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Sample records for thermal spray industry

  1. 1994 Thermal spray industrial applications: Proceedings

    International Nuclear Information System (INIS)

    Berndt, C.C.; Sampath, S.

    1994-01-01

    The 7th National Thermal Spray Conference met on June 20--24, 1994, in Boston, Massachusetts. The conference was sponsored by the Thermal Spray Division of ASM International and co-sponsored by the American Welding Society, Deutscher Verband fur Schweisstechnik e.V., High Temperature Society of Japan, International Thermal Spray Association, and Japanese Thermal Spraying Society. The conference covered applications for automobiles, aerospace, petrochemicals, power generation, and biomedical needs. Materials included metals, ceramics, and composites with a broad range of process developments and diagnostics. Other sections included modeling and systems control; spray forming and reactive spraying; post treatment; process, structure and property relationships; mechanical properties; and testing, characterization and wear. One hundred and seventeen papers have been processed separately for inclusion on the data base

  2. Thermal spray for commercial shipbuilding

    Science.gov (United States)

    Rogers, F. S.

    1997-09-01

    Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum. This extends the service life of the coating and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanizing. With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal- sprayed aluminum coating system has proved the most cost- effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Arc spray technology has reduced the application cost of thermal spraying of aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

  3. Thermal Arc Spray Overview

    Science.gov (United States)

    Hafiz Abd Malek, Muhamad; Hayati Saad, Nor; Kiyai Abas, Sunhaji; Mohd Shah, Noriyati

    2013-06-01

    Usage of protective coating for corrosion protection was on highly demand during the past decade; and thermal spray coating played a major part during that time. In recent years, the thermal arc spray coating becomes a popular coating. Many big players in oil and gas such as PETRONAS, EXXON MOBIL and SHELL in Malaysia tend to use the coating on steel structure as a corrosion protection. Further developments in coating processes, the devices, and raw materials have led to expansion of functional coatings and applications scope from conventional coating to specialized industries. It is widely used because of its ability to withstand high process temperature, offer advantages in efficiency, lower cost and acts as a corrosion protection. Previous research also indicated that the thermal arc spray offers better coating properties compared to other methods of spray. This paper reviews some critical area of thermal spray coating by discussing the process/parameter of thermal arc spray technology and quality control of coating. Coating performance against corrosion, wear and special characteristic of coating are also described. The field application of arc spray technology are demonstrated and reviewed.

  4. Thermal Arc Spray Overview

    International Nuclear Information System (INIS)

    Malek, Muhamad Hafiz Abd; Saad, Nor Hayati; Abas, Sunhaji Kiyai; Shah, Noriyati Mohd

    2013-01-01

    Usage of protective coating for corrosion protection was on highly demand during the past decade; and thermal spray coating played a major part during that time. In recent years, the thermal arc spray coating becomes a popular coating. Many big players in oil and gas such as PETRONAS, EXXON MOBIL and SHELL in Malaysia tend to use the coating on steel structure as a corrosion protection. Further developments in coating processes, the devices, and raw materials have led to expansion of functional coatings and applications scope from conventional coating to specialized industries. It is widely used because of its ability to withstand high process temperature, offer advantages in efficiency, lower cost and acts as a corrosion protection. Previous research also indicated that the thermal arc spray offers better coating properties compared to other methods of spray. This paper reviews some critical area of thermal spray coating by discussing the process/parameter of thermal arc spray technology and quality control of coating. Coating performance against corrosion, wear and special characteristic of coating are also described. The field application of arc spray technology are demonstrated and reviewed.

  5. High-Performance Molybdenum Coating by Wire–HVOF Thermal Spray Process

    Science.gov (United States)

    Tailor, Satish; Modi, Ankur; Modi, S. C.

    2018-04-01

    Coating deposition on many industrial components with good microstructural, mechanical properties, and better wear resistance is always a challenge for the thermal spray community. A number of thermal spray methods are used to develop such promising coatings for many industrial applications, viz. arc spray, flame spray, plasma, and HVOF. All these processes have their own limitations to achieve porous free, very dense, high-performance wear-resistant coatings. In this work, an attempt has been made to overcome this limitation. Molybdenum coatings were deposited on low-carbon steel substrates using wire-high-velocity oxy-fuel (W-HVOF; WH) thermal spray system (trade name HIJET 9610®). For a comparison, Mo coatings were also fabricated by arc spray, flame spray, plasma spray, and powder-HVOF processes. As-sprayed coatings were analyzed using x-ray diffraction, scanning electron microscopy for phase, and microstructural analysis, respectively. Coating microhardness, surface roughness, and porosity were also measured. Adhesion strength and wear tests were conducted to determine the mechanical and wear properties of the as-sprayed coatings. Results show that the coatings deposited by W-HVOF have better performance in terms of microstructural, mechanical, and wear resistance properties, in comparison with available thermal spray process (flame spray and plasma spray).

  6. An assessment of thermal spray coating technologies for high temperature corrosion protection

    International Nuclear Information System (INIS)

    Heath, G.R.; Heimgartner, P.; Gustafsson, S.; Irons, G.; Miller, R.

    1997-01-01

    The use of thermally sprayed coatings in combating high temperature corrosion continues to grow in the major industries of chemical, waste incineration, power generation and pulp and paper. This has been driven partially by the development of corrosion resistant alloys, improved knowledge and quality in the thermal spray industry and continued innovation in thermal spray equipment. There exists today an extensive range of thermal spray process options, often with the same alloy solution. In demanding corrosion applications it is not sufficient to just specify alloy and coating method. For the production of reliable coatings the whole coating production envelope needs to be considered, including alloy selection, spray parameters, surface preparation, base metal properties, heat input etc. Combustion, arc-wire, plasma, HVOF and spray+fuse techniques are reviewed and compared in terms of their strengths and limitations to provide cost-effective solutions for high temperature corrosion protection. Arc wire spraying, HP/HVOF and spray+fuse are emerging as the most promising techniques to optimise both coating properties and economic/practical aspects. (orig.)

  7. 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)

  8. Performances and reliability of WC based thermal spray coatings

    International Nuclear Information System (INIS)

    Scrivani, A.; Rosso, M.; Salvarani, L.

    2001-01-01

    Thermal spray processes are used for a lot of traditional and innovative applications and their importance is becoming higher and higher. WC/CoCr based thermal spray coatings represent one of the most important class of coatings that find application in a wide range of industrial sectors. This paper will address a review of current applications and characteristics of this kind of coating. The most important spraying processes, namely HVOF (high velocity oxygen fuel) are examined, the characterization of the coatings from the point of view of corrosion and wear resistance is considered. (author)

  9. Thermal Spray Applications in Electronics and Sensors: Past, Present, and Future

    Science.gov (United States)

    Sampath, Sanjay

    2010-09-01

    Thermal spray has enjoyed unprecedented growth and has emerged as an innovative and multifaceted deposition technology. Thermal spray coatings are crucial to the enhanced utilization of various engineering systems. Industries, in recognition of thermal spray's versatility and economics, have introduced it into manufacturing environments. The majority of modern thermal spray applications are "passive" protective coatings, and they rarely perform an electronic function. The ability to consolidate dissimilar material multilayers without substrate thermal loading has long been considered a virtue for thick-film electronics. However, the complexity of understanding/controlling materials functions especially those resulting from rapid solidification and layered assemblage has stymied expansion into electronics. That situation is changing: enhancements in process/material science are allowing reconsideration for novel electronic/sensor devices. This review critically examines past efforts in terms of materials functionality from a device perspective, along with ongoing/future concepts addressing the aforementioned deficiencies. The analysis points to intriguing future possibilities for thermal spray technology in the world of thick-film sensors.

  10. Kinematic Optimization of Robot Trajectories for Thermal Spray Coating Application

    Science.gov (United States)

    Deng, Sihao; Liang, Hong; Cai, Zhenhua; Liao, Hanlin; Montavon, Ghislain

    2014-12-01

    Industrial robots are widely used in the field of thermal spray nowadays. Due to their characteristics of high-accuracy and programmable flexibility, spraying on complex geometrical workpieces can be realized in the equipped spray room. However, in some cases, the robots cannot guarantee the process parameters defined by the robot movement, such as the scanning trajectory, spray angle, relative speed between the torch and the substrate, etc., which have distinct influences on heat and mass transfer during the generation of any thermally sprayed coatings. In this study, an investigation on the robot kinematics was proposed to find the rules of motion in a common case. The results showed that the motion behavior of each axis of robot permits to identify the motion problems in the trajectory. This approach allows to optimize the robot trajectory generation in a limited working envelop. It also minimizes the influence of robot performance to achieve a more constant relative scanning speed which is represented as a key parameter in thermal spraying.

  11. 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.

  12. Thermally sprayed coatings: Aluminum on lead

    International Nuclear Information System (INIS)

    Usmani, S.; Czajkowski, C.J.; Zatorski, R.

    1999-01-01

    An experimental program to determine the feasibility of thermally spraying aluminum on a lead substrate was initiated in support of the accelerator production of tritium (APT) Project for the US Department of Energy. The program consisted of two distinct parts: (1) the characterization of the thermally sprayed coatings, including microhardness testing, effects of heating, and microstructure and porosity determinations, and (2) effects of mercury doping and heat treatments on the thermally sprayed composite. The project determined that aluminum could successfully be thermally sprayed onto the lead. The coatings had a dense microstructure, with a Vicker's Pyramid Hardness (VPH) of about 60, and a maximum porosity (found in strips on the samples) of 12%

  13. Ternary ceramic thermal spraying powder and method of manufacturing thermal sprayed coating using said powder

    Energy Technology Data Exchange (ETDEWEB)

    Vogli, Evelina; Sherman, Andrew J.; Glasgow, Curtis P.

    2018-02-06

    The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

  14. 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.

  15. A new method for thermal spraying of Zn-Al coatings

    International Nuclear Information System (INIS)

    Gorlach, I.A.

    2009-01-01

    This paper presents the development of the thermal spraying system built on the principles of the high velocity air flame (HVAF) process. HVAF sprayed coatings showed considerably higher bond strength than coatings obtained by the conventional methods, indicating the advantage of this method in areas where the adhesion strength is critically important. The highly dense structure of the coating obtained with HVAF eliminates a need for a top paint coat, which is typically applied on metal sprayed coatings to extend service life. The thermal sprayed coatings were characterized by the standard techniques, such as light microscopy, scanning electron microscopy with energy-dispersive spectroscopy, X-ray diffraction, salt spray and bond strength tests. The results show that thermal sprayed coatings have a dense structure, low presence of oxides and high resistance to corrosion. High spray rate and good coating quality make the HVAF thermal spray method a viable alternative to the conventional thermal spraying technologies, such as Wire Flame and Twin-Wire Arc.

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

    Directory of Open Access Journals (Sweden)

    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.

  17. 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.

  18. Assessment of thermal spray coatings for wear and abrasion resistance applications

    Science.gov (United States)

    Karode, Ishaan Nitin

    Thermal spray cermet and metallic coatings are extensively used for wear, abrasion and corrosion control in a variety of industries. The first part of the thesis focuses mainly on testing of sand erosion resistance of thermal spray coatings on carbon composites used in the manufacture of helicopter rotor blades. The test set-up employed is a sand blasting machine and is an effort to duplicate the in-flight conditions especially those encountered in hot arid conditions. The technique adopted follows the Department of Defence test method standard. Carbon Composites have excellent stiffness, strength and low weight/density. The strength to weight ratio is high. Hence, these are used in aerospace applications to a large extent. However, the biggest problem encountered with carbon composites is its low abrasion resistance as its surface is very weak. Hence, thermal spray coatings are used to improve the surface properties of CFRP. Zinc bond coats and WC-Co coatings were tested. However, high amount of thermal stresses were developed between the substrate and the coating due to large differences in the CTE's of the both, leading to high mass losses within two minutes and just 130 grams of sand sprayed on to the coatings with the sand blasting machine built; and hence the coatings with CC as a substrate could not qualify for the application. The second part of the thesis focuses on the assessment of different thermal spray coatings used for manufacture of mechanical seals in pumps and analyze the best coating material for the wear resistance application through detail quantification of material loss by block-on-ring test set-up. A machine based on Block-on-ring test set-up following ASTM G77 (Measurement of Adhesive wear resistance of thermal spray coatings) standards was built to duplicate the pump conditions. Thermally sprayed coated materials were tested in different conditions (Load, time, abrasive). WC-Co had the highest wear resistance (lower volume losses) and

  19. Inhalation exposure to isocyanates of car body repair shop workers and industrial spray painters.

    Science.gov (United States)

    Pronk, Anjoeka; Tielemans, Erik; Skarping, Gunnar; Bobeldijk, Ivana; VAN Hemmen, Joop; Heederik, Dick; Preller, Liesbeth

    2006-01-01

    As part of a large-scale epidemiological study, occupational isocyanate exposure was assessed in spray-painting environments. The aim was to assess which compounds contribute to isocyanate exposure in car body repair shops and industrial painting companies, and to identify tasks with high risk of isocyanate exposure. Mainly personal task-based samples (n = 566) were collected from 24 car body repair shops and five industrial painting companies using impingers with DBA in toluene. Samples were analysed by LC-MS for isocyanate monomers, oligomers and products of thermal degradation. From the 23 analysed compounds, 20 were detected. Exploratory factor analysis resulted in a HDI, TDI and MDI factor with the thermal degradation products divided over the TDI and MDI factors. The HDI factor mainly consisted of HDI oligomers and was dominant in frequency and exposure levels in both industries. Spray painting of PU lacquers resulted in the highest exposures for the HDI factor (car body repair shops than in industrial painting companies. Exposure levels were low (car body repair shops (industries with highest exposures during PU spraying. However, since respiratory protection is less extensively used during other tasks, lower level exposure during these other tasks may significantly contribute to the internal dose.

  20. 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.

  1. 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

  2. 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

  3. Current situation and development tendency of thermal spraying materials in China

    Institute of Scientific and Technical Information of China (English)

    YU; Yue-guang

    2005-01-01

    The current situations of thermal spraying materials in China are described in this paper.The thermal spraying technology in China has a great progress over tens of years. More than one hundred varieties of material products serve thermal spraying producing now. They belong to three kinds, powders,wires and rods. Technologies for producing alloy, ceramic and composite powders, alloy and cored wires,and oxide ceramic rods are applied to large-scale production. Many research and development works on advanced materials for thermal spraying are carrying out recent years. They show that the general tendencies of thermal spraying materials in China are composite or low-impurity component, ultrafine or nanosized microstructure, high properties, and specialized and systematized applications. Thermal spraying materials have great prospects with the development of saving society in China.

  4. 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.

  5. 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.

  6. 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.

  7. 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

    diagnostic tools and strategies, and experimental advances that have enabled the development of a wide range of coating structures exhibiting in numerous cases unique properties. Several examples are detailed. In this paper the following aspects are presented successively (i) the two spray techniques used for manufacturing such coatings: thermal plasma and HVOF, (ii) sensors developed for in-flight diagnostics of micrometre-sized particles and the interaction of a liquid and hot gas flow, (iii) three spray processes: conventional spraying using micrometre-sized agglomerates of nanometre-sized particles, suspension spraying and solution spraying and (iv) the emerging issues resulting from the specific structures of these materials, particularly the characterization of these coatings and (v) the potential industrial applications. Further advances require the scientific and industrial communities to undertake new research and development activities to address, understand and control the complex mechanisms occurring, in particular, thermal flow—liquid drops or stream interactions when considering suspension and liquid precursor thermal spray techniques. Work is still needed to develop new measurement devices to diagnose in-flight droplets or particles below 2 µm average diameter and to validate that the assumptions made for liquid-hot gas interactions. Efforts are also required to further develop some of the characterization protocols suitable to address the specificities of such nanostructured coatings, as some existing 'conventional' protocols usually implemented on thermal spray coatings are not suitable anymore, in particular to address the void network architectures from which numerous coatings properties are derived.

  8. 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

  9. 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

  10. Development of process data capturing, analysis and controlling for thermal spray techniques - SprayTracker

    Science.gov (United States)

    Kelber, C.; Marke, S.; Trommler, U.; Rupprecht, C.; Weis, S.

    2017-03-01

    Thermal spraying processes are becoming increasingly important in high-technology areas, such as automotive engineering and medical technology. The method offers the advantage of a local layer application with different materials and high deposition rates. Challenges in the application of thermal spraying result from the complex interaction of different influencing variables, which can be attributed to the properties of different materials, operating equipment supply, electrical parameters, flow mechanics, plasma physics and automation. In addition, spraying systems are subject to constant wear. Due to the process specification and the high demands on the produced coatings, innovative quality assurance tools are necessary. A central aspect, which has not yet been considered, is the data management in relation to the present measured variables, in particular the spraying system, the handling system, working safety devices and additional measuring sensors. Both the recording of all process-characterizing variables, their linking and evaluation as well as the use of the data for the active process control presuppose a novel, innovative control system (hardware and software) that was to be developed within the scope of the research project. In addition, new measurement methods and sensors are to be developed and qualified in order to improve the process reliability of thermal spraying.

  11. 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...

  12. 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.

  13. 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

    diagnostic tools and strategies, and experimental advances that have enabled the development of a wide range of coating structures exhibiting in numerous cases unique properties. Several examples are detailed. In this paper the following aspects are presented successively (i) the two spray techniques used for manufacturing such coatings: thermal plasma and HVOF, (ii) sensors developed for in-flight diagnostics of micrometre-sized particles and the interaction of a liquid and hot gas flow, (iii) three spray processes: conventional spraying using micrometre-sized agglomerates of nanometre-sized particles, suspension spraying and solution spraying and (iv) the emerging issues resulting from the specific structures of these materials, particularly the characterization of these coatings and (v) the potential industrial applications. Further advances require the scientific and industrial communities to undertake new research and development activities to address, understand and control the complex mechanisms occurring, in particular, thermal flow-liquid drops or stream interactions when considering suspension and liquid precursor thermal spray techniques. Work is still needed to develop new measurement devices to diagnose in-flight droplets or particles below 2 μm average diameter and to validate that the assumptions made for liquid-hot gas interactions. Efforts are also required to further develop some of the characterization protocols suitable to address the specificities of such nanostructured coatings, as some existing 'conventional' protocols usually implemented on thermal spray coatings are not suitable anymore, in particular to address the void network architectures from which numerous coatings properties are derived. (topical review)

  14. 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

  15. Review of Thermal Spray Coating Applications in the Steel Industry: Part 2—Zinc Pot Hardware in the Continuous Galvanizing Line

    Science.gov (United States)

    Matthews, S.; James, B.

    2010-12-01

    This two-part article series reviews the application of thermal spray coating technology in the production of steel and steel sheet products. Part 2 of this article series is dedicated to coating solutions in the continuous galvanizing line. The corrosion mechanisms of Fe- and Co-based bulk materials are briefly reviewed as a basis for the development of thermal spray coating solutions. WC-Co thermal spray coatings are commonly applied to low Al-content galvanizing hardware due to their superior corrosion resistance compared to Fe and Co alloys. The effect of phase degradation, carbon content, and WC grain size are discussed. At high Al concentrations, the properties of WC-Co coatings degrade significantly, leading to the application of oxide-based coatings and corrosion-resistant boride containing coatings. The latest results of testing are summarized, highlighting the critical coating parameters.

  16. 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

  17. 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.

  18. 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

  19. 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

  20. 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

  1. 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

  2. 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.

  3. 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

  4. 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

  5. Applications of thermal spraying for automotive parts. Jidosha ni okeru yosha no tekiyo

    Energy Technology Data Exchange (ETDEWEB)

    Mori, K [Toyota Motor Co. Ltd., Aichi (Japan)

    1992-10-31

    Application of thermal spraying for automotive parts is described. Outlines of the spraying types that are materialized recently, like 'gel-double spraying of turbo-compressor housing part' and 'iron alloy spraying to outer portion of valve lifter made with Al alloy', are introduced. Gel-double spraying technology is widely used in the jet engine of aeroplane, however its use in automotive turbo was difficult from the reason like quality assurance relating to continuous production of automotives. As a result of the research and development based on the above reasons, a low speed torque is confirmed by the formation of gel-double spray layer. Spraying to the outer part of the valve lifter made from Al alloy is cited as the best example of thermal spraying. Relation between flying speed of spraying particles and degree of flattening, etc., relating to the conformity of adhesion power of coated layer, is explained. Further research topics are given as; improvement of spraying efficiency, improvement of resistance of spraying equipments, unification of equipments standards, quantification of spray coatings, design of spray materials, etc. 9 refs., 8 figs., 1 tab.

  6. 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.

  7. 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.

  8. 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.

  9. 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

  10. 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

  11. 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

  12. 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.

  13. 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

  14. 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.)

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  1. 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...

  2. 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

  3. 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.

  4. 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.

  5. 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

  6. 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.

  7. 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.

  8. 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

  9. 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.

  10. 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.

  11. 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.

  12. 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

  13. 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.)

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. 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.

  19. 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.

  20. 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

  1. 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...

  2. 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.

  3. 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.

  4. 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.

  5. 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).

  6. 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.

  7. 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

  8. 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.  

  9. 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.

