Exchange (ETDEWEB)

Tang Feng [Department of Chemical Engineering and Materials Science, University of California, Davis, CA 95616 (United States)]. E-mail: ftang@ucdavis.edu; Ajdelsztajn, Leonardo [Department of Chemical Engineering and Materials Science, University of California, Davis, CA 95616 (United States); Kim, George E. [Perpetual Technologies, Montreal, Que., H3E 1T8 (Canada); Provenzano, Virgil [National Institute of Standards and Technology, Gaithersburg, MD 20899 (United States); Schoenung, Julie M. [Department of Chemical Engineering and Materials Science, University of California, Davis, CA 95616 (United States)

2006-06-15

Thermal cycle tests were conducted on a variety of thermal barrier coating (TBC) specimens with bond coats that had been prepared in different ways. Variables include: (1) different thermal spray processes (high velocity oxy-fuel (HVOF) spray and low pressure plasma spray (LPPS)) (2) different feedstock powder (gas-atomized and cryomilled) (3) the introduction of nano-sized alumina additives (particles and whiskers) and (4) with and without a post-spray vacuum heat treatment. The results show that the cryomilling of the NiCrAlY powder and the post-spray heat treatment in vacuum can both lead to significant improvement in the thermal cycle lifetime of the TBCs. The TBC specimens with LPPS bond coats also generally showed longer lifetimes than those with HVOF bond coats. In contrast, the intentional dispersion of alumina particles or whiskers in the NiCrAlY powders during cryomilling did not result in the further improvement of the lifetime of the TBCs. Microstructural evolution, including the thermally grown oxide (TGO) formation, the distribution of the dispersoids in the bond coat, the internal oxidation of the bond coat, the bond coat shrinkage during the thermal cycle tests and the reduction of the ZrO{sub 2} in the top coat during the heat treatment in vacuum, was investigated.

Wear behaviour of coating of aluminium matrix composites fabricated by thermal spray method; Comportamiento a desgaste de recubrimientos de material compuesto de matriz de aluminio fabricados por proyeccion termica

Energy Technology Data Exchange (ETDEWEB)

Campo, M.; Escalera, M. D.; Torres, B.; Rams, J.; Urena, A.

2007-07-01

In this work, the wear behaviour of coatings made of aluminium matrix composites reinforced with 20% of SiC particles and manufactured by thermal spray method with oxyacetylene flame has been investigated. the wear behaviour between coating with uncoated particles and sol-gel silica coated ones heat treated at 500 degree centigree and 725 degree centigree have been compared. The sprayed coatings with silica coated particles are more homogeneous and less porous due to increase of wettability by molten aluminium that takes place on coated particles. The microstructure of the sprayed coatings, the wear surfaces and the wear debris have been analysed using optical microscopy, scanning electron microscopy and micro-analysis techniques (EDX). The results show a smaller wear rate, a lower friction coefficient and more reduced loss of mass for the coatings sprayed with particles with sol-gel silica coatings than those made with uncoated particles. (Author) 15 refs.

Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy

Science.gov (United States)

Caliari, F. R.; Miranda, F. S.; Reis, D. A. P.; Essiptchouk, A. M.; Filho, G. P.

2017-06-01

Plasma spray is a versatile technology used for production of environmental and thermal barrier coatings, mainly in the aerospace, gas turbine, and automotive industries, with potential application in the renewable energy industry. New plasma spray technologies have been developed recently to produce high-quality coatings as an alternative to the costly low-pressure plasma-spray process. In this work, we studied the properties of as-sprayed CoNiCrAlY coatings deposited on Ti-6Al-4V substrate with smooth surface ( R a = 0.8 μm) by means of a plasma torch operating in supersonic regime at atmospheric pressure. The CoNiCrAlY coatings were evaluated in terms of their surface roughness, microstructure, instrumented indentation, and phase content. Static and dynamic depositions were investigated to examine their effect on coating characteristics. Results show that the substrate surface velocity has a major influence on the coating properties. The sprayed CoNiCrAlY coatings exhibit low roughness ( R a of 5.7 μm), low porosity (0.8%), excellent mechanical properties ( H it = 6.1 GPa, E it = 155 GPa), and elevated interface toughness (2.4 MPa m1/2).

Directed-spray application of paraquat and diuron in physic nut plants

OpenAIRE

Costa,N.V.; Neunfeld,T.H.; Ohland,T.; Piano,J.T.; Klein,J.

2013-01-01

There is little information about the selectivity of herbicides in physic nut (Jatropha curcas) in Brazil. Therefore, this study aimed to evaluate the selectivity of different doses and mixtures of paraquat and diuron in direted-spray applications in physic nut plants in greenhouse conditions. The study used a randomized block design, with five replicates. The treatments were: paraquat (200 and 600 g ha-1), diuron (1,000 and 2,000 g ha-1), paraquat + diuron (200 + 1,000 g ha-1), paraquat + di...