  10. 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

  11. 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.

  12. 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.

  13. 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

  14. 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.

  15. 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

  16. 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...

  17. 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.

  18. Failure Analysis of Multilayered Suspension Plasma-Sprayed Thermal Barrier Coatings for Gas Turbine Applications

    Science.gov (United States)

    Gupta, M.; Markocsan, N.; Rocchio-Heller, R.; Liu, J.; Li, X.-H.; Östergren, L.

    2018-02-01

    Improvement in the performance of thermal barrier coatings (TBCs) is one of the key objectives for further development of gas turbine applications. The material most commonly used as TBC topcoat is yttria-stabilized zirconia (YSZ). However, the usage of YSZ is limited by the operating temperature range which in turn restricts the engine efficiency. Materials such as pyrochlores, perovskites, rare earth garnets are suitable candidates which could replace YSZ as they exhibit lower thermal conductivity and higher phase stability at elevated temperatures. The objective of this work was to investigate different multilayered TBCs consisting of advanced topcoat materials fabricated by suspension plasma spraying (SPS). The investigated topcoat materials were YSZ, dysprosia-stabilized zirconia, gadolinium zirconate, and ceria-yttria-stabilized zirconia. All topcoats were deposited by TriplexPro-210TM plasma spray gun and radial injection of suspension. Lifetime of these samples was examined by thermal cyclic fatigue and thermal shock testing. Microstructure analysis of as-sprayed and failed specimens was performed with scanning electron microscope. The failure mechanisms in each case have been discussed in this article. The results show that SPS could be a promising route to produce multilayered TBCs for high-temperature applications.

  19. Thermal-fluid assessment of multijet atomization for spray cooling applications

    International Nuclear Information System (INIS)

    Panao, Miguel R.O.; Moreira, Antonio L.N.; Durao, Diamantino F.G.

    2011-01-01

    Thermal management is a particularly difficult challenge to the miniaturization of electronic components because it requires high performance cooling systems capable of removing large heat loads at fast rates in order to keep the operating temperature low and controlled. To meet this challenge, the Intermittent Spray Cooling (ISC) concept has been suggested as a promising technology which uses a proper match between the frequency and duration of consecutive injection cycles to control heat transfer. This concept also depends on: the atomization strategy; a homogeneous dispersion of droplets impinging on the hot surface; and the quantitative control of the liquid deposited, avoiding excessive secondary atomization or pre-impingement-evaporation. In this work, the use of liquid atomization by multiple jets impact, also referred as multijet atomization, is the subject of a thermal-fluid assessment using heat transfer correlations previously derived for intermittent sprays. Simultaneous measurements of droplet size and velocity are provided as input for the correlations and the analysis explores the influence of the number of impinging jets on the heat removal pattern and magnitude. Emphasis is put on the promising applicability of multijet atomization for promoting an intelligent use of energy in the thermal management of electronic devices.

  20. 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.

  1. Next Generation Thermal Barrier Coatings for the Gas Turbine Industry

    Science.gov (United States)

    Curry, Nicholas; Markocsan, Nicolaie; Li, Xin-Hai; Tricoire, Aurélien; Dorfman, Mitch

    2011-01-01

    The aim of this study is to develop the next generation of production ready air plasma sprayed thermal barrier coating with a low conductivity and long lifetime. A number of coating architectures were produced using commercially available plasma spray guns. Modifications were made to powder chemistry, including high purity powders, dysprosia stabilized zirconia powders, and powders containing porosity formers. Agglomerated & sintered and homogenized oven spheroidized powder morphologies were used to attain beneficial microstructures. Dual layer coatings were produced using the two powders. Laser flash technique was used to evaluate the thermal conductivity of the coating systems from room temperature to 1200 °C. Tests were performed on as-sprayed samples and samples were heat treated for 100 h at 1150 °C. Thermal conductivity results were correlated to the coating microstructure using image analysis of porosity and cracks. The results show the influence of beneficial porosity on reducing the thermal conductivity of the produced coatings.

  2. 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.)

  3. 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...

  4. 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.

  5. 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.

  6. 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...

  7. 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.

  8. 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

  9. 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.

  10. 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

  11. 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

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. 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

  19. 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

  20. 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.

  1. 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.

  2. 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.

  3. 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

  4. 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.

  5. 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...

  6. 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

  7. 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

  8. 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.

  9. 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...

  10. 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.

  11. 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

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.)

  18. 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.

  19. Spray characteristics and liquid distribution of multi-hole effervescent atomisers for industrial burners

    International Nuclear Information System (INIS)

    Jedelský, Jan; Jícha, Miroslav

    2016-01-01

    Highlights: • The multi-hole (mh) spray morphology is very similar to that of single-hole nozzles. • Unsteady spray was found at low pressure and low gas-to-liquid-ratio (GLR) values. • Cone angle variation in mh spray with pressure and GLR depends on the exit nozzles angle. • A liquid–gas gravitational separation in horizontal atomiser operation was observed. • It causes up to 70% fuel supply variance into exit holes depending on design and regime. - Graphical Abstract: - Abstract: The present paper provides an experimental study and optimisation of multi-hole effervescent atomisers for industrial burners using oil-based fossil, bio- or waste fuels with prospects of emission reduction. Several multi-hole nozzles were designed based on our previous work. We probed the spray quality by phase-Doppler anemometry. 3-D plots of Sauter mean diameter and mean droplet velocity demonstrate their spatial distribution within the spray. The effect of geometrical and operational factors on the spray is discussed. Droplet size–velocity correlations as well as the size and velocity distributions are presented, and differences are found against other investigations. A spray macrostructure is photographically observed and spray cone angles of the multi-hole nozzles are analysed. An internal two-phase flow is estimated using the Baker's map for horizontal two-phase flow. Our previous two-phase flow visualisations suggested a liquid–gas gravitational separation when the multi-hole atomiser operated horizontally. This issue is addressed here; the results of spray heterogeneity measurements document that fuel flow rates through individual exit holes differ significantly. This difference spans between 0 and 70% depending on the nozzle design and flow regime. Effervescent sprays are unsteady under some operating conditions; spray unsteadiness was detected at low pressure and low gas-to-liquid-ratios.

  20. 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.

  1. 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...

  2. 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

  3. 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

  4. 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.

  5. 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

  6. 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.

  7. 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.

  8. 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

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. Physico-chemical aspects of radionuclide removal under accident conditions in nuclear power plants by means of containment-building spray systems

    International Nuclear Information System (INIS)

    Alm, M.

    1976-01-01

    A survey is given on industrial spray solutions, their thermal and radiation stability, drop effects, and the corrosion behaviour of reactor and containment materials. From the hitherto known spray experiments it may be concluded that (1) spray solutions can be used for the effective decontamination of the containment atmosphere in the event of a loss-of-coolant accident, (2) the spray efficiency for the removal of gaseous and volatile fission products can be assessed by means of simplified model considerations, (3) further work is necessary to optimize the technology of the spray process. (author)

  14. 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

  15. 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.

  16. Bioinspired hybrid materials from spray-formed ceramic templates.

    Science.gov (United States)

    Dwivedi, Gopal; Flynn, Katherine; Resnick, Michael; Sampath, Sanjay; Gouldstone, Andrew

    2015-05-20

    Thermally sprayed ceramics, when infiltrated with polymer, exhibit synergistic increases in strength and toughness. The structure of such composites-a dense, brick-mortar arrangement-is strikingly similar to that of nacre, as are the mechanisms underlying the robust mechanical behavior. This industrial-scale process thus presents an exciting tool for bio-mimetic exploration. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  17. 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

  18. Industrial application of thermal image processing and thermal control

    Science.gov (United States)

    Kong, Lingxue

    2001-09-01

    Industrial application of infrared thermography is virtually boundless as it can be used in any situations where there are temperature differences. This technology has particularly been widely used in automotive industry for process evaluation and system design. In this work, thermal image processing technique will be introduced to quantitatively calculate the heat stored in a warm/hot object and consequently, a thermal control system will be proposed to accurately and actively manage the thermal distribution within the object in accordance with the heat calculated from the thermal images.

  19. 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.

  20. 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

  1. 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)

  2. Inhalation exposure to isocyanates of car body repair shop workers and industrial spray painters

    NARCIS (Netherlands)

    Pronk, A.; Tielemans, E.; Skarping, G.; Bobeldijk, I.; Hemmen, J. van; Heederik, D.; Preller, L.

    2006-01-01

    As part of a large-scale epidemiological study, occupational isocyanate exposure was assessed in spray-painting environments. The aim was to assess which compounds contribute to isocyanate exposure in car body repair shops and industrial painting companies, and to identify tasks with high risk of

  3. 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.

  4. Simulation of thermo-Elastics Properties of Thermal Barrier Coatings ...

    African Journals Online (AJOL)

    Thermal barrier coatings are used to protect different parts in compressors and turbines from heat. They are generally composed of two layers, one metallic layer providing resistance to heat corrosion and oxidation, and one thermally insulating ceramic layer. Two different techniques are industrially used. Plasma spray ...

  5. 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.

  6. 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.)

  7. 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

  8. 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.

  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.

  10. 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.)

  11. Center for the Polyurethanes Industry summary of unpublished industrial hygiene studies related to the evaluation of emissions of spray polyurethane foam insulation.

    Science.gov (United States)

    Wood, Richard D

    2017-09-01

    Spray polyurethane foam (SPF) insulation is used as thermal insulation for residential and commercial buildings. It has many advantages over other forms insulation; however, concerns have been raised related to chemical emissions during and after application. The American Chemistry Council's (ACC's) Center for the Polyurethanes Industry (CPI) has gathered previously unpublished industrial hygiene air sampling studies submitted by member companies that were completed during an eight-year period from 2007-2014. These studies address emissions from medium density closed cell and low density open cell formulations. This article summarizes the results of personal and area air samples collected during application and post application of SPF to interior building surfaces in both laboratory and field environments. Chemicals of interest included: Volatile Organic Compounds (VOCs), methylene diphenyl diisocyanate (MDI), flame retardants, amine catalysts, blowing agents, and aldehydes. Overall, the results indicate that SPF applicators and workers in close proximity to the application are potentially exposed to MDI in excess of recommended and governmental occupational exposure limits and should use personal protective equipment (PPE) consisting of air supplied respirators and full-body protective clothing to reduce exposure. Catalyst emissions can be reduced by using reactive catalysts in SPF formulations, and mechanical ventilation is important in controlling emissions during and after application.

  12. 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.

  13. 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

  14. 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.

  15. 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

  16. 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.)

  17. 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

  18. 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.)

  19. 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.

  20. 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.

  1. Glass and glass–ceramic coatings, versatile materials for industrial ...

    Indian Academy of Sciences (India)

    Unknown

    such as abrasion, impact etc as compared to other coating materials applied by thermal spraying in its different forms viz. ... in some systematic way information on glass and glass– ... the industries by proper maintenance of the machinery/.

  2. 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.

  3. 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.

  4. 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

  5. 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

  6. 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.

  7. 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

  8. 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.)

  9. 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...

  10. 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.

  11. Spectroscopic diagnostics of industrial plasmas

    International Nuclear Information System (INIS)

    Joshi, N.K.

    2004-01-01

    Plasmas play key role in modern industry and are being used for processing micro electronic circuits to the destruction of toxic waste. Characterization of industrial plasmas which includes both 'thermal plasmas' and non-equilibrium plasmas or 'cold plasmas' in industrial environment offers quite a challenge. Numerous diagnostic techniques have been developed for the measurement of these partially ionized plasma and/or particulate parameters. The 'simple' non-invasive spectroscopic methods for characterization of industrial plasmas will be discussed in detail in this paper. The excitation temperature in thermal (DC/RF) plasma jets has been determined using atomic Boltzmann technique. The central axis temperature of thermal plasma jets in a spray torch can be determined using modified atomic Boltzmann technique with out using Abel inversion. The Stark broadening of H β and Ar-I (430 nm) lines have been used to determine the electron number density in thermal plasma jets. In low-pressure non-equilibrium argon plasma, electron temperature has been measured using the Corona model from the ratio of line intensities of atomic and ionic transitions. (author)

  12. Vacuum-plasma-sprayed silicon coatings

    International Nuclear Information System (INIS)

    Varacalle, D.J. Jr.; Herman, H.; Bancke, G.A.; Burchell, T.D.; Romanoski, G.R.

    1991-01-01

    Vacuum plasma spraying produces well-bonded dense stress-free coatings for a variety of materials on a wide range of substrates. The process is used in many industries for the excellent wear, corrosion resistance and high temperature behavior of the fabricated coatings. In this study, silicon metal was deposited on graphite to study the feasibility of preventing corrosion and oxidation of graphite components for nuclear reactors. Operating parameters were varied in a Taguchi design of experiments to display the range of the plasma processing conditions and their effect on the measured coating characteristics. The coating attributes evaluated were thickness, porosity, microhardness and phase content. This paper discusses the influence of the processing parameters on as-sprayed coating qualities. The paper also discusses the effect of thermal cycling on silicon samples in an inert helium atmosphere. The diffraction spectrum for a sample that experienced a 1600degC temperature cycle indicated that more than 99% of the coating transformed to β-SiC. The silicon coatings protected the graphite substrates from oxidation in one experiment. (orig.)

  13. Proceedings of the 1992 DOE-industry thermal distribution conference

    Energy Technology Data Exchange (ETDEWEB)

    Andrews, J.W. (ed.)

    1992-06-01

    The subject of the conference was thermal distribution in small buildings. Thermal distribution systems are the ductwork, piping, or other means used to transport heat or cooling effect from the equipment in which the heat or cooling is produced to the building spaces in which it is used. The small buildings category is defined to include single-family residential and multifamily and commercial buildings with less than 10,000 ft{sup 2} floor area. The 1992 DOE-Industry Thermal Distribution Conference was conceived as the beginning of a process of information transfer between the DOE and the industries having a stake in thermal distribution systems, whereby the DOE can make the industry aware of its thinking and planned directions early enough for changes to be made, and whereby the industries represented can provide this input to the DOE on a timely and informed basis. In accordance with this, the objectives of the Conference were: To present--to a representative group of researchers and industry representative--the current industry thinking and DOE's current directions for research in small-building thermal distribution. To obtain from industry and the research community a critique of the DOE priorities and additional ideas concerning how DOE can best assist the industry in promoting energy conservation in thermal distribution systems.

  14. Proceedings of the 1992 DOE-industry thermal distribution conference

    Energy Technology Data Exchange (ETDEWEB)

    Andrews, J.W. [ed.

    1992-06-01

    The subject of the conference was thermal distribution in small buildings. Thermal distribution systems are the ductwork, piping, or other means used to transport heat or cooling effect from the equipment in which the heat or cooling is produced to the building spaces in which it is used. The small buildings category is defined to include single-family residential and multifamily and commercial buildings with less than 10,000 ft{sup 2} floor area. The 1992 DOE-Industry Thermal Distribution Conference was conceived as the beginning of a process of information transfer between the DOE and the industries having a stake in thermal distribution systems, whereby the DOE can make the industry aware of its thinking and planned directions early enough for changes to be made, and whereby the industries represented can provide this input to the DOE on a timely and informed basis. In accordance with this, the objectives of the Conference were: To present--to a representative group of researchers and industry representative--the current industry thinking and DOE`s current directions for research in small-building thermal distribution. To obtain from industry and the research community a critique of the DOE priorities and additional ideas concerning how DOE can best assist the industry in promoting energy conservation in thermal distribution systems.

  15. Plasma sprayed thermal barrier coatings for industrial gas turbines: morphology, processing and properties

    International Nuclear Information System (INIS)

    Gruenling, H.W.; Mannsmann, W.

    1993-01-01

    Thermal barrier coatings out of fully or partially stabilized zirconia offer a unique chance in gas turbines to increase the gas inlet temperature significantly while keeping the temperature of the structural material of the component within conventional limits. The protection of combustor parts and transition pieces as well as of some stationary gas turbine parts however is state of the art. As a consequence of still insufficient reliability, the application for hot rotating parts is very limited. The introduction as a design element requires safe life within defined time intervals. These depend on the overhaul and repair intervals of the engines. For large land based industrial or utility gas turbines, for example, coating life between 25.000 and 30.000 hrs. is a minimum requirement. Premature failure of a coating by e.g. local spalling causes local overheating of the component with the consequence of its total destruction or even more expensive secondary damages. Life limiting is the corrosion rate at the ceramic-metal interface and the behavior of the coated system under transient operating conditions, where multiaxial strain and stress distributions are generated. Sufficient strain tolerance of the coating both under tensile as well as compressive conditions is required. The properties of thermal barrier coating systems depend strongly on the structure and phase composition of the coating layers and the morphology of and the adhesion at the ceramic-metal interface. They have to be controlled by the process itself, the process parameters and the characteristics of the applied materials (e.g. chemical composition, processing, morphology, particle size and size distribution). It will be reviewed, how properties and structures of coating systems correlate and how structures can be modified by careful control of the process parameters. (orig.)

  16. 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%.

  17. 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.

  18. 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.

  19. 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.

  20. 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).

  1. 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)

  2. 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.)

  3. 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.

  4. Thermal energy consumption and carbon dioxide emissions in ceramic tile manufacture - Analysis of the Spanish and Brazilian industries

    International Nuclear Information System (INIS)

    Monfort, E.; Mezquita, A.; Vaquer, E.; Mallol, G.; Alves, H. J.; Boschi, A. O.

    2012-01-01

    Spain and Brazil are two of the world's biggest ceramic tile producers. The tile manufacturing process consumes a great quantity of thermal energy that, in these two countries, is mainly obtained from natural gas combustion, which entails CO 2 emission, a greenhouse gas. This study presents a comparative analysis of the thermal energy consumption and CO 2 emissions in the ceramic tile manufacturing process in Spain and Brazil, in terms of the different production technologies and different products made. The energy consumption and CO 2 emissions in ceramic tile manufacture by the wet process are very similar in both countries. In the dry process used in Brazil, less thermal energy is consumed and less CO 2 is emitted than in the wet process, but it is a process that is only used in manufacturing one particular type of product, which exhibits certain technical limitations. While in Spain the use of cogeneration systems in spray-dryers improves significantly the global energy efficiency. The average energy consumption in the different process stages, in both countries, lies within the range indicated in the Reference Document on Best Available Techniques in the Ceramic Manufacturing Industry (BREF of the Ceramic Manufacturing Industry) of the European Union. (Author) 14 refs.

  5. 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.

  6. 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.

  7. 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.)

  8. Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former

    Science.gov (United States)

    Medřický, Jan; Curry, Nicholas; Pala, Zdenek; Vilemova, Monika; Chraska, Tomas; Johansson, Jimmy; Markocsan, Nicolaie

    2015-04-01

    Yttria-stabilized zirconia thermal barrier coatings are extensively used in turbine industry; however, increasing performance requirements have begun to make conventional air plasma sprayed coatings insufficient for future needs. Since the thermal conductivity of bulk material cannot be lowered easily; the design of highly porous coatings may be the most efficient way to achieve coatings with low thermal conductivity. Thus the approach of fabrication of coatings with a high porosity level based on plasma spraying of ceramic particles of dysprosia-stabilized zirconia mixed with polymer particles, has been tested. Both polymer and ceramic particles melt in plasma and after impact onto a substrate they form a coating. When the coating is subjected to heat treatment, polymer burns out and a complex structure of pores and cracks is formed. In order to obtain desired porosity level and microstructural features in coatings; a design of experiments, based on changes in spray distance, powder feeding rate, and plasma-forming atmosphere, was performed. Acquired coatings were evaluated for thermal conductivity and thermo-cyclic fatigue, and their morphology was assessed using scanning electron microscopy. It was shown that porosity level can be controlled by appropriate changes in spraying parameters.

  9. 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

  10. 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

  11. 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.

  12. 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

  13. 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.

  14. 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.

  15. 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

  16. 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.

  17. 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.

  18. 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.

  19. 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)

  20. 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.

  1. 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.

  2. Thermal barrier coatings - Technology for diesel engines

    International Nuclear Information System (INIS)

    Harris, D.H.; Lutz, J.

    1988-01-01

    Thermal Barrier Coatings (TBC) are a development of the aerospace industry primarily aimed at hot gas flow paths in turbine engines. TBC consists of zirconia ceramic coatings applied over (M)CrAlY. These coatings can provide three benefits: (1) a reduction of metal surface operating temperatures, (2) a deterrent to hot gas corrosion, and (3) improved thermal efficiencies. TBC brings these same benefits to reciprocal diesel engines but coating longevity must be demonstrated. Diesels require thicker deposits and have challenging geometries for the arc-plasma spray (APS) deposition process. Different approaches to plasma spraying TBC are required for diesels, especially where peripheral edge effects play a major role. Bondcoats and ceramic top coats are modified to provide extended life as determined by burner rig tests, using ferrous and aluminum substrates

  3. 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.

  4. 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

  5. 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)

  6. 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

  7. 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

  8. Micro/nano structured coatings of light alloys by cold spray for surface protection and repair of high value-added components: State of the art

    International Nuclear Information System (INIS)

    Bedoya, J.; Cinca, N.; Guilemany, J. M.

    2013-01-01

    The Cold Gas Spray - CGS technique has greatly attracted the attention of the researchers in the last decade due to advantages compared to other conventional thermal spray processes. It presents outstanding characteristics such as high density coatings and absence of thermal degradation (oxidation or phase transformation). In addition, CGS is an efficient and green technology. This paper presents a bibliographic review related to micro/nano structured aluminium-based coatings of by CGS on light alloy substrates. It provides an overview of the feasibility of using the Cold Gas Spray as a technique for the protection, recovery and repair of high value-added components, especially those made of light alloys (aluminium and magnesium base) which, by their low density and mechanical properties, are widely used in several industrial sectors such as transport, aerospace and power generation. (Author)

  9. 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

  10. Influence of Solvent Composition on the Performance of Spray-Dried Co-Amorphous Formulations

    Directory of Open Access Journals (Sweden)

    Jaya Mishra

    2018-04-01

    Full Text Available Ball-milling is usually used to prepare co-amorphous drug–amino acid (AA mixtures. In this study, co-amorphous drug–AA mixtures were produced using spray-drying, a scalable industrially preferred preparation method. The influence of the solvent type and solvent composition was investigated. Mixtures of indomethacin (IND and each of the three AAs arginine, histidine, and lysine were ball-milled and spray-dried at a 1:1 molar ratio, respectively. Spray-drying was performed at different solvent ratios in (a ethanol and water mixtures and (b acetone and water mixtures. Different ratios of these solvents were chosen to study the effect of solvent mixtures on co-amorphous formulation. Residual crystallinity, thermal properties, salt/partial salt formation, and powder dissolution profiles of the IND–AA mixtures were investigated and compared to pure crystalline and amorphous IND. It was found that using spray-drying as a preparation method, all IND–AA mixtures could be successfully converted into the respective co-amorphous forms, irrespective of the type of solvent used, but depending on the solvent mixture ratios. Both ball-milled and spray-dried co-amorphous samples showed an enhanced dissolution rate and maintained supersaturation compared to the crystalline and amorphous IND itself. The spray-dried samples resulting in co-amorphous samples were stable for at least seven months of storage.

  11. Thermal plasma spraying for SOFCs: Applications, potential advantages, and challenges

    Energy Technology Data Exchange (ETDEWEB)

    Hui, Rob; Wang, Zhenwei; Jankovic, Jasna; Yick, Sing; Maric, Radenka; Ghosh, Dave [National Research Council Institute for Fuel Cell Innovation, 4250 Wesbrook Mall, Vancouver, BC V6T 1W5 (Canada); Kesler, Olivera [National Research Council Institute for Fuel Cell Innovation, 4250 Wesbrook Mall, Vancouver, BC V6T 1W5 (Canada); Department of Mechanical Engineering, University of British Columbia, 2054-6250 Applied Science Lane, Vancouver, BC V6T 1Z4 (Canada); Rose, Lars [National Research Council Institute for Fuel Cell Innovation, 4250 Wesbrook Mall, Vancouver, BC V6T 1W5 (Canada); Department of Materials Engineering, University of British Columbia, 309-6350 Stores Road, Vancouver, BC V6T 1Z4 (Canada)

    2007-07-10

    In this article, the applications, potential advantages, and challenges of thermal plasma spray (PS) processing for nanopowder production and cell fabrication of solid oxide fuel cells (SOFCs) are reviewed. PS processing creates sufficiently high temperatures to melt all materials fed into the plasma. The heated material can either be quenched into oxide powders or deposited as coatings. This technique has been applied to directly deposit functional layers as well as nanopowder for SOFCs application. In particularly, low melting point and highly active electrodes can be directly fabricated on zirconia-based electrolytes. This is a simple processing technique that does not require the use of organic solvents, offering the opportunity for flexible adjustment of process parameters, and significant time saving in production of the cell and cost reduction compared with tape casting, screen printing and sintering processing steps. Most importantly, PS processing shows strong potential to enable the deposition of metal-supported SOFCs through the integrated fabrication of membrane-electrode assemblies (MEA) on porous metallic substrates with consecutive deposition steps. On the other hand, the application of PS processing to produce SOFCs faces some challenges, such as insufficient porosity of the electrodes, the difficulty of obtaining a thin (<10 {mu}m) and dense electrolyte layer. Fed with H{sub 2} as the fuel gas and oxygen as the oxidant gas, the plasma sprayed cell reached high power densities of 770 mW cm{sup -2} at 900 C and 430 mW cm{sup -2} at 800 C at a cell voltage of 0.7 V. (author)

  12. 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)

  13. 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...

  14. 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.

  15. Agricultural utilization of industrial thermal effluents

    International Nuclear Information System (INIS)

    Guillermin, P.; Delmas, J.; Grauby, A.

    1976-01-01

    An assessment is made of the utilization of thermal effluent for agricultural purpose (viz. early vegetables, cereals, trees). Heated waters are being used in field experiments on soil heating, improvement of agricultural procedures and crop yields. Thermal pollution cannot be removed yet it is reduced to acceptable limits. New prospects are open to traditional agriculture, leading towards a more competitive industrial model [fr

  16. 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.

  17. 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...

  18. 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.

  19. 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)

  20. 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...

  1. 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.

  2. 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

  3. 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.

  4. Particle size distribution of aerosols sprayed from household hand-pump sprays containing fluorine-based and silicone-based compounds.

    Science.gov (United States)

    Kawakami, Tsuyoshi; Isama, Kazuo; Ikarashi, Yoshiaki

    2015-01-01

    Japan has published safety guideline on waterproof aerosol sprays. Furthermore, the Aerosol Industry Association of Japan has adopted voluntary regulations on waterproof aerosol sprays. Aerosol particles of diameter less than 10 µm are considered as "fine particles". In order to avoid acute lung injury, this size fraction should account for less than 0.6% of the sprayed aerosol particles. In contrast, the particle size distribution of aerosols released by hand-pump sprays containing fluorine-based or silicone-based compounds have not been investigated in Japan. Thus, the present study investigated the aerosol particle size distribution of 16 household hand-pump sprays. In 4 samples, the ratio of fine particles in aerosols exceeded 0.6%. This study confirmed that several hand-pump sprays available in the Japanese market can spray fine particles. Since the hand-pump sprays use water as a solvent and their ingredients may be more hydrophilic than those of aerosol sprays, the concepts related to the safety of aerosol-sprays do not apply to the hand pump sprays. Therefore, it may be required for the hand-pump spray to develop a suitable method for evaluating the toxicity and to establish the safety guideline.

  5. 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)

  6. Spray Forming Aluminum - Final Report (Phase II)

    Energy Technology Data Exchange (ETDEWEB)

    D. D. Leon

    1999-07-08

    The U.S. Department of Energy - Office of Industrial Technology (DOE) has an objective to increase energy efficient and enhance competitiveness of American metals industries. To support this objective, ALCOA Inc. entered into a cooperative program to develop spray forming technology for aluminum. This Phase II of the DOE Spray Forming Program would translate bench scale spray forming technology into a cost effective world class process for commercialization. Developments under DOE Cooperative Agreement No. DE-FC07-94ID13238 occurred during two time periods due to budgetary constraints; April 1994 through September 1996 and October 1997 and December 1998. During these periods, ALCOA Inc developed a linear spray forming nozzle and specific support processes capable of scale-up for commercial production of aluminum sheet alloy products. Emphasis was given to alloys 3003 and 6111, both being commercially significant alloys used in the automotive industry. The report reviews research performed in the following areas: Nozzel Development, Fabrication, Deposition, Metal Characterization, Computer Simulation and Economics. With the formation of a Holding Company, all intellectual property developed in Phases I and II of the Project have been documented under separate cover for licensing to domestic producers.

  7. 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.

  8. 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.

  9. 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.

  10. 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

  11. 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.

  12. 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

  13. 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.

  14. 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.

  15. 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.

  16. Sprayed concrete linings

    Energy Technology Data Exchange (ETDEWEB)

    Hindle, D.

    1999-12-01

    Sprayed concrete, or shotcrete, was invented in the 1920s for preserving dinosaur skeletons and was used underground initially in coalmines for the preservation and fine proofing of timber supports. Its use as a support lining in rock tunnelling was developed in the 1950s and 60s. The article surveys equipment available from major manufacturers and suppliers of concrete spraying equipment (Aliva, Cifa, GIA, Industri, Ingersoll Rand, etc.), specialist cement and additive manufacturers (Castle, Cement, Moria Carbotech). manufacturers of lattice girders and fibre reinforcement, and manufacturers of instrumentation for tunnel linings. 5 tabs., 9 photos.

  17. On-line control of the plasma spraying process by monitoring the temperature, velocity, and trajectory of in-flight particles

    International Nuclear Information System (INIS)

    Moreau, C.; Gougeon, P.; Lamontagne, M.; Lacasse, V.; Vaudreuil, G.; Cielo, P.

    1994-01-01

    This paper describes a new optical sensing device for on-line monitoring of the temperature, velocity and trajectory of in-flight particles during industrial coating production. Thermal radiation emitted by the in-flight particles is collected by a small and robust sensing head that can be attached to the plasma gun providing continuous monitoring of the spray process. The collected radiation is transmitted through optical fibers to a detection cabinet located away from the dusty environment around the operating plasma gun. On-line measurement of the particle velocity, temperature and trajectory can provide an efficient diagnostic tool to maintain optimum spraying conditions leading to a better reproducibility of the coating properties

  18. 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.

  19. 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.

  20. 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

  1. 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.

  2. 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.

  3. 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

  4. 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)

  5. 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

  6. 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.

  7. 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

  8. 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

  9. 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.

  10. 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)

  11. 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

  12. Development of Ceramic Coating on Metal Substrate using Industrial Waste and Ore Minerals

    Science.gov (United States)

    Bhuyan, S. K.; Thiyagarajan, T. K.; Mishra, S. C.

    2017-02-01

    The technological advancement in modern era has a boon for enlightening human life; but also is a bane to produce a huge amount of (industrial) wastes, which is of great concern for utilization and not to create environmental threats viz. polution etc. In the present piece of research work, attempts have been made to utilize fly ash (wastes of thermal power plants) and along with alumina bearing ore i.e. bauxite, for developing plasma spray ceramic coatings on metals. Fly ash and with 10 and 20% bauxite addition is used to deposit plasma spray coatings on a metal substrate. The surface morphology of the coatings deposited at different power levels of plasma spraying investigated through SEM and EDS analysis. The coating thickness is measured. The porosity levels of the coatings are evaluated. The coating hardness isalso measured. This piece of research work will be beneficial for future development and use of industrial waste and ore minerals for high-valued applications.

  13. 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)

  14. 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.

  15. 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

  16. 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

  17. 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)

  18. 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.

  19. 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.

  20. New atomization nozzle for spray drying

    NARCIS (Netherlands)

    Deventer, H.C. van; Houben, R.J.; Koldeweij, R.B.J.

    2013-01-01

    A new atomization nozzle based on ink jet technology is introduced for spray drying. Application areas are the food and dairy industry, in the first instance, because in these industries the quality demands on the final powders are high with respect to heat load, powder shape, and size distribution.

  1. 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.

  2. 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.)

  3. 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

  4. Dermal, inhalation, and internal exposure to 1,6-HDI and its oligomers in car body repair shop workers and industrial spray painters

    NARCIS (Netherlands)

    Pronk, A.; Yu, F.; Vlaanderen, J.; Tielemans, E.; Preller, L.; Bobeldijk, I.; Deddens, J.A.; Latza, U.; Baur, X.; Heederik, D.

    2006-01-01

    Objectives: To study inhalation and dermal exposure to hexamethylene diisocyanate (HDI) and its oligomers as well as personal protection equipment (PPE) use during task performance in conjunction with urinary hexamethylene diamine (HDA) in car body repair shop workers and industrial spray painters.

  5. Technical characteristics of rigid sprayed PUR and PIR foams used in construction industry

    Science.gov (United States)

    Gravit, Marina; Kuleshin, Aleksey; Khametgalieva, Elina; Karakozova, Irina

    2017-10-01

    The article describes the distinctive properties of rigid polyurethane foam and polyisocyanurate (PUR and PIR). A brief review of the research was carried out on their modification with an objective to improve the thermal insulation properties and reducing the combustibility. A comparative analysis of the technical characteristics of rigid PUR and PIR foams of various manufacturers is presented. The problems of the state of the market for the production of polyurethane foam and polyisocyanurate in Russia have been marked. It is established that the further development of the fabrication technology of heat-insulating sprayed rigid PUR and PIR foams requires uniformity of technical characteristics of original components and finished products. Moreover, it requires the creation of unified information base for raw materials and auxiliary materials used in the production of PUR and PIR foam.

  6. 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

  7. 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.

  8. 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

  9. 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.

  10. 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)

  11. Dermal, inhalation, and internal exposure to 1,6-HDI and its oligomers in car body repair shop workers and industrial spray painters.

    Science.gov (United States)

    Pronk, A; Yu, F; Vlaanderen, J; Tielemans, E; Preller, L; Bobeldijk, I; Deddens, J A; Latza, U; Baur, X; Heederik, D

    2006-09-01

    To study inhalation and dermal exposure to hexamethylene diisocyanate (HDI) and its oligomers as well as personal protection equipment (PPE) use during task performance in conjunction with urinary hexamethylene diamine (HDA) in car body repair shop workers and industrial spray painters. Personal task based inhalation samples (n = 95) were collected from six car body repair shops and five industrial painting companies using impingers with di-n-butylamine (DBA) in toluene. In parallel, dermal exposure was assessed using nitril rubber gloves. Gloves were submerged into DBA in toluene after sampling. Analysis for HDI and its oligomers was performed by LC-MS/MS. Urine samples were collected from 55 workers (n = 291) and analysed for HDA by GC-MS. Inhalation exposure was strongly associated with tasks during which aerosolisation occurs. Dermal exposure occurred during tasks that involve direct handling of paint. In car body repair shops associations were found between detectable dermal exposure and glove use (odds ratio (OR) 0.22, 95% confidence interval (CI) 0.09 to 0.57) and inhalation exposure level (OR 1.34, 95% CI 0.97 to 1.84 for a 10-fold increase). HDA in urine could be demonstrated in 36% and 10% of car body repair shop workers and industrial painting company workers respectively. In car body repair shops, the frequency of detectable HDA was significantly elevated at the end of the working day (OR 2.13, 95% CI 1.07 to 4.22 for 3-6 pm v 0-8 am). In both branches HDA was detected in urine of approximately 25% of the spray painters. In addition HDA was detected in urine of a large proportion of non-spray painters in car body repair shops. Although (spray) painting with lacquers containing isocyanate hardeners results in the highest external exposures to HDI and oligomers, workers that do not perform paint related tasks may also receive a considerable internal dose.

  12. Metallic coating deposited by Cold Gas Spray onto Light alhoys

    OpenAIRE

    Villa Vidaller, Maria

    2013-01-01

    This thesis focuses on the use of Cold Gas Spray technology (CGS) to spray different nature powders onto light alloys with the aim of increasing their wear resistance. The growing industrial interest for costs reduction (fuel consumption, machinery lifetime, or personal security) has emphasized the necessity to investigate the potential applications that light alloys can offer. Weight reduction is a reason why light metals and its alloys have been associated with strong industries a...

  13. Rotating thermal flows in natural and industrial processes

    CERN Document Server

    Lappa, Marcello

    2012-01-01

    Rotating Thermal Flows in Natural and Industrial Processes provides the reader with a systematic description of the different types of thermal convection and flow instabilities in rotating systems, as present in materials, crystal growth, thermal engineering, meteorology, oceanography, geophysics and astrophysics. It expressly shows how the isomorphism between small and large scale phenomena becomes beneficial to the definition and ensuing development of an integrated comprehensive framework.  This allows the reader to understand and assimilate the underlying, quintessential mechanisms withou

  14. 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.

  15. Fine Sprays for Disinfection within Healthcare

    OpenAIRE

    G Nasr; A Whitehead; A Yule

    2016-01-01

    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 coatin...

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. Effect of Bauxite addition on Adhesion Strength and Surface Roughness of Fly ash based Plasma Sprayed Coatings

    Science.gov (United States)

    Bhuyan, S. K.; Samal, S.; Pattnaik, D.; Sahu, A.; Swain, B.; Thiyagarajan, T. K.; Mishra, S. C.

    2018-03-01

    The environment is being contaminated with advancement of new technology, day by day. One of the primary sources for this contamination is the industrial waste. Industrialization is the prime reason behind the prosperity of any country to meet the materialistic demand. To run the industries, a huge amount of (electric) power is needed and hence need for thermal power plants to serve the purpose. In present scenario, coal fired thermal power plants are set up which generates a huge quantity of Fly ash. Consumption of industrial waste (Fly ash), continually a major concern for human race. In recent years, fly ash is being utilized for various purposes i.e. making bricks, mine reclamation, production of cements etc. The presence of Silica and Alumina in fly ash makes it useful for thermal barrier applications also. The plasma spray technology has the advantage of being able to process any types of metal/ceramic mineral, low-grade-ore minerals etc. to make value-added products and also to deposit ceramics, metals and a combination of these to deposit composite coatings with desired microstructure and required properties on a range of substrate materials. The present work focuses on utilization of fly ash mixing with bauxite (ore mineral) for a high valued application. Fly ash with 10 and 20% bauxite addition is used to deposit plasma spray overlay coatings at different power levels (10-20kW) on aluminum and mild steel substrates. Adhesion strength and surface roughness of the coatings are evaluated. Phase composition analysis of the coatings were done using X-ray diffraction analysis. Surface morphology of the coatings was studied using a scanning electron microscope (SEM). Maximum adhesion strength of 4.924 MPa is obtained for the composition fly ash and bauxite (10%), coated on mild steel at 16kW torch power level. The surface roughness (Ra) of the coatings is found to vary between 10.0102 to 17.2341 micron.

  1. A Two-Continua Approach to Eulerian Simulation of Water Spray

    DEFF Research Database (Denmark)

    Nielsen, Michael Bang; Østerby, Ole

    2013-01-01

    Physics based simulation of the dynamics of water spray - water droplets dispersed in air - is a means to increase the visual plausibility of computer graphics modeled phenomena such as waterfalls, water jets and stormy seas. Spray phenomena are frequently encountered by the visual effects industry...

  2. 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

  3. 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.

  4. 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

  5. Dermal, inhalation, and internal exposure to 1,6‐HDI and its oligomers in car body repair shop workers and industrial spray painters

    Science.gov (United States)

    Pronk, A; Yu, F; Vlaanderen, J; Tielemans, E; Preller, L; Bobeldijk, I; Deddens, J A; Latza, U; Baur, X; Heederik, D

    2006-01-01

    Objectives To study inhalation and dermal exposure to hexamethylene diisocyanate (HDI) and its oligomers as well as personal protection equipment (PPE) use during task performance in conjunction with urinary hexamethylene diamine (HDA) in car body repair shop workers and industrial spray painters. Methods Personal task based inhalation samples (n = 95) were collected from six car body repair shops and five industrial painting companies using impingers with di‐n‐butylamine (DBA) in toluene. In parallel, dermal exposure was assessed using nitril rubber gloves. Gloves were submerged into DBA in toluene after sampling. Analysis for HDI and its oligomers was performed by LC‐MS/MS. Urine samples were collected from 55 workers (n = 291) and analysed for HDA by GC‐MS. Results Inhalation exposure was strongly associated with tasks during which aerosolisation occurs. Dermal exposure occurred during tasks that involve direct handling of paint. In car body repair shops associations were found between detectable dermal exposure and glove use (odds ratio (OR) 0.22, 95% confidence interval (CI) 0.09 to 0.57) and inhalation exposure level (OR 1.34, 95% CI 0.97 to 1.84 for a 10‐fold increase). HDA in urine could be demonstrated in 36% and 10% of car body repair shop workers and industrial painting company workers respectively. In car body repair shops, the frequency of detectable HDA was significantly elevated at the end of the working day (OR 2.13, 95% CI 1.07 to 4.22 for 3–6 pm v 0–8 am). In both branches HDA was detected in urine of ∼25% of the spray painters. In addition HDA was detected in urine of a large proportion of non‐spray painters in car body repair shops. Conclusion Although (spray) painting with lacquers containing isocyanate hardeners results in the highest external exposures to HDI and oligomers, workers that do not perform paint related tasks may also receive a considerable internal dose. PMID:16728504

  6. 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

  7. 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.

  8. Ecological safety of thermal power industry and investments

    International Nuclear Information System (INIS)

    Glebov, V.P.

    1995-01-01

    Evaluation of ecological safety of domestic fossil fuel thermal power industry is given in comparison with foreign one. Ways of solving ecological problems are considered. They are based on introduction of new technologies, providing decrease of ecological effect, on development of effective ash-and sulfur-trapping, nitrogen purification equipment, on production of ecologically improved fuel. The necessity of investments to power industry is noted

  9. 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

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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)

  15. 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

  16. 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.

  17. 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 ...

  18. 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

  19. 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.

  20. 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.