Application of laser assisted cold spraying process for metal deposition

CSIR Research Space (South Africa)

Tlotleng, Monnamme

2014-02-01

Full Text Available Laser assisted cold spraying (LACS) process is a hybrid technique that uses laser and cold spray to deposit solid powders on metal substrates. For bonding to occur, the particle velocities must be supersonic which are achieved by entraining...

SPRAY code user's report

International Nuclear Information System (INIS)

Shire, P.R.

1977-03-01

The SPRAY computer code has been developed to model the effects of postulated sodium spray release from LMFBR piping within containment chambers. The calculation method utilizes gas convection, heat transfer and droplet combustion theory to calculate the pressure and temperature effects within the enclosure. The applicable range is 0-21 mol percent oxygen and .02-.30 inch droplets with or without humidity. Droplet motion and large sodium surface area combine to produce rapid heat release and pressure rise within the enclosed volume

Selected Parameters of Micro-Jet Cooling Gases in Hybrid Spraying Process

Directory of Open Access Journals (Sweden)

Szczucka-Lasota B.

2016-06-01

Full Text Available The innovative technology, like thermal spraying with a micro-jet cooling is one of the important modification of classical ultrasonic spraying methods. Using of micro-stream with gases like argon or nitrogen allows to cool the coating immediately after spraying, and thereby reduce the time of transition during the injection of each layer. As a result of the process, the fine dispersive structure of coatings is obtained during the shorter time in comparable to the classical high velocity oxygen fuel process (HVOF. The parameter of process and the type of stream equipment determine the quality of the obtained structure and thermal stress in the coating. The article presents the relationship between selected parameters of hybrid process and properties of the coatings. The presented technology should be adapted to the actual production of protective coating for machines and construction working in wear conditions.

Preparation of cellulose based microspheres by combining spray coagulating with spray drying.

Science.gov (United States)

Wang, Qiao; Fu, Aiping; Li, Hongliang; Liu, Jingquan; Guo, Peizhi; Zhao, Xiu Song; Xia, Lin Hua

2014-10-13

Porous microspheres of regenerated cellulose with size in range of 1-2 μm and composite microspheres of chitosan coated cellulose with size of 1-3 μm were obtained through a two-step spray-assisted approach. The spray coagulating process must combine with a spray drying step to guarantee the formation of stable microspheres of cellulose. This approach exhibits the following two main virtues. First, the preparation was performed using aqueous solution of cellulose as precursor in the absence of organic solvent and surfactant; Second, neither crosslinking agent nor separated crosslinking process was required for formation of stable microspheres. Moreover, the spray drying step also provided us with the chance to encapsulate guests into the resultant cellulose microspheres. The potential application of the cellulose microspheres acting as drug delivery vector has been studied in two PBS (phosphate-buffered saline) solution with pH values at 4.0 and 7.4 to mimic the environments of stomach and intestine, respectively. Copyright © 2014 Elsevier Ltd. All rights reserved.

Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers

Science.gov (United States)

Oksa, M.; Metsäjoki, J.; Kärki, J.

2015-01-01

There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. Many of them encounter serious problems with high-temperature corrosion due to detrimental elements such as chlorides, alkali metals, and heavy metals. By HVOF spraying, it is possible to produce very dense and well-adhered coatings, which can be applied for corrosion protection of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation for 5900 h at 550 and 750 °C. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo, and Ni-Cr-Ti. CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-Cr coating structures. Reference materials were ferritic steel T92 and nickel super alloy A263. The circulating fluidized bed boiler burnt a mixture of wood, peat and coal. The coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

Development and Application of Binary Suspensions in the Ternary System Cr2O3-TiO2-Al2O3 for S-HVOF Spraying

Science.gov (United States)

Potthoff, Annegret; Kratzsch, Robert; Barbosa, Maria; Kulissa, Nick; Kunze, Oliver; Toma, Filofteia-Laura

2018-04-01

Compositions in the system Cr2O3-TiO2-Al2O3 are among the most used ceramic materials for thermally sprayed coating solutions. Cr2O3 coatings present good sliding wear resistance; Al2O3 coatings show excellent insulation behavior and TiO2 striking corrosion properties. In order to combine these properties, coatings containing more than one oxide are highly interesting. The conventional spraying process is limited to the availability of binary feedstock powders with defined compositions. The use of suspensions offers the opportunity for tailor-made chemical compositions: within the triangle of Cr2O3-TiO2-Al2O3, each mixture of oxides can be created. Criteria for the selection of raw materials as well as the relevant aspects for the development of binary suspensions in the Cr2O3-TiO2-Al2O3 system to be used as feedstock for thermal spraying are presented. This formulation of binary suspensions required the development of water-based single-oxide suspensions with suitable behavior; otherwise, the interaction between the particles while mixing could lead up to a formation of agglomerates, which affect both the stability of the spray process and the coating properties. For the validation of this formulation procedure, binary Cr2O3-TiO2 and Al2O3-TiO2 suspensions were developed and sprayed using the S-HVOF process. The binary coatings were characterized and discussed in terms of microstructure and microhardness.