  1. Enhancement of low pressure cold sprayed copper coating adhesion by laser texturing on aluminum substrates

    Science.gov (United States)

    Knapp, Wolfgang; Gillet, Vincent; Courant, Bruno; Aubignat, Emilie; Costil, Sophie; Langlade, Cécile

    2017-02-01

    Surface pre-treatment is fundamental in thermal spraying processes to obtain a sufficient bonding strength between substrate and coating. Different pre-treatments can be used, mostly grit-blasting for current industrial applications. This study is focused on Cu-Al2O3 coatings obtained by Low Pressure Cold Spray on AW5083 aluminum alloy substrate. Bonding strength is measured by tensile adhesion test, while deposition efficiency is measured. Substrates are textured by laser, using a pattern of equally spaced grooves with almost constant diameter and variations of depth. Results show that bonding strength is improved up to +81% compared to non-treated substrate, while deposition efficiency remains constant. The study of the samples after rupture reveals a modification of the failure mode, from mixed failure to cohesive failure. A modification of crack propagation is also noticed, the shape of laser textured grooves induces a deviation of cracks inside the coating instead of following the interface between the layers.

  2. Microencapsulation of Garcinia fruit extract by spray drying and its effect on bread quality.

    Science.gov (United States)

    Ezhilarasi, Perumal Natarajan; Indrani, Dasappa; Jena, Bhabani Sankar; Anandharamakrishnan, Chinnaswamy

    2014-04-01

    (-)-Hydroxycitric acid (HCA) is the major acid present in the fruit rinds of certain species of Garcinia. HCA has been reported to have several health benefits. As HCA is highly hygroscopic in nature and thermally sensitive, it is difficult to incorporate in foodstuffs. Hence, Garcinia cowa fruit extract was microencapsulated using three different wall materials such as whey protein isolate (WPI), maltodextrin (MD) and a combination of whey protein isolate and maltodextrin (WPI + MD) by spray drying. Further, these microencapsulated powders were evaluated for their impact on bread quality and HCA retention. Maltodextrin (MD) encapsulates had higher free (86%) and net HCA (90%) recovery. Microencapsulates incorporated breads had enhanced qualitative characteristics and higher HCA content than water extract incorporated bread due to efficient encapsulation during bread baking. Comparatively, bread with MD encapsulates showed softer crumb texture, desirable sensory attributes with considerable volume and higher HCA content. The higher HCA contents of encapsulate incorporated breads were sufficient to claim for functionality of HCA in bread. Comparatively, MD had efficiently encapsulated Garcinia fruit extract during spray drying and bread baking. Spray drying proved to be an excellent encapsulation technique for incorporation into the food system. © 2013 Society of Chemical Industry.

  3. 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.

  4. Electrostatic spraying in the chemical control of Triozoida limbata (Enderlein) (Hemiptera: Triozidae) in guava trees (Psidium guajava L.).

    Science.gov (United States)

    Tavares, Rafael M; Cunha, João Par; Alves, Thales C; Bueno, Mariana R; Silva, Sérgio M; Zandonadi, César Hs

    2017-06-01

    Owing to the difficulty in reaching targets during pesticide applications on guava trees, it is important to evaluate new technologies that may improve pest management. In electrostatic spraying, an electric force is added to the droplets to control their movements such that they are efficiently directed to the target. The present study evaluated the performance of electrostatic and non-electrostatic spraying in the control of the guava psyllid, the deposition of the spray mixture on the leaves and the losses to the soil. The deposition of the spray mixture was up to 2 times greater when using electrostatic spraying in comparison with non-electrostatic application. The losses of the spray mixture to the soil were up to 4 times smaller with the electrostatic spraying. Electrostatic spraying had better control of the psyllid. It was possible to reduce the volume rate of application with electrostatic spraying without adversely affecting the control of the guava psyllid. © 2016 Society of Chemical Industry. © 2016 Society of Chemical Industry.

  5. Optimization of Robotic Spray Painting process Parameters using Taguchi Method

    Science.gov (United States)

    Chidhambara, K. V.; Latha Shankar, B.; Vijaykumar

    2018-02-01

    Automated spray painting process is gaining interest in industry and research recently due to extensive application of spray painting in automobile industries. Automating spray painting process has advantages of improved quality, productivity, reduced labor, clean environment and particularly cost effectiveness. This study investigates the performance characteristics of an industrial robot Fanuc 250ib for an automated painting process using statistical tool Taguchi’s Design of Experiment technique. The experiment is designed using Taguchi’s L25 orthogonal array by considering three factors and five levels for each factor. The objective of this work is to explore the major control parameters and to optimize the same for the improved quality of the paint coating measured in terms of Dry Film thickness(DFT), which also results in reduced rejection. Further Analysis of Variance (ANOVA) is performed to know the influence of individual factors on DFT. It is observed that shaping air and paint flow are the most influencing parameters. Multiple regression model is formulated for estimating predicted values of DFT. Confirmation test is then conducted and comparison results show that error is within acceptable level.

  6. Remotely sensed thermal pollution and its relationship with energy consumption and industry in a rapidly urbanizing Chinese city

    International Nuclear Information System (INIS)

    Zhao, Xiaofeng; Jiang, Hui; Wang, Huina; Zhao, Juanjuan; Qiu, Quanyi; Tapper, Nigel; Hua, Lizhong

    2013-01-01

    Taking the city of Xiamen, China, as an example, we used thermal infrared remote sensing to detect thermal pollution, and examined its relationship to energy consumption and the industrial economy. Monthly changes in 2002 and dynamics throughout the period of rapid urbanization (1987–2007) are analysed. It is found that seasonal variation led to distinct shapes and sizes of thermal pollution areas, and winter thermal pollution was highly indicative of industrial and energy transformation sources. Industrial enterprises were the dominant sources of winter thermal pollution in Xiamen. The number and ratio of industrial thermal pollution sources increased stably in the earlier years, and dramatically in the later period (2002–2007), attributable to the effects of China entering the World Trade Organization. Linear regression shows that the number of thermal pollution sources was strongly correlated with several factors of the industrial economy and energy consumption, including industrial outputs, industrial enterprise numbers, LPG and electricity. Related mitigation measures are also discussed. This research builds a link between remote sensing-detected thermal pollution information and statistical energy consumption data, as well as industrial economy statistics. It thereby enhances understanding of the relationship between urbanization, industrialization, energy consumption and related environmental effects. - Highlights: ► A method was provided for detecting thermal pollution through remote sensing. ► Seasonal dynamics and dynamics with the process of urbanization were examined. ► Winter thermal pollution is quite indicative of industrial energy consumption. ► Thermal pollution has high correlations with industrial economy and energy factors. ► It builds a link between remotely sensed thermal pollution and energy-economic data

  7. Fundamental Study on the Effect of Spray Parameters on Characteristics of P3HT:PCBM Active Layers Made by Spray Coating

    Directory of Open Access Journals (Sweden)

    Yu Xie

    2015-08-01

    Full Text Available This paper is an attempt to elucidate the effects of the important spray characteristics on the surface morphology and light absorbance of spray-on P3HT:PCBM thin-films, used as an active layer in polymer solar cells (PSCs. Spray coating or deposition is a viable scalable technique for the large-scale, fast, and low-cost fabrication of solution-processed solar cells, and has been widely used for device fabrication, although the fundamental understanding of the underlying and controlling parameters, such as spray characteristics, droplet dynamics, and surface wettability, is still limited, making the results on device fabrication not reproducible and unreliable. In this paper, following the conventional PSC architecture, a PEDOT:PSS layer is first spin-coated on glass substrates, followed by the deposition of P3HT:PCBM using an automatic ultrasonic spray coating system, with a movable nozzle tip, to mimic an industrial manufacturing process. To gain insight, the effects of the spray carrier air pressure, the number of spray passes, the precursor flow rate, and precursor concentration are studied on the surface topography and light absorbance spectra of the spray-on films. Among the results, it is found that despite the high roughness of spray-on films, the light absorbance of the film is satisfactory. It is also found that the absorbance of spray-on films is a linear function of the number of spray passes or deposition layers, based on which an effective film thickness is defined for rough spray-on films. The effective thickness of a rough spray-on P3HT:PCBM film was found to be one-quarter of that of a flat film predicted by a simple mass balance.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. Simulation of exhaust gas heat recovery from a spray dryer

    International Nuclear Information System (INIS)

    Golman, Boris; Julklang, Wittaya

    2014-01-01

    This study explored various alternatives in improving the energy utilization of spray drying process through the exhaust gas heat recovery. Extensible and user-friendly simulation code was written in Visual Basic for Applications within Microsoft Excel for this purpose. The effects of process parameters were analyzed on the energy efficiency and energy saving in the industrial-scale spray drying system with exhaust gas heat recovery in an air-to-air heat exchanger and in the system with partial recirculation of exhaust air. The spray dryer is equipped with an indirect heater for heating the drying air. The maximum gains of 16% in energy efficiency and 50% in energy saving were obtained for spray drying system equipped with heat exchanger for exhaust air heat recovery. In addition, 34% in energy efficiency and 61% in energy saving for system with recirculation of exhaust air in the present range of process parameters. The high energy efficiency was obtained during drying of large amount of dilute slurry. The energy saving was increased using the large amount of hot drying air. - Highlights: • We model industrial-scale spray drying process with the exhaust gas heat recovery. • We develop an Excel VBA computer program to simulate spray dryer with heat recovery. • We examine effects of process parameters on energy efficiency and energy saving. • High energy efficiency is obtained during drying of large amount of dilute slurry. • Energy saving is increased using the large amount of hot drying air

  13. 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.)

  14. Technological challenges in thermal plasma production

    International Nuclear Information System (INIS)

    Ramakrishnan, S.

    1995-01-01

    Thermal plasmas, generated by electric arc discharges, are used in a variety of industrial applications. The electric arc is a constricted electrical discharge with a high temperature in the range 6000-25,000 K. These characteristics are useful in plasma cutting, spraying, welding and specific areas of material processing. The thermal plasma technology is an enabling process technology and its status in the market depends upon its advantages over competing technologies. A few technological challenges to enhance the status of plasma technology are to improve the utilisation of the unique characteristics of the electric arc and to provide enhanced control of the process. In particular, new solutions are required for increasing the plasma-material interaction, controlling the electrode roots and controlling the thermal power generated by the arcing process. In this paper, the advantages of plasma technology, its constraints and future challenges for technology developments are highlighted. 36 refs., 14 figs

  15. 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.

  16. Behaviour of plasma spray coatings under disruption simulation

    International Nuclear Information System (INIS)

    Brossa, F.; Rigon, G.; Looman, B.

    1988-01-01

    The behaviour of metallic and ceramic protective coatings under disruption simulations was studied correlating the damage with their physical and structural parameters. Plasma Spray (PS) and Vacuum Plasma Spray (VPS) were the techniques used for the production of the coatings. W-5% Re was selected for divertor plates, and TiC, TiO 2 , Al 2 O 3 , low-Z ceramic materials for the first wall protection on 316 SS, Cu and Al as substrates. An electron beam gun was used to simulate the plasma disruptions. The tests were carried out from 0.6 to 6 MJ/m 2 . The thermal effects were studied by metallographic and EDXA analysis. The damage was observed comparing the degree of protection provided by each coating to discover the minimum thickness necessary to prevent the underlying material from melting. Good protective coatings must have a high melting point, great porosity and low thermal conductivity. Such coatings act as thermal barriers, increasing the surface temperature and radiating back large parts of the energy. (orig.)

  17. 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.

  18. Consolidation of tungsten disilicide by plasma spraying

    Czech Academy of Sciences Publication Activity Database

    Brožek, Vlastimil; Ctibor, Pavel; Matějíček, Jiří; Rohan, Pavel; Janča, J.

    2007-01-01

    Roč. 52, č. 3 (2007), s. 311-320 ISSN 0001-7043 R&D Projects: GA ČR(CZ) GA104/05/0540 Institutional research plan: CEZ:AV0Z20430508 Keywords : Water stabilized plasma * tungsten disilicide * plasma deposition * thermal spray coatings Subject RIV: JJ - Other Materials

  19. 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

  20. Industrial implementation of plasma deposition using the expanding thermal plasma technique

    NARCIS (Netherlands)

    Sanden, van de M.C.M.; Oever, van den P.J.; Creatore, M.; Schaepkens, M.; Miebach, T.; Iacovangelo, C.D.; Bosch, R.C.M.; Bijker, M.D.; Evers, M.F.J.; Schram, D.C.; Kessels, W.M.M.

    2004-01-01

    Two successful industrial implementations of the expanding thermal plasma setup, a novel plasma source, obtaining high deposition rate are discussed. The Ar/O2/hexamethyldisiloxane and Ar/O2/octamethyl-cyclosiloxane-fed expanding thermal plasma setup is used to deposit scratch resistant silicone

  1. Water spray interaction with air-steam mixtures under containment spray conditions: experimental study in the TOSQAN facility

    Energy Technology Data Exchange (ETDEWEB)

    Porcheron, E.; Lemaitre, P.; Malet, J.; Nuboer, A.; Brun, P.; Bouilloux, L.; Vendel, J. [Institut de Radioprotection et de Surete Nucleaire (IRSN), Direction de la Surete des Usines, des laboratoires, des transports et des dechets, Saclay, BP 68 - 91192 Gif-sur-Yvette cedex (France)

    2005-07-01

    Full text of publication follows: During the course of an hypothetical severe accident in a Pressurized Water Reactor (PWR), hydrogen can be produced by the reactor core oxidation and distributed into the reactor containment according to convection flows and steam wall condensation. In order to assess the risk of detonation generated by a high local hydrogen concentration, hydrogen distribution in the containment has to be known. The TOSQAN experimental program has been created to simulate typical accidental thermal hydraulic flow conditions in the reactor containment. The present work is devoted to study the interaction of a water spray injection used as a mitigation mean in order to reduce containment pressure and to produce a mixing of air, steam and hydrogen induced by spray entrainment and condensation on droplet. In order to have a better understanding of physical phenomena, we need to make a detailed characterization of the spray and the gas. The TOSQAN facility that is highly instrumented with non-intrusive diagnostics consists in a closed cylindrical vessel (7 m{sup 3} volume, 4 m high, 1.5 m i.d.) into which steam is injected. Water droplets size is measured in the vessel by the Interferometric Laser Imaging for Droplet Sizing technique. Droplet velocity is obtained by Particle Image Velocimetry and Laser Doppler Velocimetry, and droplet temperature is measured by global rainbow refractometry. Gas concentration measurements are performed by Spontaneous Raman Scattering. The walls of the vessel are thermostatically controlled by heated oil circulation. Inner spray system that is located on the top of the enclosure on the vertical axis, is composed of a single nozzle producing a full cone water spray. Spray test scenario consists of water spray injection in TOSQAN that is first pressurized with a steam injection (steam injection is stopped before spray injection). Water spray falling into the sump is removed to avoid accumulation and evaporation

  2. 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.

  3. Heat removal tests for pressurized water reactor containment spray by largescale facility

    International Nuclear Information System (INIS)

    Motoki, Y.; Hashimoto, K.; Kitani, S.; Naritomi, M.; Nishio, G.; Tanaka, M.

    1983-01-01

    Heat removal tests for pressurized water reactor (PWR) containment spray were carried out to investigate effectiveness of the depressurization by Japan Atomic Energy Research Institute model containment (7-m diameter, 20 m high, and 708-m 3 volume) with PWR spray nozzles. The depressurization rate is influenced by the spray heat transfer efficiency and the containment wall surface heat transfer coefficient. The overall spray heat transfer efficiency was investigated with respect to spray flow rate, weight ratio of steam/air, and spray height. The spray droplet heat transfer efficiency was investigated whether the overlapping of spray patterns gives effect or not. The effect was not detectable in the range of large value of steam/air, however, it was better in the range of small value of it. The experimental results were compared with the calculated results by computer code CONTEMPT-LT/022. The overall spray heat transfer efficiency was almost 100% in the containment pressure, ranging from 2.5 to 0.9 kg/cm 2 X G, so that the code was useful on the prediction of the thermal hydraulic behavior of containment atmosphere in a PWR accident condition

  4. Assessment of industry views on international business prospects for solar thermal technology

    Energy Technology Data Exchange (ETDEWEB)

    Easterling, J.C.

    1984-09-01

    This report contains a review of solar thermal industry viewpoints on their prospects for developing international business. The report documents the industry's current involvement in foreign markets, view of foreign competition in overseas applications, and view of federal R and D and policy requirements to strengthen international business prospects. The report is based on discussions with equipment manufacturers and system integrators who have a product or service with potential international demand. Interviews with manufacturers and system integrators were conducted by using a standard format for interview questions. The use of a standard format for questions provided a basis for aggregating similar views expressed by US companies concerning overseas business prospects. A special effort was made to gather responses from the entire solar thermal industry, including manufacturers of line-focus, point-focus, and central receiver systems. General, technical, economic, institutional, and financial findings are provided in this summary. In addition, Pacific Northwest Laboratory (PNL) recommendations are provided (based upon advice from the Solar Thermal Review Panel) for activities to improve US solar thermal business prospects overseas.

  5. The potential estimation and factor analysis of China′s energy conservation on thermal power industry

    International Nuclear Information System (INIS)

    Lin, Boqiang; Yang, Lisha

    2013-01-01

    At present, researches about energy conservation are focused on prediction. But there are few researches focused on the estimation of effective input and energy conservation potential, and there has been even no research on energy conservation of thermal power industry of China. This paper will try to fill in such a blank. Panel data on Chinese thermal power industry over 2005–2010 are established, and we adopt the stochastic frontier analysis approach to estimate the energy saving potential of thermal power industry. The results are as follows: (1) the average efficiency of energy inputs in China′s thermal power industry over 2005–2010 was about 0.85, and cumulative energy saving potential equals to 551.04 (Mtce); (2) by improving the non-efficiency factors, the relatively backward inland cities could achieve higher energy saving in thermal power industry; (3) the energy input efficiency of Eastern China Grid is shown to be the highest; (4) in order to realize the energy-saving goal of thermal power industry, one important policy method the government should adopt is to conduct a market-oriented reform in power industry and break the state-owned monopoly to provide incentives for private and foreign direct investment in thermal power sector. -- Highlights: •We adopt SFA model to estimate the coal input efficiency of power sector in China. •We calculate the cumulative energy saving potential equals to 551.04 Mtce. •East China power grid has the highest energy input efficiency. •Some backward inland cities may be the main force for future energy conservation. •Encourage private and foreign direct investment in power sector might be effective

  6. Micro/nano structured coatings of light alloys by cold spray for surface protection and repair of high value-added components: State of the art; Recubrimientos micro/nanoestructurados de aleaciones ligeras mediante proyeccion fria para la proteccion y reparacion de componentes de elevado valor anadido: Estado del arte

    Energy Technology Data Exchange (ETDEWEB)

    Bedoya, J.; Cinca, N.; Guilemany, J. M.

    2013-09-01

    The Cold Gas Spray - CGS technique has greatly attracted the attention of the researchers in the last decade due to advantages compared to other conventional thermal spray processes. It presents outstanding characteristics such as high density coatings and absence of thermal degradation (oxidation or phase transformation). In addition, CGS is an efficient and green technology. This paper presents a bibliographic review related to micro/nano structured aluminium-based coatings of by CGS on light alloy substrates. It provides an overview of the feasibility of using the Cold Gas Spray as a technique for the protection, recovery and repair of high value-added components, especially those made of light alloys (aluminium and magnesium base) which, by their low density and mechanical properties, are widely used in several industrial sectors such as transport, aerospace and power generation. (Author)

  7. Development of corrosion and wear resistant coatings by an improved HVOF spraying process

    Energy Technology Data Exchange (ETDEWEB)

    Ishikawa, Y.; Kawakita, J.; Kuroda, S. [National Inst. for Materials Science, Tsukuba (Japan)

    2005-07-01

    We have developed an improved HVOF spray process called ''Gas-shrouded HVOF'' (GS-HVOF) over the past several years. By using an extension nozzle at the exit of a commercial HVOF spray gun, GS-HVOF is capable of controlling the oxidation of sprayed materials during flight as well as achieving higher velocity of sprayed particles. These features result in extremely dense and clean microstructure of the sprayed coatings. The process has been successfully applied to corrosion resistant alloys such as SUS316L, Hastelloy C, and alloy 625 as well as cermets such as WC-Cr{sub 3}C{sub 2}-Ni. The spray process, coatings microstructure and property evaluation will be discussed with potential industrial applications in the near future. (orig.)

  8. Structural and photocatalytic characteristics of TiO2 coatings produced by various thermal spray techniques

    Czech Academy of Sciences Publication Activity Database

    Ctibor, Pavel; Štengl, Václav; Pala, Zdeněk

    2013-01-01

    Roč. 2, č. 3 (2013), s. 218-226 ISSN 2226-4108 R&D Projects: GA ČR(CZ) GAP108/12/1872 Institutional support: RVO:61389021 ; RVO:61388980 Keywords : plasma spraying * high velocity oxy–fuel (HVOF) spraying * flame spraying * titanium dioxide (TiO2) * photocatalysis * band gap Subject RIV: BL - Plasma and Gas Discharge Physics; CA - Inorganic Chemistry (UACH-T) http://www.springerlink.com/openurl.asp?genre=article&id=doi:10.1007/s40145-013-0063-z

  9. Plasma Sprayed Coatings for RF Wave Absorption

    Czech Academy of Sciences Publication Activity Database

    Nanobashvili, S.; Matějíček, Jiří; Žáček, František; Stöckel, Jan; Chráska, Pavel; Brožek, Vlastimil

    307-311, - (2002), s. 1334-1338 ISSN 0022-3115 Grant - others: COST (XE) Euratom DV4/04(TWO) Institutional research plan: CEZ:AV0Z2043910 Keywords : boron carbide, thermal spray coatings, fusion materials, RF wave absorption Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.730, year: 2002

  10. Thermal stratifications. An industrial point of view

    International Nuclear Information System (INIS)

    Peniguel, C.

    1995-11-01

    In PWR's, mechanical damages (cracks) have been detected at the internal faces of steam generator feedwater piping when thermal stratification occurs. This paper reports some studies of flows under operating conditions leading to of a stable stratified flow. Two geometries corresponding to different mock-up studied at EDF and CEA have been investigated. Numerical simulations have been performed with the code ESTET. Good agreement is observed on the mean temperature but it seems that the present modelling of the temperature variance fails to reproduce correctly the fluctuating phenomena It appears that with a stably stratified flow, wall conduction should be taken into account. It lead us to create a new numerical tool (SYRTHES) to compute the thermal field inside the wall, and the thermal coupling between the fluid and the solid at the interface. Some industrial examples illustrating the use of such a numerical tool are briefly presented. (author). 12 refs., 13 figs

  11. 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

  12. 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.

  13. 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; Schutz durch Hochgeschwindigkeitsflammspritzschichten auf dickwandigen End- und Zwischenlagerbauteilen zur Reduktion von Reparaturen, Korrosion und Kosten 'SHARK'. Ein Ueberblick zum Abschluss des Projektes

    Energy Technology Data Exchange (ETDEWEB)

    Behrens, Sabine; Hassel, Thomas; Bach, Friedrich-Wilhelm [Unterwassertechnikum Hannover, Garbsen (Germany). Inst. fuer Werkstoffkunde; Steinwarz, Wolfgang; Dyllong, Nobert; Tragsdorf, Inga Maren [Siempelkamp Nukleartechnik GmbH, Krefeld (Germany)

    2012-04-15

    The corrosion protection of the internal space of thick-walled interim and permanent storage facility components, such as Castor {sup 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 {mu}m 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

  14. High temperature corrosion of thermally sprayed NiCr- and amorphous Fe-based coatings covered with a KCl-K{sub 2}SO{sub 4} salt

    Energy Technology Data Exchange (ETDEWEB)

    Varis, T.; Suhonen, T.; Tuurna, S.; Ruusuvuori, K.; Holmstroem, S.; Salonen, J. [VTT, Espoo (Finland); Bankiewicz, D.; Yrjas, P. [Aabo Akademi Univ., Turku (Finland)

    2010-07-01

    New process conditions due to the requirement of higher efficiency together with the use of high-chlorine and alkali containing fuels such as biomass and waste fuels for heat and electricity production will challenge the resistance and life of tube materials. In conventional materials the addition of alloying elements to increase the corrosion resistance in aggressive combustion conditions increases costs relatively rapidly. Thermally sprayed coating offer promising, effective, flexible and cost efficient solutions to fulfill the material needs for the future. Some heat exchanger design alteractions before global commercialization have to be overcome, though. High temperature corrosion in combustion plants can occur by a variety of mechanisms including passive scale degradation with subsequent rapid scaling, loss of adhesion and scale detachment, attack by melted or partly melted deposits via fluxing reactions and intergranular-/interlamellar corrosion. A generally accepted model of the ''active oxidation'' attributes the responsibility for inducing corrosion to chlorine. The active oxidation mechanism plays a key role in the thermally sprayed coatings due to their unique lamellar structure. In this study, the corrosion behaviour of NiCr (HVOF and Wire Arc), amorphous Fe-based, and Fe13Cr (Wire Arc) thermally sprayed coatings, were tested in the laboratory under simplified biomass combustion conditions. The tests were carried out by using a KCl-K{sub 2}SO{sub 4} salt mixture as a synthetic biomass ash, which was placed on the materials and then heat treated for one week (168h) at two different temperatures (550{sup 0}C and 600 C) and in two different gas atmospheres (air and air+30%H{sub 2}O). After the exposures, the metallographic cross sections of the coatings were studied with SEM/EDX analyzer. The results showed that the coatings behaved relatively well at the lower test temperature while critical corrosion through the lamella boundaries

  15. 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)

  16. From drop impact physics to spray cooling models: a critical review

    Science.gov (United States)

    Breitenbach, Jan; Roisman, Ilia V.; Tropea, Cameron

    2018-03-01

    Spray-wall interaction is an important process encountered in a large number of existing and emerging technologies and is the underlying phenomenon associated with spray cooling. Spray cooling is a very efficient technology, surpassing all other conventional cooling methods, especially those not involving phase change and not exploiting the latent heat of vaporization. However, the effectiveness of spray cooling is dependent on a large number of parameters, including spray characteristics like drop size, velocity and number density, the surface morphology, but also on the temperature range and thermal properties of the materials involved. Indeed, the temperature of the substrate can have significant influence on the hydrodynamics of drop and spray impact, an aspect which is seldom considered in model formulation. This process is extremely complex, thus most design rules to date are highly empirical in nature. On the other hand, significant theoretical progress has been made in recent years about the interaction of single drops with heated walls and improvements to the fundamentals of spray cooling can now be anticipated. The present review has the objective of summarizing some of these recent advances and to establish a framework for future development of more reliable and universal physics-based correlations to describe quantities involved in spray cooling.

  17. Preparing Al-Mg Substrate for Thermal Spraying: Evaluation of Surface State After Different Pretreatments

    Science.gov (United States)

    Lukauskaitė, R.; Valiulis, A. V.; Černašėjus, O.; Škamat, J.; Rębiś, J. A.

    2016-08-01

    The article deals with the pretreatment technique for preparing the surface of aluminum alloy EN AW 5754 before thermal spray. The surface after different pretreatments, including degreasing with acetone, chemical etching with acidic and alkali solutions, grit-blasting, cathodic cleaning, and some combinations of these techniques, has been studied. The investigation of pre-treated surfaces covered the topographical study (using scanning electron microscopy, atomic force microscopy, and 3D profilometry), the chemical analysis by x-ray photoelectron spectroscopy, the evaluation of surface wettability (sessile drop method), and the assessment of surface free energy. Compared with all the techniques used in present work, the cathodic cleaning and its combination with grit-blasting provide the most preferable chemistry of the surface. Due to the absence of hydroxides at the surface and, possible, due to the diffusion of magnesium to the surface of substrate, the surface wettability and the surface free energy have been significantly improved. No direct correlation between the surface topography and the surface wettability has been established.

  18. Workshop on technical assessment of industrial thermal insulation materials: summary

    International Nuclear Information System (INIS)

    Peterson, S.

    1976-07-01

    Over 80 participants representing 50 organizations met to discuss the report, Industrial Thermal Insulation--An Assessment, ORNL/TM-5283. Presentations on the performance of available materials, economic considerations, and measurement problems were followed by discussion. A final wrap-up session concluded that the report was valuable in pointing the direction for needed effort in the area, confirmed the indicated actions needed to further industrial application of insulation, and called for future meetings to continue the dialogue between the various facets of the industry

  19. Advanced high-temperature thermal energy storage media for industrial applications

    Science.gov (United States)

    Claar, T. D.; Waibel, R. T.

    1982-02-01

    An advanced thermal energy storage media concept based on use of carbonate salt/ceramic composite materials is being developed for industrial process and reject heat applications. The composite latent/sensible media concept and its potential advantages over state of the art latent heat systems is described. Media stability requirements, on-going materials development efforts, and planned thermal energy storage (TES) performance evaluation tests are discussed.

  20. SPRAY CASTING

    OpenAIRE

    SALAMCI, Elmas

    2010-01-01

    ABSTRACT This paper is designed to provide a basic review of spray casting. A brief overview of the historical development of spray  casting and the description of plant and equipment have been given. Following metallurgical characteristics of spray formed alloys, process parameters and solidification mechanism of spray deposition have been discussed in detail. Finally, microstructure and mechanical properties of the selected spray cast Al-Zn-Mg-Cu alloys have been presented and comp...

  1. 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

  2. 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.)

  3. Plasma sprayed alumina-titania coatings

    International Nuclear Information System (INIS)

    Steeper, T.J.; Rotolico, A.J.; Nerz, J.E.; Riggs, W.L. II; Varacalle, D.J. Jr.; Wilson, G.C.

    1992-01-01

    This paper presents an experimental study of the air plasma spraying (APS) of alumina-titania powder using argon-hydrogen working gases. This powder system is being used in the fabrication of heater tubes that emulate nuclear fuel tubes for use in thermal-hydraulic testing. Experiments were conducted using a Taguchi fractional-factorial design parametric study. Operating parameters were varied around the typical spray parameters in a systematic design of experiments in order to display the range of plasma processing conditions and their effect on the resultant coatings. The coatings were characterized by hardness and electrical tests, surface profilometry, image analysis, optical metallography, and x-ray diffraction. Coating qualities are discussed with respect to dielectric strength, hardness, porosity, surface roughness, deposition efficiency, and microstructure. attempts are made to correlate the features of the coatings with the changes in operating parameters

  4. A contribution to understanding the results of instrumented indentation on thermal spray coatings - Case study on Al2O3 and stainless steel

    Czech Academy of Sciences Publication Activity Database

    Nohava, J.; Mušálek, Radek; Matějíček, Jiří; Vilémová, Monika

    2014-01-01

    Roč. 240, February (2014), s. 243-249 ISSN 0257-8972 R&D Projects: GA ČR(CZ) GAP108/12/1872; GA ČR(CZ) GPP108/12/P552 Institutional support: RVO:61389021 Keywords : Thermal spray coating * Instrumented indentation * Al2O3 * Stainless steel * Scale effect Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.998, year: 2014 http://www.sciencedirect.com/science/article/pii/S0257897213011869#

  5. Thermal energy storage for industrial waste heat recovery

    Science.gov (United States)

    Hoffman, H. W.; Kedl, R. J.; Duscha, R. A.

    1978-01-01

    The potential is examined for waste heat recovery and reuse through thermal energy storage in five specific industrial categories: (1) primary aluminum, (2) cement, (3) food processing, (4) paper and pulp, and (5) iron and steel. Preliminary results from Phase 1 feasibility studies suggest energy savings through fossil fuel displacement approaching 0.1 quad/yr in the 1985 period. Early implementation of recovery technologies with minimal development appears likely in the food processing and paper and pulp industries; development of the other three categories, though equally desirable, will probably require a greater investment in time and dollars.

  6. Comparison between freeze and spray drying to obtain powder Rubrivivax gelatinosus biomass

    Directory of Open Access Journals (Sweden)

    Edson Francisco do Espírito Santo

    2013-03-01

    Full Text Available The use of colorants in products of animal origin is justified by the improvement in the color of foods since this attribute is considered a quality criterion. These additives can be produced using industrial effluents as substrates and appropriate organisms, such as Rubrivivax gelatinosus. Oxycarotenoids represent a class of carotenes responsible for the pigmentation of animals and vegetables. R. gelatinosus grows in fish industry effluent with the resulting production of a bacterial biomass containing oxycarotenoids. The purpose of this study was to compare the use of two drying processes - spray and freeze drying - to obtain powder biomass in terms of the process parameters (yield, productivity, and product recovery and the product characteristics (color, proximate composition, and oxycarotenoids. No difference was detected in the yield between these techniques, while productivity was higher using spray drying. Higher product recovery and moisture were achieved with freeze drying, while ash was higher with spray drying. The freeze dried biomass was redder, darker and less saturated than the spray dried biomass. No difference in oxycarotenoids was detected between the biomasses. Although it results in lower recovery rate, spray drying was faster and more productive, and it provided the same yield as freeze drying, which makes it the method of choice for obtaining R. gelatinosus biomass.

  7. 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)

  8. Terahertz thickness measurements for real industrial applications: from automotive paints to aerospace industry (Conference Presentation)

    Science.gov (United States)

    Krimi, Soufiene; Beigang, René

    2017-02-01

    In this contribution, we present a highly accurate approach for real-time thickness measurements of multilayered coatings using terahertz time domain spectroscopy in reflection geometry. The proposed approach combines the benefits of a model-based material parameters extraction method to calibrate the specimen under test, a generalized modeling method to simulate the terahertz radiation behavior within arbitrary thin films, and the robustness of a powerful evolutionary optimization algorithm to increase the sensitivity and the precision of the minimum thickness measurement limit. Furthermore, a novel self-calibration model is introduced, which takes into consideration the real industrial challenges such as the effect of wet-on-wet spray in the car painting process and the influence of the spraying conditions and the sintering process on ceramic thermal barrier coatings (TBCs) in aircraft industry. In addition, the developed approach enables for some applications the simultaneous determination of the complex refractive index and the coating thickness. Hence, a pre-calibration of the specimen under test is not required for such cases. Due to the high robustness of the self-calibration method and the genetic optimization algorithms, the approach has been successfully applied to resolve individual layer thicknesses within multi-layered coated samples down to less than 10 µm. The regression method can be applied in time-domain, frequency-domain or in both the time and frequency-domain simultaneously. The data evaluation uses general-purpose computing on graphics processing units and thanks to the developed highly parallelized algorithm lasts less than 300 ms. Thus, industrial requirements for fast thickness measurements with an "every-second-cycle" can be fulfilled.

  9. The Tribological Performance of Hardfaced/ Thermal Sprayed Coatings for Increasing the Wear Resistance of Ventilation Mill Working Parts

    Directory of Open Access Journals (Sweden)

    A. Vencl

    2015-09-01

    Full Text Available During the coal pulverizing, the working parts of the ventilation mill are being worn by the sand particles. For this reason, the working parts are usually protected with materials resistant to wear (hardfaced/thermal sprayed coatings. The aim of this study was to evaluate the tribological performance of four different types of coatings as candidates for wear protection of the mill’s working parts. The coatings were produced by using the filler materials with the following nominal chemical composition: NiFeBSi-WC, NiCrBSiC, FeCrCTiSi, and FeCrNiCSiBMn, and by using the plasma arc welding and flame and electric arc spraying processes. The results showed that Ni-based coatings exhibited higher wear resistance than Fe-based coatings. The highest wear resistance showed coating produced by using the NiFeBSi-WC filler material and plasma transferred arc welding deposition process. The hardness was not the only characteristic that affected the wear resistance. In this context, the wear rate of NiFeBSi-WC coating was not in correlation with its hardness, in contrast to other coatings. The different wear performance of NiFeBSi-WC coating was attributed to the different type and morphological features of the reinforcing particles (WC.

  10. Green production of cocrystals using a new solvent-free approach by spray congealing.

    Science.gov (United States)

    Duarte, Íris; Andrade, Rita; Pinto, João F; Temtem, Márcio

    2016-06-15

    Pharmaceutical cocrystals are used as a strategy to overcome poor physicochemical properties of drugs. The use of cocrystals in the pharmaceutical industry remains to be fully exploited due, in part, to the scarcity of suitable large-scale production methods and lack of robust and cost-effective processes. To overcome these challenges, spray congealing was used for the first time in the preparation of cocrystals. The work considered a feasibility study, followed by a design of experiments to assess the impact of varying atomization and cooling-related process parameters on cocrystal formation, purity, particle size, shape and bulk powder flow properties. It was demonstrated that spray congealing could be used to produce cocrystals. The thermal analysis and X-ray results of the spray-congealed products were different from the pure components or physical mixtures and were aligned with those reported for the same cocrystals systems produced by other techniques. Cocrystal particles were compact and spherical consisting of aggregates of individual cocrystals entangled or adhered with each other. From the design of experiments, the results demonstrated that varying the process parameters did not influence cocrystal formation, but had an impact on cocrystal purity. Moreover, it was demonstrated that cocrystal particle properties can be adjusted, in situ, by varying atomization and cooling efficiency, in order to produce particles more suited for incorporation in final dosage forms such as tablets. Copyright © 2016 Elsevier B.V. All rights reserved.

  11. Can Thermally Sprayed Aluminum (TSA) Mitigate Corrosion of Carbon Steel in Carbon Capture and Storage (CCS) Environments?

    Science.gov (United States)

    Paul, S.; Syrek-Gerstenkorn, B.

    2017-01-01

    Transport of CO2 for carbon capture and storage (CCS) uses low-cost carbon steel pipelines owing to their negligible corrosion rates in dry CO2. However, in the presence of liquid water, CO2 forms corrosive carbonic acid. In order to mitigate wet CO2 corrosion, use of expensive corrosion-resistant alloys is recommended; however, the increased cost makes such selection economically unfeasible; hence, new corrosion mitigation methods are sought. One such method is the use of thermally sprayed aluminum (TSA), which has been used to mitigate corrosion of carbon steel in seawater, but there are concerns regarding its suitability in CO2-containing solutions. A 30-day test was carried out during which carbon steel specimens arc-sprayed with aluminum were immersed in deionized water at ambient temperature bubbled with 0.1 MPa CO2. The acidity (pH) and potential were continuously monitored, and the amount of dissolved Al3+ ions was measured after completion of the test. Some dissolution of TSA occurred in the test solution leading to nominal loss in coating thickness. Potential measurements revealed that polarity reversal occurs during the initial stages of exposure which could lead to preferential dissolution of carbon steel in the case of coating damage. Thus, one needs to be careful while using TSA in CCS environments.

  12. Coherent gradient sensing method for measuring thermal stress field of thermal barrier coating structures

    Directory of Open Access Journals (Sweden)

    Kang Ma

    2017-01-01

    Full Text Available Coherent gradient sensing (CGS method can be used to measure the slope of a reflective surface, and has the merits of full-field, non-contact, and real-time measurement. In this study, the thermal stress field of thermal barrier coating (TBC structures is measured by CGS method. Two kinds of powders were sprayed onto Ni-based alloy using a plasma spraying method to obtain two groups of film–substrate specimens. The specimens were then heated with an oxy-acetylene flame. The resulting thermal mismatch between the film and substrate led to out-of-plane deformation of the specimen. The deformation was measured by the reflective CGS method and the thermal stress field of the structure was obtained through calibration with the help of finite element analysis. Both the experiment and numerical results showed that the thermal stress field of TBC structures can be successfully measured by CGS method.

  13. Properties of Agro-Industrial Aerated Concrete as Potential Thermal Insulation for Building

    Directory of Open Access Journals (Sweden)

    Aminudin Eeydzah

    2016-01-01

    Full Text Available The present paper is aiming to provide an actual state of the development of non autoclaved Agro-Industrial aerated concrete by using multiple ashes as improvement of thermal behavior for building. The feasibility of Agro-Industrial wastes as lightweight concrete by utilizing the Palm Oil Fuel Ash (POFA as binder replacement and bottom ash as fine aggregate was investigated in this paper. Portland cement, bottom ash, aluminum powder and lime (Ca(OH2 were used in this study. The POFA was used to replace Portland cement and Hydrated Lime at 0%, 5%, 10% and 15% by weight and aluminum powder was added at 0.75% dry weight in order to form bubbles. The compressive strength, water absorption, porosity and the thermal conductivity test were carried out after the concrete were water cured for 7 days and later being exposed to the air and water until 28days. The results show that the 20% replacements give the optimum strength of 7.143MPa and 30% give the best thermal conductivity with 0.48W/mK. Hence, this study aim, was to develop an agro-industrial aerated concrete good in insulation but having an optimum strength. Hence, it has been found that the more the percentage of POFA is added the lower the thermal conductivity since the pore structure is increasing and by the optimization done, 30% replacement has been chosen as the best mix design for Agro-Industrial Aerated Concrete.

  14. 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.

  15. A brief review on fly ash and its use in surface engineering

    Science.gov (United States)

    Bhajantri, Vishwanath; Krishna, Prasad; Jambagi, Sudhakar

    2018-04-01

    Fly ash is a by-product obtained from coal power plants. Over the past two decades, handling this industrial waste has been a great challenge for many developing countries. However, this menace can be used in many industrial applications viz., civil, automobile and aerospace applications. In civil industry, the fly ash has been used in concreate to enhance the porosity that increases the curing time of the concrete. The fly ash has been gaining importance these days as a feedstock material for many thermal spray processes. In automobile sector, the fly ash has been used as a thermal barrier coating in IC engines, whereas in aerospace industry, which demands lighter and stronger materials, the fly ash has been used as a reinforcement material. Hence, so far, fly ash has been used as an either single or a composite feed stock material in thermal spray processes. The fly ash with other materials like alumina, titania and red mud have been deposited using thermal spray processes. These coatings have exhibited higher wear, corrosion and erosion resistance as compared to the uncoated specimens. In this paper, a brief review on fly ash and its use, especially its use as a feed stock in thermal spray coating, is presented. Therefore, the use of fly ash has opened a new frontier of research in thermal spray coating area where economically viable coatings can be produced using industrial waste like fly ash.