Development and Application of Binary Suspensions in the Ternary System Cr2O3-TiO2-Al2O3 for S-HVOF Spraying

Science.gov (United States)

Potthoff, Annegret; Kratzsch, Robert; Barbosa, Maria; Kulissa, Nick; Kunze, Oliver; Toma, Filofteia-Laura

2018-03-01

Compositions in the system Cr2O3-TiO2-Al2O3 are among the most used ceramic materials for thermally sprayed coating solutions. Cr2O3 coatings present good sliding wear resistance; Al2O3 coatings show excellent insulation behavior and TiO2 striking corrosion properties. In order to combine these properties, coatings containing more than one oxide are highly interesting. The conventional spraying process is limited to the availability of binary feedstock powders with defined compositions. The use of suspensions offers the opportunity for tailor-made chemical compositions: within the triangle of Cr2O3-TiO2-Al2O3, each mixture of oxides can be created. Criteria for the selection of raw materials as well as the relevant aspects for the development of binary suspensions in the Cr2O3-TiO2-Al2O3 system to be used as feedstock for thermal spraying are presented. This formulation of binary suspensions required the development of water-based single-oxide suspensions with suitable behavior; otherwise, the interaction between the particles while mixing could lead up to a formation of agglomerates, which affect both the stability of the spray process and the coating properties. For the validation of this formulation procedure, binary Cr2O3-TiO2 and Al2O3-TiO2 suspensions were developed and sprayed using the S-HVOF process. The binary coatings were characterized and discussed in terms of microstructure and microhardness.

Metallization of Various Polymers by Cold Spray

Science.gov (United States)

Che, Hanqing; Chu, Xin; Vo, Phuong; Yue, Stephen

2018-01-01

Previous results have shown that metallic coatings can be successfully cold sprayed onto polymeric substrates. This paper studies the cold sprayability of various metal powders on different polymeric substrates. Five different substrates were used, including carbon fiber reinforced polymer (CFRP), acrylonitrile butadiene styrene (ABS), polyether ether ketone (PEEK), polyethylenimine (PEI); mild steel was also used as a benchmark substrate. The CFRP used in this work has a thermosetting matrix, and the ABS, PEEK and PEI are all thermoplastic polymers, with different glass transition temperatures as well as a number of distinct mechanical properties. Three metal powders, tin, copper and iron, were cold sprayed with both a low-pressure system and a high-pressure system at various conditions. In general, cold spray on the thermoplastic polymers rendered more positive results than the thermosetting polymers, due to the local thermal softening mechanism in the thermoplastics. Thick copper coatings were successfully deposited on PEEK and PEI. Based on the results, a method is proposed to determine the feasibility and deposition window of cold spraying specific metal powder/polymeric substrate combinations.

Role of thermo-physical properties on design and development of thermal plasma devices

International Nuclear Information System (INIS)

Ghorui, S.

2014-01-01

Thermal plasma devices find wide application in variety of technological areas like cutting, welding, spray coating, waste management, material processing, chemical reduction, nano-synthesis, novel material synthesis etc. Highly non-linear behavior of the plasma properties coupled with inherent instabilities, extremely high temperature, high gradients in thermal, and flow field, presence of thermal and chemical non-equilibrium make design and development of the plasma generating devices a challenging task as power levels of the devices increase

Deposition of Lanthanum Strontium Cobalt Ferrite (LSCF) Using Suspension Plasma Spraying for Oxygen Transport Membrane Applications

Science.gov (United States)

Fan, E. S. C.; Kesler, O.

2015-08-01

Suspension plasma spray deposition was utilized to fabricate dense lanthanum strontium cobalt ferrite oxygen separation membranes (OSMs) on porous metal substrates for mechanical support. The as-sprayed membranes had negligible and/or reversible material decomposition. At the longer stand-off distance (80 mm), smooth and dense membranes could be manufactured using a plasma with power below approximately 81 kW. Moreover, a membrane of 55 μm was observed to have very low gas leakage rates desirable for OSM applications. This thickness could potentially be decreased further to improve oxygen diffusion by using metal substrates with finer surface pores.

Spray drying of silica microparticles for sustained release application with a new sol-gel precursor.