  16. Production of press moulds by plasma spray forming process

    International Nuclear Information System (INIS)

    Borisov, Y.; Myakota, I.; Polyakov, S.

    2001-01-01

    Plasma spray forming process for production of press moulds which are used for manufacture of articles from plastics was developed. The press moulds were produced by plasma spraying of Cu-Al-Fe-alloy powder on surface of a master model. The master models were made from non-metallic materials with heat resistance below 70 C (wood, gypsum etc). Double cooling system which provides for a control of surface model temperature and quenching conditions of sprayed material was designed. It made possible on the one hand to support model surface temperature below 70 C and on the other hand to provide for temperature conditions of martensite transformation in Cu-Al-system with a fixation of metastable ductile α + β 1 -phase. This allowed to decrease residual stresses in sprayed layer (up to 0,5-2,5 MPa), to increase microhardness of the coating material (up to 1200-1800 MPa) and its ductility (σ B = 70-105 MPa, δ = 6-12 %). This plasma spray forming process makes possible to spray thick layers (5-20 mm and more) without their cracking and deformation. The process is used for a production of press moulds which are applied in shoes industry, for fabrication of toys, souvenirs etc. (author)

  17. The Influence of Anode Inner Contour on Atmospheric DC Plasma Spraying Process

    Directory of Open Access Journals (Sweden)

    Kui Wen

    2017-01-01

    Full Text Available In thermal plasma spraying process, anode nozzle is one of the most important components of plasma torch. Its inner contour controls the characteristics of plasma arc/jet, determining the motion and heating behaviors of the in-flight particles and hence influencing the coating quality. In this study, the effects of anode inner contour, standard cylindrical nozzle, and cone-shaped Laval nozzle with conical shape diverging exit (CSL nozzle on the arc voltage, net power, thermal efficiency, plasma jet characteristics, in-flight particle behaviors, and coating properties have been systematically investigated under atmospheric plasma spraying conditions. The results show that the cylindrical nozzle has a higher arc voltage, net power, and thermal efficiency, as well as the higher plasma temperature and velocity at the torch exit, while the CSL nozzle has a higher measured temperature of plasma jet. The variation trends of the plasma jet characteristics for the two nozzles are comparable under various spraying parameters. The in-flight particle with smaller velocity of CSL nozzle has a higher measured temperature and melting fraction. As a result, the coating density and adhesive strength of CSL nozzle are lower than those of cylindrical nozzle, but the deposition efficiency is greatly improved.

  18. Development of process maps for plasma spray: case study for molybdenum

    International Nuclear Information System (INIS)

    Sampath, S.; Jiang, X.; Kulkarni, A.; Matejicek, J.; Gilmore, D.L.; Neiser, R.A.

    2003-01-01

    A schematic representation referred to as 'process maps' examines the role of process variables on the properties of plasma-sprayed coatings. Process maps have been developed for air plasma spraying of molybdenum. Experimental work was done to investigate the importance of such spray parameters as gun current, primary gas flow, auxiliary gas flow, and powder carrier gas flow. In-flight particle temperatures and velocities were measured and diameters estimated in various areas of the spray plume. Empirical models were developed relating the input parameters to the in-flight particle characteristics. Molybdenum splats and coatings were produced at three distinct process conditions identified from the first-order process map experiments. In addition, substrate surface temperature during deposition was treated as a variable. Within the tested range, modulus, hardness and thermal conductivity increases with particle velocity, while oxygen content and porosity decreases. Increasing substrate deposition temperature resulted in dramatic improvement in coating thermal conductivity and modulus, while simultaneously increasing coating oxide content. Indentation reveals improved fracture resistance for the coatings prepared at higher substrate temperature. Residual stress was significantly affected by substrate temperature, although not to a great extent by particle conditions within the investigated parameter range. Coatings prepared at high substrate temperature with high-energy particles suffered considerably less damage in a wear test. The mechanisms behind these changes are discussed within the context relational maps, which have been proposed

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

    International Nuclear Information System (INIS)

    Ramm, D.A.J.; Hutchings, I.M.; Clyne, T.W.

    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 sharply reducing the erosive wear at high erodent impact angles, whilst retaining the good erosion resistance of ceramics at low angles. It is shown that the proportion of metal and ceramic at the free surface can be specified so as to optimise the erosion resistance. Experiments have also been carried out on the resistance of the coatings to debonding during four-point bending of the coated substrate. Progress is being made towards the tailoring of composition profiles in graded coatings so as to optimise the combination of erosion resistance and adhesion. (orig.)

  20. Microtexture of the thermally grown alumina in commercial thermal barrier coatings

    Energy Technology Data Exchange (ETDEWEB)

    Karadge, M. [School of Materials, University of Manchester, Grosvenor St., Manchester M1 7HS (United Kingdom); Zhao, X. [School of Materials, University of Manchester, Grosvenor St., Manchester M1 7HS (United Kingdom); Preuss, M. [School of Materials, University of Manchester, Grosvenor St., Manchester M1 7HS (United Kingdom); Xiao, P. [School of Materials, University of Manchester, Grosvenor St., Manchester M1 7HS (United Kingdom)]. E-mail: Ping.Xiao@manchester.ac.uk

    2006-02-15

    otextures of the thermally grown {alpha}-alumina (TGO) in isothermally treated and thermal cycled electron beam physical vapor deposited thermal barrier coatings (EB-PVD-TBC) and isothermally treated air plasma sprayed (APS-TBC) specimens were studied by high resolution electron back-scattered diffraction. The TGO in EB-PVD specimens exhibited a basal microtexture. The TGO in APS specimens, however, did not show any significant microtexture development.

  1. A unified spray forming model for the prediction of billet shape geometry

    DEFF Research Database (Denmark)

    Hattel, Jesper; Pryds, Nini

    2004-01-01

    In the present work a unified model for simulating the spray forming process has been developed. Models for the atomization and the deposition processes have been coupled together in order to obtain a new unified description of the spray forming process. The model is able to predict the shape...... and the temperatures of a spray-formed billet and takes into account the thermal coupling between the gas and the droplets, the change in droplet size distribution along the r-axis in the spray cone and the shading effect. The deposition describes the evolution of the preform with time. For this stage a novel 3D model......, which allows the atomizer to be placed asymmetrically over the substrate and also includes the withdrawal of the deposit, was developed. This makes it possible to model not only the growth of a Gaussian shaped preform in which case the spray axis and the rotation axis coincide, but also the surface...

  2. Laser assisted cold spraying of aluminium alloy powder on stainless steel substrate

    CSIR Research Space (South Africa)

    Tlotleng, Monnamme

    2012-12-01

    Full Text Available A newly acquired, in-house assembled laser assisted cold spraying coating technique had to be commissioned for use in future for metal coating for different industrial application which include, but not limited to chemical and orthopedic industries...

  3. 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

  4. Analysis of processes in DC arc plasma torches for spraying that use air as plasma forming gas

    International Nuclear Information System (INIS)

    Frolov, V; Ivanov, D; Toropchin, A

    2014-01-01

    Developed in Saint Petersburg State Polytechnical University technological processes of air-plasma spraying of wear-resistant, regenerating, hardening and decorative coatings used in number of industrial areas are described. The article contains examples of applications of air plasma spraying of coatings as well as results of mathematical modelling of processes in air plasma torches for spraying

  5. A study on erosive wear behavior of HVOF sprayed nanostructured WC-CoCr coatings

    International Nuclear Information System (INIS)

    Thakur, Lalit; Arora, Navneet

    2013-01-01

    WC-CoCr cermet coatings were deposited on stainless steel substrate using high-velocity oxy-fuel (HVOF) thermal spray process. The coatings were developed with two different thermal spray powders: one has WC grains of conventional micron size and the other is composed of nanosized (near-nanostructured) grains. HVOF spraying was assisted with in-flight particle temperature and velocity measurement system to control the process parameters that have resulted in quality coatings. Cavitation erosion testing was performed using a vibratory test apparatus based on ASTM standard G32-98. Surface morphology of powders and coatings was examined using the FESEM images, and phase identification was performed by XRD analysis. The erosion behavior of coatings and mechanism of material removal was discussed by examining the microstructure images of worn-out surfaces. WC-CoCr cermet coating deposited with nanosized WC grains exhibited higher cavitation erosion resistance as compared to conventional coating.

  6. A study on erosive wear behavior of HVOF sprayed nanostructured WC-CoCr coatings

    Energy Technology Data Exchange (ETDEWEB)

    Thakur, Lalit; Arora, Navneet [Indian Institute of Technology Roorkee, Roorkee (India)

    2013-05-15

    WC-CoCr cermet coatings were deposited on stainless steel substrate using high-velocity oxy-fuel (HVOF) thermal spray process. The coatings were developed with two different thermal spray powders: one has WC grains of conventional micron size and the other is composed of nanosized (near-nanostructured) grains. HVOF spraying was assisted with in-flight particle temperature and velocity measurement system to control the process parameters that have resulted in quality coatings. Cavitation erosion testing was performed using a vibratory test apparatus based on ASTM standard G32-98. Surface morphology of powders and coatings was examined using the FESEM images, and phase identification was performed by XRD analysis. The erosion behavior of coatings and mechanism of material removal was discussed by examining the microstructure images of worn-out surfaces. WC-CoCr cermet coating deposited with nanosized WC grains exhibited higher cavitation erosion resistance as compared to conventional coating.

  7. Layered Thermal Insulation Systems for Industrial and Commercial Applications

    Science.gov (United States)

    Fesmire, James E.

    2015-01-01

    From the high performance arena of cryogenic equipment, several different layered thermal insulation systems have been developed for industrial and commercial applications. In addition to the proven areas in cold-work applications for piping and tanks, the new Layered Composite Insulation for Extreme Environments (LCX) has potential for broader industrial use as well as for commercial applications. The LCX technology provides a unique combination of thermal, mechanical, and weathering performance capability that is both cost-effective and enabling. Industry applications may include, for example, liquid nitrogen (LN2) systems for food processing, liquefied natural gas (LNG) systems for transportation or power, and chilled water cooling facilities. Example commercial applications may include commercial residential building construction, hot water piping, HVAC systems, refrigerated trucks, cold chain shipping containers, and a various consumer products. The LCX system is highly tailorable to the end-use application and can be pre-fabricated or field assembled as needed. Product forms of LCX include rigid sheets, semi-flexible sheets, cylindrical clam-shells, removable covers, or flexible strips for wrapping. With increasing system control and reliability requirements as well as demands for higher energy efficiencies, thermal insulation in harsh environments is a growing challenge. The LCX technology grew out of solving problems in the insulation of mechanically complex cryogenic systems that must operate in outdoor, humid conditions. Insulation for cold work includes equipment for everything from liquid helium to chilled water. And in the middle are systems for LNG, LN2, liquid oxygen (LO2), liquid hydrogen (LH2) that must operate in the ambient environment. Different LCX systems have been demonstrated for sub-ambient conditions but are capable of moderately high temperature applications as well.

  8. Micro-structural investigations of spray hydrolyzed TiO{sub 2}

    Energy Technology Data Exchange (ETDEWEB)

    Lakhotiya, H. [Solid State Physics Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Centre for Converging Technologies, University of Rajasthan, Jaipur (India); Singh, Ripandeep; Bahadur, J. [Solid State Physics Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Sen, D., E-mail: debasis@barc.gov.in [Solid State Physics Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Das, Avik; Mazumder, S. [Solid State Physics Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Paul, B. [Materials Processing Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Sastry, P.U. [Solid State Physics Division, Bhabha Atomic Research Centre, Mumbai-400085 (India); Lemmel, H. [Atominstitut, Vienna University of Technology, 1020 Vienna (Austria); Institut Laue-Langevin, 38000 Grenoble (France)

    2014-01-25

    Highlights: • Titania microstructure formation by spray hydrolysis. • Morphological transition during spray hydrolysis process. • Hollow microspheres and fractal like grains depending on precursor concentration. • Use of scattering and microscopy techniques in probing mesoscopic structures. • A plausible mechanism regarding the morphological transition is also introduced. -- Abstract: Hydrolysis across tiny spray droplet allows a facile one step synthesis of interesting sub-micrometric structures owing to the large available surface area unlike bulk hydrolysis. In the present work, it has been demonstrated that titania precursor concentration plays a significant role in effecting morphological transformation during spray hydrolysis. While hollow microspheres are formed primarily at low precursor concentration, fractal like grains, having two levels of hierarchy, result at high precursor concentration. Mesoscopic structure of these spray hydrolyzed grains has been investigated by ultra small-angle neutron scattering, small-angle X-ray scattering and scanning electron microscopy. Thermal evolution of initial amorphous phase of titania into crystalline rutile phase, through intermediate anatase and brookite phases, is followed by high temperature X-ray diffraction. A plausible mechanism has been elucidated for the observed morphological transition with variation of precursor concentration.

  9. Thermally Sprayed Aluminum Coatings for the Protection of Subsea Risers and Pipelines Carrying Hot Fluids

    Directory of Open Access Journals (Sweden)

    Nataly Ce

    2016-11-01

    Full Text Available This paper reports the effect of boiling synthetic seawater on the performance of damaged Thermally Sprayed Aluminum (TSA on carbon steel. Small defects (4% of the sample’s geometric surface area were drilled, exposing the steel, and the performance of the coating was analyzed for corrosion potential for different exposure times (2 h, 335 h, and 5000 h. The samples were monitored using linear polarization resistance (LPR in order to obtain their corrosion rate. Scanning electron microscopy (SEM/energy dispersive X-ray spectroscopy (EDX and X-ray diffraction (XRD were used for post-test characterization. The results showed that a protective layer of Mg(OH2 formed in the damaged area, which protected the underlying steel. Additionally, no coating detachment from the steel near the defect region was observed. The corrosion rate was found to be 0.010–0.015 mm/year after 5000 h in boiling synthetic seawater.

  10. Isocyanate exposure and respiratory health effects in the spray painting industry

    NARCIS (Netherlands)

    Pronk, A.

    2007-01-01

    In this thesis exposure-response relationships between isocyanate exposure and respiratory health end-points and specific sensitization in spray painters were investigated. Isocyanates, a group of compounds characterized by reactive N=C=O groups, are among the most frequently identified causes of

  11. Systematic Investigation on the Influence of Spray Parameters on the Mechanical Properties of Atmospheric Plasma-Sprayed YSZ Coatings

    Science.gov (United States)

    Mutter, Markus; Mauer, Georg; Mücke, Robert; Guillon, Olivier; Vaßen, Robert

    2018-04-01

    In the atmospheric plasma spray (APS) process, micro-sized ceramic powder is injected into a thermal plasma where it is rapidly heated and propelled toward the substrate. The coating formation is characterized by the subsequent impingement of a large number of more or less molten particles forming the so-called splats and eventually the coating. In this study, a systematic investigation on the influence of selected spray parameters on the coating microstructure and the coating properties was conducted. The investigation thereby comprised the coating porosity, the elastic modulus, and the residual stress evolution within the coating. The melting status of the particles at the impingement on the substrate in combination with the substrate surface condition is crucial for the coating formation. Single splats were collected on mirror-polished substrates for selected spray conditions and evaluated by identifying different types of splats (ideal, distorted, weakly bonded, and partially molten) and their relative fractions. In a previous study, these splat types were evaluated in terms of their effect on the above-mentioned coating properties. The particle melting status, which serves as a measure for the particle spreading behavior, was determined by in-flight particle temperature measurements and correlated to the coating properties. It was found that the gun power and the spray distance have a strong effect on the investigated coating properties, whereas the feed rate and the cooling show minor influence.

  12. Gene Expression, Bacteria Viability and Survivability Following Spray Drying of Mycobacterium smegmatis

    Directory of Open Access Journals (Sweden)

    Elizabeth Hunter Lauten

    2010-04-01

    Full Text Available We find that Mycobacterium smegmatis survives spray drying and retains cell viability in accelerated temperature stress (40 °C conditions with a success rate that increases with increasing thermal, osmotic, and nutrient-restriction stresses applied to the mycobacterium prior to spray drying. M.smegmatis that are spray dried during log growth phase, where they suffer little or no nutrient-reduction stress, survive for less than 7 days in the dry powder state at accelerated temperature stress conditions, whereas M. smegmatis that are spray dried during stationary phase, where cells do suffer nutrient reduction, survive for up to 14 days. M. smegmatis that are spray dried from stationary phase, subjected to accelerated temperature stress conditions, regrown to stationary phase, spray dried again, and resubmitted to this same process four consecutive times, display, on the fourth spray drying iteration, an approximate ten-fold increase in stability during accelerated temperature stress testing, surviving up to 105 days. Microarray tests revealed significant differences in genetic expression of M. smegmatis between log phase and stationary phase conditions, between naïve (non spray-dried and multiply cycled dried M. smegmatis (in log and stationary phase, and between M. smegmatis in the dry powder state following a single spray drying operation and after four consecutive spray drying operations. These differences, and other phenotypical differences, point to the carotenoid biosynthetic pathway as a probable pathway contributing to bacteria survival in the spray-dried state and suggests strategies for spray drying that may lead to significantly greater room-temperature stability of mycobacteria, including mycobacterium bovis bacille Calmette-Guerin (BCG, the current TB vaccine.

  13. Water spray interaction with air-steam mixtures under containment spray conditions: comparison of heat and mass transfer modelling with the TOSQAN spray tests

    International Nuclear Information System (INIS)

    Malet, J.; Lemaitre, P.; Porcheron, E.; Vendel, J.

    2005-01-01

    Full text of publication follows: During the course of a hypothetical severe accident in a Pressurized Water Reactor (PWR), hydrogen can be produced by the reactor core oxidation and distributed into the reactor containment according to convection flows and water steam wall condensation. In order to mitigate the risk of detonation generated by a high local hydrogen concentration, spray systems are used in the containment. The TOSQAN programme has been created to simulate separate-effect tests representative of typical accidental thermal-hydraulic flow conditions in the reactor containment. The present work concerns the interaction of a water spray, used at the top of the containment in order to reduce the steam partial pressure, with air-steam mixtures. The main phenomena occurring when water spray is used are the mixing induced by spray entrainment and the condensation on droplets. In order to improve the latter phenomena, different levels of modelling can be used. The objective of this paper is to analyze experimental results obtained for water spray interaction with air-steam mixtures using different heat and mass transfer modelling. For this purpose, two modelling issues have been used: the first one is devoted for the determination of the gas thermodynamical properties, and the second one concerns the droplets characterization. In the first one, the gas thermodynamical analysis is performed using depressurization, gas temperature variation and humidity decrease during the spray injection. In this modelling, heat and mass transfer between the spray and the surrounding gas is treated in a global way by energy balance between the total amount of water and the gas. In the second one, droplets characterization is obtained by means of droplet size, temperature and velocities evolutions. In this modelling, the spray is considered as a single droplet falling with an initial velocity. Droplet interactions are neglected. Assessment of these two modelling is performed

  14. HVOF-Sprayed Nano TiO2-HA Coatings Exhibiting Enhanced Biocompatibility

    Science.gov (United States)

    Lima, R. S.; Dimitrievska, S.; Bureau, M. N.; Marple, B. R.; Petit, A.; Mwale, F.; Antoniou, J.

    2010-01-01

    Biomedical thermal spray coatings produced via high-velocity oxy-fuel (HVOF) from nanostructured titania (n-TiO2) and 10 wt.% hydroxyapatite (HA) (n-TiO2-10wt.%HA) powders have been engineered as possible future alternatives to HA coatings deposited via air plasma spray (APS). This approach was chosen due to (i) the stability of TiO2 in the human body (i.e., no dissolution) and (ii) bond strength values on Ti-6Al-4V substrates more than two times higher than those of APS HA coatings. To explore the bioperformance of these novel materials and coatings, human mesenchymal stem cells (hMSCs) were cultured from 1 to 21 days on the surface of HVOF-sprayed n-TiO2 and n-TiO2-10 wt.%HA coatings. APS HA coatings and uncoated Ti-6Al-4V substrates were employed as controls. The profiles of the hMSCs were evaluated for (i) cellular proliferation, (ii) biochemical analysis of alkaline phosphatase (ALP) activity, (iii) cytoskeleton organization (fluorescent/confocal microscopy), and (iv) cell/substrate interaction via scanning electron microscopy (SEM). The biochemical analysis indicated that the hMSCs cultured on n-TiO2-10 wt.%HA coatings exhibited superior levels of bioactivity than hMSCs cultured on APS HA and pure n-TiO2 coatings. The cytoskeleton organization demonstrated a higher degree of cellular proliferation on the HVOF-sprayed n-TiO2-10wt.%HA coatings when compared to the control coatings. These results are considered promising for engineering improved performance in the next generation of thermally sprayed biomedical coatings.

  15. Box-Behnken analysis and storage of spray-dried collagenolytic proteases from Myceliophthora thermophila submerged bioprocess.

    Science.gov (United States)

    Hamin Neto, Youssef Ali Abou; Coitinho, Luciana Barbosa; de Freitas, Luis Alexandre Pedro; Cabral, Hamilton

    2017-05-28

    Enzymes do not have long-term storage stability in soluble forms, thus drying methods could minimize the loss of enzymatic activity, the spray dryer removes water under high temperatures and little time. The aims of this study were to improve the stability of enzymatic extract from Myceliophthora thermophila for potential applications in industry and to evaluate the best conditions to remove the water by spray drying technique. The parameters were tested according to Box-Behnken and evaluated by analysis of variance (ANOVA), all the parameters measured were found to influence the final enzyme activity and spray drying process yield ranged from 38.65 to 63.75%. Enzyme powders showed increased storage stability than extract and maintained about 100% of collagenolytic activity after 180 days of storage at 30°C. The results showed that the microbial enzymes maintained activity during the spray drying process and were stable during long-term storage; these are promising characteristics for industrial applications.

  16. Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology

    Czech Academy of Sciences Publication Activity Database

    Mušálek, Radek; Medřický, Jan; Tesař, T.; Kotlan, Jiří; Pala, Zdeněk; Lukáč, František; Chráska, Tomáš; Curry, N.

    2017-01-01

    Roč. 26, 1-2 (2017), s. 37-46 ISSN 1059-9630. [ISTC 2016: International Thermal Spray Conference. Shanghai, 10.05.2016-12.05.2016] R&D Projects: GA ČR GA15-12145S Institutional support: RVO:61389021 Keywords : alumina * ceramics * dense * hybrid plasma torch * suspension plasma spraying * water-stabilized plasma * yttria-stabilized zirconia (YSZ) Subject RIV: JK - Corrosion ; Surface Treatment of Materials OBOR OECD: Coating and films Impact factor: 1.488, year: 2016 http://link.springer.com/article/10.1007/s11666-016-0493-6

  17. 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.

  18. High quality ceramic coatings sprayed by high efficiency hypersonic plasma spraying gun

    International Nuclear Information System (INIS)

    Zhu Sheng; Xu Binshi; Yao JiuKun

    2005-01-01

    This paper introduced the structure of the high efficiency hypersonic plasma spraying gun and the effects of hypersonic plasma jet on the sprayed particles. The optimised spraying process parameters for several ceramic powders such as Al 2 O 3 , Cr 2 O 3 , ZrO 2 , Cr 3 C 2 and Co-WC were listed. The properties and microstructure of the sprayed ceramic coatings were investigated. Nano Al 2 O 3 -TiO 2 ceramic coating sprayed by using the high efficiency hypersonic plasma spraying was also studied. Compared with the conventional air plasma spraying, high efficiency hypersonic plasma spraying improves greatly the ceramic coatings quality but at low cost. (orig.)

  19. Characterizing Suspension Plasma Spray Coating Formation Dynamics through Curvature Measurements

    Science.gov (United States)

    Chidambaram Seshadri, Ramachandran; Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay

    2016-12-01

    Suspension plasma spraying (SPS) enables the production of variety of microstructures with unique mechanical and thermal properties. In SPS, a liquid carrier (ethanol/water) is used to transport the sub-micrometric feedstock into the plasma jet. Considering complex deposition dynamics of SPS technique, there is a need to better understand the relationships among spray conditions, ensuing particle behavior, deposition stress evolution and resultant properties. In this study, submicron yttria-stabilized zirconia particles suspended in ethanol were sprayed using a cascaded arc plasma torch. The stresses generated during the deposition of the layers (termed evolving stress) were monitored via the change in curvature of the substrate measured using an in situ measurement apparatus. Depending on the deposition conditions, coating microstructures ranged from feathery porous to dense/cracked deposits. The evolving stresses and modulus were correlated with the observed microstructures and visualized via process maps. Post-deposition bi-layer curvature measurement via low temperature thermal cycling was carried out to quantify the thermo-elastic response of different coatings. Lastly, preliminary data on furnace cycle durability of different coating microstructures were evaluated. This integrated study involving in situ diagnostics and ex situ characterization along with process maps provides a framework to describe coating formation mechanisms, process parametrics and microstructure description.

  20. 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)

  1. Synthesis of Cr-doped CaTiSiO5 ceramic pigments by spray drying

    International Nuclear Information System (INIS)

    Lyubenova, T. Stoyanova; Matteucci, F.; Costa, A.L.; Dondi, M.; Ocana, M.; Carda, J.

    2009-01-01

    Cr-doped CaTiSiO 5 was synthesized by spray drying and conventional ceramic method in order to assess its potential as ceramic pigment. The evolution of the phase composition with thermal treatment was investigated by X-ray powder diffraction (XRPD) and thermal analyses (DTA-TGA-EGA). Powder morphology and particle size distribution were analyzed by scanning electron microscopy (SEM) and laser diffraction, respectively. The color efficiency of pigments was evaluated by optical spectroscopy (UV-vis-NIR) and colorimetric analysis (CIE Lab). Results proved that spray drying is an efficient procedure to prepare highly reactive pigment precursors. The spray-dried powders consist of hollow spherical particles with aggregate size in the 1-10 μm range, developing a brown coloration. Optical spectra reveal the occurrence of Cr(III) and Cr(IV), both responsible for the brown color of this pigment. The former occupies the octahedral site of titanite, in substitution of Ti(IV), while the latter is located at the tetrahedral site, where replaces Si(IV)

  2. 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

  3. Influence of Solvent Composition on the Performance of Spray-Dried Co-Amorphous Formulations

    DEFF Research Database (Denmark)

    Mishra, Jaya; Rades, Thomas; Löbmann, Korbinian

    2018-01-01

    Ball-milling is usually used to prepare co-amorphous drug–amino acid (AA) mixtures. In this study, co-amorphous drug–AA mixtures were produced using spray-drying, a scalable industrially preferred preparation method. The influence of the solvent type and solvent composition was investigated....... Mixtures of indomethacin (IND) and each of the three AAs arginine, histidine, and lysine were ball-milled and spray-dried at a 1:1 molar ratio, respectively. Spray-drying was performed at different solvent ratios in (a) ethanol and water mixtures and (b) acetone and water mixtures. Different ratios...... that using spray-drying as a preparation method, all IND–AA mixtures could be successfully converted into the respective co-amorphous forms, irrespective of the type of solvent used, but depending on the solvent mixture ratios. Both ball-milled and spray-dried co-amorphous samples showed an enhanced...

  4. Pharmaceutical spray drying: solid-dose process technology platform for the 21st century.

    Science.gov (United States)

    Snyder, Herman E

    2012-07-01

    Requirement for precise control of solid-dosage particle properties created with a scalable process technology are continuing to expand in the pharmaceutical industry. Alternate methods of drug delivery, limited active drug substance solubility and the need to improve drug product stability under room-temperature conditions are some of the pharmaceutical applications that can benefit from spray-drying technology. Used widely for decades in other industries with production rates up to several tons per hour, pharmaceutical uses for spray drying are expanding beyond excipient production and solvent removal from crystalline material. Creation of active pharmaceutical-ingredient particles with combinations of unique target properties are now more common. This review of spray-drying technology fundamentals provides a brief perspective on the internal process 'mechanics', which combine with both the liquid and solid properties of a formulation to enable high-throughput, continuous manufacturing of precision powder properties.

  5. 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.

  6. Improved the microstructures and properties of M3:2 high-speed steel by spray forming and niobium alloying

    Energy Technology Data Exchange (ETDEWEB)

    Lu, L. [State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Xueyuan Road 30, Haidian District, Beijing 100083 (China); Hou, L.G., E-mail: lghou@skl.ustb.edu.cn [State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Xueyuan Road 30, Haidian District, Beijing 100083 (China); Zhang, J.X.; Wang, H.B.; Cui, H.; Huang, J.F. [State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Xueyuan Road 30, Haidian District, Beijing 100083 (China); Zhang, Y.A. [State Key Laboratory of Non-Ferrous Metals and Process, General Research Institute for Non-Ferrous Metals, Beijing 100088 (China); Zhang, J.S. [State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Xueyuan Road 30, Haidian District, Beijing 100083 (China)

    2016-07-15

    The microstructures and properties of spray formed (SF) high-speed steels (HSSs) with or without niobium (Nb) addition were studied. Particular emphasis was placed on the effect of Nb on the solidification microstructures, decomposition of M{sub 2}C carbides, thermal stability and mechanical properties. The results show that spray forming can refine the cell size of eutectic carbides due to the rapid cooling effect during atomization. With Nb addition, further refinement of the eutectic carbides and primary austenite grains are obtained. Moreover, the Nb addition can accelerate the decomposition of M{sub 2}C carbides and increase the thermal stability of high-speed steel, and also can improve the hardness and bending strength with slightly decrease the impact toughness. The high-speed steel made by spray forming and Nb alloying can give a better tool performance compared with powder metallurgy M3:2 and commercial AISI M2 high-speed steels. - Highlights: • Spray forming can effectively refine the microstructure of M3:2 steel. • Niobium accelerates the decomposition of M{sub 2}C carbides. • Niobium increases the hardness and bending strength of spray formed M3:2 steel. • Spray-formed niobium-containing M3:2 steel has the best tool performance.

  7. Spray Drying Processing: granules production and drying kinetics of droplets

    International Nuclear Information System (INIS)

    Mondragon, R.; Julia, J. E.; Barba, A.; Jarque, J. C.

    2013-01-01

    Spray drying is a unit operation very common in many industrial processes. For each particular application, the resulting granulated material must possess determined properties that depend on the conditions in which the spray drying processing has been carried out, and whose dependence must be known in order to optimize the quality of the material obtained. The large number of variables that influence on the processes of matter and energy transfer and on the formation of granular material has required a detailed analysis of the drying process. Over the years there have been many studies on the spray drying processing of all kind of materials and the influence of process variables on the drying kinetics of the granulated material properties obtained. This article lists the most important works published for both the spray drying processing and the drying of individual droplets, as well as studies aimed at modeling the drying kinetics of drops. (Author)

  8. Fabrication of polyacrylate core–shell nanoparticles via spray drying method

    Energy Technology Data Exchange (ETDEWEB)

    Chen, Pengpeng, E-mail: chenpp@ahu.edu.cn [Anhui University, College of Chemistry and Chemical Engineering (China); Cheng, Zenghui; Chu, Fuxiang; Xu, Yuzhi; Wang, Chunpeng, E-mail: wangcpg@163.com [Chinese Academy of Forestry, Institute of Chemical Industry of Forest Products (China)

    2016-05-15

    Fine polyacrylate particles are thought to be environmental plastisols for car industry. However, these particles are mainly dried through demulsification of the latexes, which is not reproducible and hard to be scaled up. In this work, a spray drying method had been applied to the plastisols-used acrylate latex. By adjusting the core/shell ratio, spray drying process of the latex was fully studied. Scanning electronic microscopy observation of the nanoparticles before and after spray drying indicated that the core–shell structures could be well preserved and particles were well separated by spray drying if the shell was thick enough. Otherwise, the particles fused into each other and core–shell structures were destroyed. Polyacrylate plastisols were developed using diisononylphthalate as a plasticizer, and plastigels were obtained after heat treatment of the sols. Results showed that the shell thickness also had a great influence on the storage stability of the plastisols and mechanical properties of the plastigels.Graphical Abstract.

  9. Fabrication of polyacrylate core–shell nanoparticles via spray drying method

    International Nuclear Information System (INIS)

    Chen, Pengpeng; Cheng, Zenghui; Chu, Fuxiang; Xu, Yuzhi; Wang, Chunpeng

    2016-01-01

    Fine polyacrylate particles are thought to be environmental plastisols for car industry. However, these particles are mainly dried through demulsification of the latexes, which is not reproducible and hard to be scaled up. In this work, a spray drying method had been applied to the plastisols-used acrylate latex. By adjusting the core/shell ratio, spray drying process of the latex was fully studied. Scanning electronic microscopy observation of the nanoparticles before and after spray drying indicated that the core–shell structures could be well preserved and particles were well separated by spray drying if the shell was thick enough. Otherwise, the particles fused into each other and core–shell structures were destroyed. Polyacrylate plastisols were developed using diisononylphthalate as a plasticizer, and plastigels were obtained after heat treatment of the sols. Results showed that the shell thickness also had a great influence on the storage stability of the plastisols and mechanical properties of the plastigels.Graphical Abstract

  10. The influence of substrate temperature and spraying distance on the properties of plasma sprayed tungsten and steel coatings deposited in a shrouding chamber

    Czech Academy of Sciences Publication Activity Database

    Matějíček, Jiří; Vilémová, Monika; Nevrlá, Barbara; Kocmanová, Lenka; Veverka, Jakub; Halasová, Martina; Hadraba, Hynek

    2017-01-01

    Roč. 318, May (2017), s. 217-223 ISSN 0257-8972. [International Meeting on Thermal Spraying (RIPT)/7./. Limoges, 09.12.2015-11.12.2015] R&D Projects: GA ČR GB14-36566G EU Projects: European Commission(XE) 633053 - EUROfusion Institutional support: RVO:61389021 ; RVO:68081723 Keywords : Tungsten * Steel * Atmospheric plasma spraying * Shrouding * Substrate temperature * Fusion reactor materials * Plasma facing components Subject RIV: JK - Corrosion ; Surface Treatment of Materials; JK - Corrosion ; Surface Treatment of Materials (UFM-A) OBOR OECD: Coating and films; Coating and films (UFM-A) Impact factor: 2.589, year: 2016 http://www.sciencedirect.com/science/ article /pii/S0257897216310520

  11. The effects of a spray slurry nozzle on copper CMP for reduction in slurry consumption

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Da Sol; Jeong, Hae Do [Pusan National University, Busan (Korea, Republic of); Lee, Hyun Seop [Tongmyong University, Busan (Korea, Republic of)

    2015-12-15

    The environmental impact of semiconductor manufacturing has been a big social problem, like greenhouse gas emission. Chemical mechanical planarization (CMP), a wet process which consumes chemical slurries, seriously impacts environmental sustain ability and cost-effectiveness. This paper demonstrates the superiority of a full-cone spray slurry nozzle to the conventional tube-type slurry nozzle in Cu CMP. It was observed that the spray nozzle made a weak slurry wave at the retaining ring unlike a conventional nozzle, because the slurry was supplied uniformly in broader areas. Experiments were implemented with different slurry flow rates and spray nozzle heights. Spray nozzle performance is controlled by the spray angle and spray height. The process temperature was obtained with an infrared (IR) sensor and an IR thermal imaging camera to investigate the cooling effect of the spray. The results show that the spray nozzle provides a higher Material removal rate (MRR), lower non-uniformity (NU), and lower temperature than the conventional nozzle. Computational fluid dynamics techniques show that the turbulence kinetic energy and slurry velocity of the spray nozzle are much higher than those of the conventional nozzle. Finally, it can be summarized that the spray nozzle plays a significant role in slurry efficiency by theory of Minimum quantity lubrication (MQL).

  12. The effects of a spray slurry nozzle on copper CMP for reduction in slurry consumption

    International Nuclear Information System (INIS)

    Lee, Da Sol; Jeong, Hae Do; Lee, Hyun Seop

    2015-01-01

    The environmental impact of semiconductor manufacturing has been a big social problem, like greenhouse gas emission. Chemical mechanical planarization (CMP), a wet process which consumes chemical slurries, seriously impacts environmental sustain ability and cost-effectiveness. This paper demonstrates the superiority of a full-cone spray slurry nozzle to the conventional tube-type slurry nozzle in Cu CMP. It was observed that the spray nozzle made a weak slurry wave at the retaining ring unlike a conventional nozzle, because the slurry was supplied uniformly in broader areas. Experiments were implemented with different slurry flow rates and spray nozzle heights. Spray nozzle performance is controlled by the spray angle and spray height. The process temperature was obtained with an infrared (IR) sensor and an IR thermal imaging camera to investigate the cooling effect of the spray. The results show that the spray nozzle provides a higher Material removal rate (MRR), lower non-uniformity (NU), and lower temperature than the conventional nozzle. Computational fluid dynamics techniques show that the turbulence kinetic energy and slurry velocity of the spray nozzle are much higher than those of the conventional nozzle. Finally, it can be summarized that the spray nozzle plays a significant role in slurry efficiency by theory of Minimum quantity lubrication (MQL).

  13. Drop formation of black liquor spraying; Mustalipeaen pisaroituminen

    Energy Technology Data Exchange (ETDEWEB)

    Fogelholm, C J; Kankkunen, A; Nieminen, K; Laine, J; Miikkulainen, P [Helsinki Univ. of Technology, Otaniemi (Finland): Lab. of Energy Technology and Environmental Protection

    1997-10-01

    Black liquor is a spent liquor of the pulp and paper industry. It is burned in kraft recovery boilers for chemical and energy recovery. The high dry solids content and viscosity of black liquor require a high spraying temperature. This affects the performance of the boiler. Kraft recovery boiler deposit formation, emissions and chemical recovery are strongly affected by the drop size and the velocity of the black liquor spray formed by a splashplate nozzle. The sheet breakup mechanism is studied with a system based on a video and image-analysis. The drop size of mill-scale nozzles was measured also with an image-analysis-system. Measurements were carried out in a spray test chamber. The sheet breakup mechanism and drop size tests were carried out both below and over the boiling point of black liquor. Special attention was paid to the effect of flashing on drop formation. Temperature increase normally decreases drop size. In the temperature where the wavy-sheet disintegration changes to perforated-sheet disintegration the drop size increases. Spray velocity rises when the temperature is increased above the boiling point. (orig.)

  14. Optical fuel spray measurements

    Energy Technology Data Exchange (ETDEWEB)

    Hillamo, H.

    2011-07-01

    Diesel fuel sprays, including fuel/air mixing and the physics of two-phase jet formation, are discussed in the thesis. The fuel/air mixing strongly affects emissions formation in spray combustion processes where the local combustion conditions dictate the emission formation. This study comprises optical measurements both in pressurized spray test rigs and in a running engine.The studied fuel injection was arranged with a common rail injection system and the injectors were operated with a solenoid-based injection valve. Both marine and heavy-duty diesel engine injectors were used in the study. Optical fuel spray measurements were carried out with a laser-based double-framing camera system. This kind of equipments is usually used for flow field measurements with Particle Image Velocimetry technique (PIV) as well as for backlight imaging. Fundamental fuel spray properties and spray formation were studied in spray test rigs. These measurements involved studies of mixing, atomization, and the flow field. Test rig measurements were used to study the effect of individual injection parameters and component designs. Measurements of the fuel spray flow field, spray penetration, spray tip velocity, spray angle, spray structure, droplet accumulation, and droplet size estimates are shown. Measurement campaign in a running optically accessible large-bore medium-speed engine was also carried out. The results from engine tests were compared with equivalent test rig measurements, as well as computational results, to evaluate the level of understanding of sprays. It was shown that transient spray has an acceleration and a deceleration phase. Successive flow field measurements (PIV) in optically dense diesel spray resulted in local and average velocity data of diesel sprays. Processing fuel spray generates a flow field to surrounding gas and entrainment of surrounding gas into fuel jet was also seen at the sides of the spray. Laser sheet imaging revealed the inner structure of diesel

  15. Mathematical modeling of a mixed flow spray dryer

    International Nuclear Information System (INIS)

    Kasiri, N.; Delkhan, F.

    2001-01-01

    In this paper a mathematical model has been developed to simulate the behavior of spray dryers with an up-flowing spray. The model is based on mass, energy and momentum balance on a single droplet , and mass and energy balances on the drying gas. The system of nonlinear differential equations thus obtained is solved to predict the changes in temperature, humidity, diameter, velocity components and the density of the droplets as well as the temperature and the humidity changes of the drying gas. The predicted results were then compared with an industrially available set of results. A good degree of proximity between the two is reported

  16. Sustainability assessment of heat exchanger units for spray dryers

    International Nuclear Information System (INIS)

    Caglayan, Hasan; Caliskan, Hakan

    2017-01-01

    In this study, the sustainability assessment is performed to the system known as heat exchanger unit with spray dryer. The five-different dead state temperatures (0-5-10-15-20 °C) are considered. It is found that the heat exchanger has the highest energy efficiency (63.32%), while the overall system has the lowest one (5.56%). So, the combination of the spray dryer with the heat exchanger is more effective. On the other hand, the overall exergy efficiency of the system is lower than the heat exchanger and spray dryer for all of the dead state (environmental) temperatures. The exergy efficiency of the heat exchanger is inversely proportional to the dead state temperature, and the maximum rate is found as 49.65% at 0 °C. Furthermore, the exergy efficiencies of the spray dryer and overall system are directly proportional to the dead state temperatures, and the corresponding maximum rates are found to be 26.41% and 24.32% at 20 °C, respectively. Also, the exergy destruction is directly proportional to the dead state temperatures. The minimum and maximum exergy destruction rates are found at the dead state temperatures of 0 °C and 20 °C, respectively. Furthermore, the most sustainable system is found as the heat exchanger unit. - Highlights: • Thermodynamic analyses of industrial heat exchangers and spray dryers. • Sustainability of heat exchangers for spray dryers. • Dead state temperature effects on exergy efficiencies of heat exchangers and spray dryers.

  17. Sodium spray and jet fire model development within the CONTAIN-LMR code

    International Nuclear Information System (INIS)

    Scholtyssek, W.