Science.gov (United States)

Wang, Bifeng; Friess, Wolfgang

2017-10-30

A new precursor, tetrakis(2-methoxyethyl) orthosilicate (TMEOS) was used to fabricate microparticles for sustained release application, specifically for biopharmaceuticals, by spray drying. The advantages of TMEOS over the currently applied precursors are its water solubility and hydrolysis at moderate pH without the need of organic solvents or catalyzers. Thus a detrimental effect on biomolecular drug is avoided. By generating spray-dried silica particles encapsulating the high molecular weight model compound FITC-dextran 150 via the nano spray dryer Büchi-90, we demonstrated how formulation parameters affect and enable control of drug release properties. The implemented strategies to regulate release included incorporating different quantities of dextrans with varying molecular weight as well as adjusting the pH of the precursor solution to modify the internal microstructures. The addition of dextran significantly altered the released amount, while the release became faster with increasing dextran molecular weight. A sustained release over 35days could be achieved with addition of 60 kD dextran. The rate of FITC-Dextran 150 release from the dextran 60 containing particles decreased with higher precursor solution pH. In conclusion, the new precursor TMEOS presents a promising alternative sol-gel technology based carrier material for sustained release application of high molecular weight biopharmaceutical drugs. Copyright © 2017 Elsevier B.V. All rights reserved.

Evaluation of ULV and Thermal Fog Mosquito Control Applications in Temperate and Desert Environments

Science.gov (United States)

Ultra low volume (ULV) and thermal fog aerosol dispersals of pesticides have been used against mosquitoes and other insects for half a century. Although each spray technology has advantages and disadvantages, only 7 studies have been identified that directly compare their performance in the field. U...

Thermal plasma chemical vapor deposition

International Nuclear Information System (INIS)

Heberlein, J.; Pfender, E.

1993-01-01

Thermal plasmas, with temperatures up to and even exceeding 10 4 K, are capable of producing high density vapor phase precursors for the deposition of relatively thick films. Although this technology is still in its infancy, it will fill the void between the relatively slow deposition processes such as physical vapor deposition and the high rate thermal spray deposition processes. In this chapter, the present state-of-the-art of this field is reviewed with emphasis on the various types of reactors proposed for this emerging technology. Only applications which attracted particular attention, namely diamond and high T c superconducting film deposition, are discussed in greater detail. (orig.)

Deposition and characterization of plasma sprayed Ni-5A1/ magnesia stabilized zirconia based functionally graded thermal barrier coating

International Nuclear Information System (INIS)

Baig, M N; Khalid, F A

2014-01-01

Thermal barrier coatings (TBCs) are employed to protect hot section components in industrial and aerospace gas turbine engines. Conventional TBCs frequently fail due to high residual stresses and difference between coefficient of thermal expansion (CTE) of the substrate and coatings. Functionally graded thermal barrier coatings (FG-TBCs) with gradual variation in composition have been proposed to minimize the problem. In this work, a five layered functionally graded thermal barrier coating system was deposited by atmospheric plasma spray (APS) technique on Nimonic 90 substrates using Ni-5Al as bond coat (BC) and magnesia stabilized zirconia as top coat (TC). The coatings were characterized by SEM, EDS, XRD and optical profilometer. Microhardness and coefficient of thermal expansion of the five layers deposited as individual coatings were also measured. The deposited coating system was oxidized at 800°C. SEM analysis showed that five layers were successfully deposited by APS to produce a FG-TBC. The results also showed that roughness (Ra) of the individual layers decreased with an increase in TC content in the coatings. It was found that microhardness and CTE values gradually changed from bond coat to cermet layers to top coat. The oxidized coated sample revealed parabolic behavior and changes in the surface morphology and composition of coating

Numerical heat transfer model for frost protection of citrus fruits by water from a spraying system

Directory of Open Access Journals (Sweden)

Issa Roy J.

2012-01-01

Full Text Available A simplified model is developed to simulate the conditions associated with the protection of fruits from frost damage using water from a spraying system. The model simulates the movement of the solidifying water front on a single fruit, and based on that determines the spray frequency needed for a water film to continuously surround the ice-coated fruit to prevent the fruit temperature from dropping below 0ºC. Simulations are presented for the frost protection of sweet oranges (citrus sinensis. The effect of environmental conditions such as air temperature, air velocity, surface radiation and water film evaporation on the development of the ice layer encasing is considered. Simulations show the effect the encasing ice sheet thickness has on the fruit temperature if water from a spraying system is turned off permanently. Experimental tests are also conducted to determine the change in the thermal properties of citrus sinensis for operating temperatures that range from above freezing to sub-freezing. The results of the experimental tests and the numerical simulations shall lead to a better understanding of fruit protection from frost damage by the application of water from a spraying system.

Application of cyclodextrins in antibody microparticles: potentials for antibody protection in spray drying.

Science.gov (United States)

Ramezani, Vahid; Vatanara, Alireza; Seyedabadi, Mohammad; Nabi Meibodi, Mohsen; Fanaei, Hamed

2017-07-01