    1993-01-01

    An assessment was made of the sodium spray fire model implemented in the CONTAIN code. The original droplet burn model, which was based on the NACOM code, was improved in several aspects, especially concerning evaluation of the droplet burning rate, reaction chemistry and heat balance, spray geometry and droplet motion, and consistency with CONTAIN standards of gas property evaluation. An additional droplet burning model based on a proposal by Krolikowski was made available to include the effect of the chemical equilibrium conditions at the flame temperature. The models were validated against single-droplet burn experiments as well as spray and jet fire experiments. Reasonable agreement was found between the two burn models and experimental data. When the gas temperature in the burning compartment reaches high values, the Krolikowski model seems to be preferable. Critical parameters for spray fire evaluation were found to be the spray characterization, especially the droplet size, which largely determines the burning efficiency, and heat transfer conditions at the interface between the atmosphere and structures, which controls the thermal hydraulic behavior in the burn compartment

  18. Intermittent cryogen spray cooling for optimal heat extraction during dermatologic laser treatment

    Science.gov (United States)

    Majaron, Boris; Svaasand, Lars O.; Aguilar, Guillermo; Nelson, J. Stuart

    2002-09-01

    Fast heat extraction is critically important to obtain the maximal benefit of cryogen spray cooling (CSC) during laser therapy of shallow skin lesions, such as port wine stain birthmarks. However, a film of liquid cryogen can build up on the skin surface, impairing heat transfer due to the relatively low thermal conductivity and higher temperature of the film as compared to the impinging spray droplets. In an attempt to optimize the cryogen mass flux, while minimally affecting other spray characteristics, we apply a series of 10 ms spurts with variable duty cycles. Heat extraction dynamics during such intermittent cryogen sprays were measured using a custom-made metal-disc detector. The highest cooling rates were observed at moderate duty cycle levels. This confirms the presence, and offers a practical way to eliminate the adverse effect of liquid cryogen build-up on the sprayed surface. On the other hand, lower duty cycles allow a substantial reduction in the average rate of heat extraction, enabling less aggressive and more efficient CSC for treatment of deeper targets, such as hair follicles.

  19. Preparation of polymer-organo clay nano composites through the spray drying process

    International Nuclear Information System (INIS)

    Bernardo, Paulo R.A.; Pessan, Luiz A.; Carvalho, Antonio J.F. de; Vidotti, Suel E.

    2011-01-01

    The objective of the work was the study and preparation of polymer nano composites with montmorillonite organo clays (MMT) through the spray drying process. A new technique was proposed and tested to obtaining polymer nano composites, based on the use of the spray drying process to produce a nano composite with high clay content. The process consisted of the following stages: clay intercalation in water solution, with after addition of polyvinyl alcohol (PVOH) and a hydro soluble polyester ionomer (GEROLPS20) as exfoliation agents; spray drying the mixture obtained; incorporation powder in EVOH, PET e PP matrix. The effects of exfoliation agent on morphological and thermal properties of the nano composites were studied by XRD, transmission electron microscopy (TEM) and TGA. The results demonstrate that the process of spray drying is an innovative way to obtain a nano composite with high clay content. (author)

  20. 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.

  1. The influence of pore formers on the microstructure of plasma-sprayed NiO-YSZ anodes

    Science.gov (United States)

    Poon, Michael; Kesler, Olivera

    2012-07-01

    Four types of pore formers: high-density polyethylene (HDPE), polyether-ether-ketone (PEEK), mesocarbon-microbead (MCMB) carbon powder, and baking flour, are processed and characterized, then incorporated with NiO-YSZ nano-agglomerate powder to produce plasma sprayed SOFC anode coatings. Scanning electron microscopy (SEM) of the coating microstructure, gas permeability measurements, and porosity determinations by image analysis are used to evaluate the effectiveness of each potential pore former powder. Under the spray conditions studied, the flour and MCMB pore former powders are effective as plasma sprayed pore formers, increasing the permeability of the coatings by factors of four and two, respectively, compared to a similarly sprayed NiO-YSZ coating without pore formers. The HDPE powder is unable to survive the plasma spray process and does not contribute to the final coating porosity. The PEEK pore former, though ineffective with the current powder characteristics and spray parameters, exhibits the highest relative deposition efficiency and the most favorable thermal characteristics.

  2. ENVIRONMENTAL TECHNOLOGY VERIFICATION REPORT: DEVILBISS JGHV-531-46FF HVLP SPRAY GUN

    Science.gov (United States)

    This report presents the results of the verification test of the DeVilbiss JGHV-531-46FF high-volume, low-pressure pressure-feed spray gun, hereafter referred to as the DeVilbiss JGHV, which is designed for use in industrial finishing. The test coating chosen by ITW Industrial Fi...

  3. 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.

  4. Comparison of W–TiC composite coatings fabricated by atmospheric plasma spraying and supersonic atmospheric plasma spraying

    International Nuclear Information System (INIS)

    Hou, Qing Yu; Luo, Lai Ma; Huang, Zhen Yi; Wang, Ping; Ding, Ting Ting; Wu, Yu Cheng

    2016-01-01

    Highlights: • W–TiC composite coatings were fabricated by APS and SAPS technologies. • TiC had filling effect on pores and coating/fixing effect on un-melted particles. • Porosity and oxygen content in SAPS coating were lower than that in APS coating. • Thermal conductivity of SAPS coating was higher than that of APS coating. • SAPS coating has better ability to resist to elastic fracture than APS coating does. - Abstract: Tungsten coatings with 1.5 wt.% TiC (W/TiC) were fabricated by atmospheric plasma spraying (APS) and supersonic atmospheric plasma spraying (SAPS) techniques, respectively. The results showed that the typical lamellar structure of plasma spraying and columnar crystalline grains formed in the coatings. Pores located mainly at lamellar gaps in association with oxidation were also observed. TiC phase, distributed at lamellar gaps filled the gaps; and that distributed around un-melted tungsten particles and splashed debris coated the particles or debris that were linked with the TiC at lamellar gaps. The coating and linking of the retained TiC phase prevented the tungsten particles to come off from the coatings. The porosity and the oxygen content of the SAPS-W/TiC were lower than those of the APS-W/TiC coating. The mechanical response of the coatings was strongly dependent on the H/E* ratio (H and E* are the hardness and effective Young’s modulus, respectively). The SAPS-W/TiC coating with a higher H/E* ratio had a better ability to resist to elastic fracture and better fracture toughness as compared with the APS-W/TiC coating with a smaller H/E* ratio. The thermal conductivity of the SAPS-W/TiC coating was greater than that of the APS-W/TiC coating.

  5. Controlling in situ crystallization of pharmaceutical particles within the spray dryer.

    Science.gov (United States)

    Woo, Meng Wai; Lee, May Ginn; Shakiba, Soroush; Mansouri, Shahnaz

    2017-11-01

    Simultaneous solidification and in situ crystallization (or partial crystallization) of droplets within the drying chamber are commonly encountered in the spray drying of pharmaceuticals. The crystallinity developed will determine the functionality of the powder and its stability during storage. This review discusses strategies that can be used to control the in situ crystallization process. Areas covered: The premise of the strategies discussed focuses on the manipulation of the droplet drying rate relative to the timescale of crystallization. This can be undertaken by the control of the spray drying operation, by the use of volatile materials and by the inclusion of additives. Several predictive approaches for in situ crystallization control and new spray dryer configuration strategies are further discussed. Expert opinion: Most reports, hitherto, have focused on the crystallinity of the spray dried material or the development of crystallinity during storage. More mechanistic understanding of the in situ crystallization process during spray drying is required to guide product formulation trials. The key challenge will be in adapting the mechanistic approach to the myriad possible formulations in the pharmaceutical industry.

  6. Evaluation of Steadiness and Drop Size Distribution in Sprays Generated by Different Twin-Fluid Atomizers

    Directory of Open Access Journals (Sweden)

    Zaremba Matouš

    2015-01-01

    Full Text Available Twin-fluid atomizers underwent a significant development during the last few decades. They are common in many industrial applications such as fuel spraying, melt atomization and food processing. This paper is focused on the evaluation of four different twin-fluid atomizers. The aim is to compare the quality of sprays generated by various atomizers with similar dimensions and in the same operating regimes. A phase- Doppler anemometry (PDA and particle image velocimetry (PIV were used to measure spray characteristics such as velocity and size of the droplets. Measured data were used to compare droplet size distribution and to evaluate steadiness of the spray. Visualisations were made to support measured data and to clarify the principles of primary atomization and its influence on the spray.

  7. Evaluation of Steadiness and Drop Size Distribution in Sprays Generated by Different Twin-Fluid Atomizers

    Science.gov (United States)

    Zaremba, Matouš; Mlkvik, Marek; Malý, Milan; Jedelský, Jan; Jícha, Miroslav

    2015-05-01

    Twin-fluid atomizers underwent a significant development during the last few decades. They are common in many industrial applications such as fuel spraying, melt atomization and food processing. This paper is focused on the evaluation of four different twin-fluid atomizers. The aim is to compare the quality of sprays generated by various atomizers with similar dimensions and in the same operating regimes. A phase- Doppler anemometry (PDA) and particle image velocimetry (PIV) were used to measure spray characteristics such as velocity and size of the droplets. Measured data were used to compare droplet size distribution and to evaluate steadiness of the spray. Visualisations were made to support measured data and to clarify the principles of primary atomization and its influence on the spray.

  8. Spray deposition and spray drift in orchard spraying by multiple row sprayers

    NARCIS (Netherlands)

    Wenneker, M.; Zande, van de J.C.; Michielsen, J.G.P.; Stallinga, H.; Velde, van P.

    2016-01-01

    The evaluation of the latest data on spray drift in orchard spraying in the Netherlands, and measurements of surface water quality parameters show that the current legislation and measures are insufficient to protect the surface water. To meet the national and European objectives regarding surface

  9. Generation of 1:1 Carbamazepine:Nicotinamide cocrystals by spray drying.

    Science.gov (United States)

    Patil, Shashank P; Modi, Sameer R; Bansal, Arvind K

    2014-10-01

    The present study investigates the potential of spray drying as a technique for generation of pharmaceutical cocrystals. Carbamazepine-Nicotinamide cocrystal (CNC) was chosen as model cocrystal system for this study. Firstly, CNC was generated using liquid assisted grinding and used for generation of phase solubility diagram (PSD) and ternary phase diagram (TPD). Both PSD and TPD were carefully evaluated for phase behavior of CNC when equilibrated with solvent. The undersaturated region with respect to CNC, as depicted by TPD, was selected as target region to initiate cocrystallization experiments. Various points in this region, representative of different compositions of Carbamazepine, Nicotinamide and CNC, were selected and spray drying was carried out. The spray dried product was characterized for solid state properties and was compared with CNC generated by liquid assisted grinding. Spray drying successfully generated CNC of similar quality as those generated by liquid assisted grinding. Moreover, there was no significant impact of process variables on formation of CNC. Spray drying, owing to its simplicity and industrial scalability, can be a promising method for large scale cocrystal generation. Copyright © 2014 Elsevier B.V. All rights reserved.

  10. Investigations of combined used of cooling ponds with cooling towers or spraying systems

    International Nuclear Information System (INIS)

    Farforovsky, V.B.

    1990-01-01

    Based on a brief analysis of the methods of investigating cooling ponds, spraying systems and cooling towers, a conclusion is made that the direct modelling of the combined use of cooling systems listed cannot be realized. An approach to scale modelling of cooling ponds is proposed enabling all problems posed by the combined use of coolers to be solved. Emphasized is the importance of a proper choice of a scheme of including a cooler in a general water circulation system of thermal and nuclear power plants. A sequence of selecting a cooling tower of the type and spraying system of the size ensuring the specified temperature regime in a water circulation system is exemplified by the water system of the Ghorasal thermal power plant in Bangladesh

  11. Hot melt extrusion versus spray drying: hot melt extrusion degrades albendazole.

    Science.gov (United States)

    Hengsawas Surasarang, Soraya; Keen, Justin M; Huang, Siyuan; Zhang, Feng; McGinity, James W; Williams, Robert O

    2017-05-01

    The purpose of this study was to enhance the dissolution properties of albendazole (ABZ) by the use of amorphous solid dispersions. Phase diagrams of ABZ-polymer binary mixtures generated from Flory-Huggins theory were used to assess miscibility and processability. Forced degradation studies showed that ABZ degraded upon exposure to hydrogen peroxide and 1 N NaOH at 80 °C for 5 min, and the degradants were albendazole sulfoxide (ABZSX), and ABZ impurity A, respectively. ABZ was chemically stable following exposure to 1 N HCl at 80 °C for one hour. Thermal degradation profiles show that ABZ, with and without Kollidon ® VA 64, degraded at 180 °C and 140 °C, respectively, which indicated that ABZ could likely be processed by thermal processing. Following hot melt extrusion, ABZ degraded up to 97.4%, while the amorphous ABZ solid dispersion was successfully prepared by spray drying. Spray-dried ABZ formulations using various types of acids (methanesulfonic acid, sulfuric acid and hydrochloric acid) and polymers (Kollidon ® VA 64, Soluplus ® and Eudragit ® E PO) were studied. The spray-dried ABZ with methanesulfonic acid and Kollidon ® VA 64 substantially improved non-sink dissolution in acidic media as compared to bulk ABZ (8-fold), physical mixture of ABZ:Kollidon ® VA 64 (5.6-fold) and ABZ mesylate salt (1.6-fold). No degradation was observed in the spray-dried product for up to six months and less than 5% after one-year storage. In conclusion, amorphous ABZ solid dispersions in combination with an acid and polymer can be prepared by spray drying to enhance dissolution and shelf-stability, whereas those made by melt extrusion are degraded.

  12. Advanced Microstructural Study of Suspension Plasma Sprayed Hydroxyapatite Coatings

    Science.gov (United States)

    Podlesak, Harry; Pawlowski, Lech; D'Haese, Romain; Laureyns, Jacky; Lampke, Thomas; Bellayer, Severine

    2010-03-01

    Fine, home-synthesized, hydroxyapatite powder was formulated with water and alcohol to obtain a suspension used to plasma spray coatings onto a titanium substrate. The deposition process was optimized using statistical design of 2 n experiments with two variables: spray distance and electric power input to plasma. X-ray diffraction (XRD) was used to determine quantitatively the phase composition of obtained deposits. Raman microscopy and electron probe microanalysis (EPMA) enabled localization of the phases in different positions of the coating cross sections. Transmission electron microscopic (TEM) study associated with energy-dispersive x-ray spectroscopy (EDS) enabled visualization and analysis of a two-zone microstructure. One zone contained crystals of hydroxyapatite, tetracalcium phosphate, and a phase rich in calcium oxide. This zone included lamellas, usually observed in thermally sprayed coatings. The other zone contained fine hydroxyapatite grains that correspond to nanometric and submicrometric solids from the suspension that were agglomerated and sintered in the cold regions of plasma jet and on the substrate.

  13. Laser-assisted selective fusing of thermal sprayed Ni-based self-fluxing alloys by using high-power diode lasers

    Science.gov (United States)

    Chun, Eun-Joon; Kim, Min-Su; Nishikawa, Hiroshi; Park, Changkyoo; Suh, Jeong

    2018-03-01

    Fusing treatment of Ni-based self-fluxing alloys (Metco-16C and 1276F) was performed using high-power diode lasers to control the temperature of the substrate's surface in real time. The effects of the fusing treatment temperature on the microstructural change and hardness distribution were also investigated. For Metco-16C and 1276F, the macrostructural inhomogeneity (voids) within the thermal sprayed layer decreased considerably as the fusing temperature increased. For both self-fluxing alloys, the optimal temperature for fusing was approximately 1423 K (for Metco-16C) and 1373 K (for 1276F), both of which are within the solid state temperature range; these temperatures maximize the alloy hardness together with the macrostructural homogeneity. In this temperature range, the microstructure consists of a lamellar-structured matrix phase with fine (diode laser system.

  14. Applications of thermal energy storage to waste heat recovery in the food processing industry

    Science.gov (United States)

    Wojnar, F.; Lunberg, W. L.

    1980-01-01

    A study to assess the potential for waste heat recovery in the food industry and to evaluate prospective waste heat recovery system concepts employing thermal energy storage was conducted. The study found that the recovery of waste heat in canning facilities can be performed in significant quantities using systems involving thermal energy storage that are both practical and economical. A demonstration project is proposed to determine actual waste heat recovery costs and benefits and to encourage system implementation by the food industry.

  15. Physics and Industrial Development - Proceedings of the 2nd International Conference on Physics and Industrial Development

    Science.gov (United States)

    Gazzinelli, R.; Moreira, R. L.; Rodrigues, W. N.

    1997-04-01

    Fluorescence Detector in Biological Sciences and Chemistry * Quality Assessment of Solder Bonds of Printed Circuit Boards by Metallography * Observation of InAs Nanostructures on (100)-GaAs Substrate with Atomic Force Microscopy * In Situ Observations By Atomic Force Microscopy of Corrosion of An Aluminium Film in a Solution of HCl * Atomic Force Microscopy of Metallurgical Interactions in Integrated Circuit Contacts * Atomic Force Microscopy of Microcavity Semiconductor Devices * Characterization of the Emitted Air Particies By Steel Industries * A Comparative Study of the Anodic Behavior of Duplex Stainless Steels - Din 1.4462-In Synthetic Sea-water * Study of the Corrosion Resistance of Duplex Stainless Steels in Solutions Containing Chlorides, Compared with other Stainless Steels * Development of New Materials and Devices * Development of the Electronic Signal in Proportional Detectors * Development of a Portable Ultrasound Equipment for Backfat Evaluation of Live Pigs * Thermal Barrier Coatings by Plasma Spraying * Scaling in Fragmentation Phenomena * A Study of Sn:In2O3 (ITO)/CuInSe2 Heterojunction for Solar Energy Applications * Organising a Ceramic Powder Shape Electronic Database * Feasibility of a Mixer Using the Negative Resistance of a SNS Junction * Characteristics of v-SiO2 Melted in Refractory Metal Furnace * Lasers for Industrial and Medical Applications * Portable Cat Scanner Applied to Collapsible Soil Studies * Experiments with Slip Casting of Fine Ceramics and v-SiO2 * R2Fe17 Halides: The Birth of a Material for Potential Hard Magnetic Applications * Computerized System for Embryos Freezing Protocols Development * Ferroelectric Parent Materials as Possible High-Tc Superconductors: High Temperature Magnetic and Electric Properties of Modified BNN and SBN * CVD Diamond: Emerging Technology for Many Applications * Development of New Techniques and Processes * Application of Mechanical Relaxation Spectroscopy to the Development of Low Carbon Steels

  16. Design and performance of atomizing nozzles for spray calcination of high-level wastes

    International Nuclear Information System (INIS)

    Miller, F.A.; Stout, L.A.

    1981-05-01

    A key aspect of high-level liquid-waste spray calcination is waste-feed atomization by using air atomizing nozzles. Atomization substantially increases the heat transfer area of the waste solution, which enhances rapid drying. Experience from the spray-calciner operations has demonstrated that nozzle flow conditions that produce 70-μ median-volume-diameter or smaller spray droplets are required for small-scale spray calciners (drying capacity less than 80 L/h). For large-scale calciners (drying capacity greater than 300 L/h), nozzle flow conditions that produce 100-μ median-volume-diameter or smaller spray droplets are required. Mass flow ratios of 0.2 to 0.4, depending on nozzle size, are required for proper operation of internal-mix atomizing nozzles. Both internal-mix and external-mix nozzles have been tested at PNL. Due to the lower airflow requirements and fewer large droplets produced, the internal-mix nozzle has been chosen for primary development in the spray calciner program at PNL. Several nozzle air-cap materials for internal-mix nozzles have been tested for wear resistance. Results show that nozzle air caps of stainless steel and Cer-vit (a machineable glass ceramic) are suceptible to rapid wear by abrasive slurries, whereas air caps of alumina and reaction-bonded silicon nitride show only slow wear. Longer-term testing is necessary to determine more accurately the actual frequency of nozzle replacement. Atomizing nozzle air caps of alumina are subject to fracture from thermal shock, whereas air caps of silicon nitride and Cer-vit are not. Fractured nozzles are held in place by the air-cap retaining ring and continue to atomize satisfactorily. Therefore, fractures caused by thermal shocking do not necessarily result in nozzle failure

  17. Candidate thermal energy storage technologies for solar industrial process heat applications

    Science.gov (United States)

    Furman, E. R.

    1979-01-01

    A number of candidate thermal energy storage system elements were identified as having the potential for the successful application of solar industrial process heat. These elements which include storage media, containment and heat exchange are shown.

  18. 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.

  19. Sprayable Thermal Insulation for Cryogenic Tanks, Phase II

    Data.gov (United States)

    National Aeronautics and Space Administration — The Sprayable Thermal Insulation for Cryogenic Tanks (STICT) is a thermal management system applied by either an automated or manual spraying process with less...

  20. Experimental Studies of Spray Deposition on a Flat Surface in a Vacuum Environment

    Science.gov (United States)

    Golliher, Eric L.; Yao, S. C.

    2015-01-01

    Cooling of spacecraft components in the space environment is an on-going research effort. The electronics used in modern spacecraft are always changing and the heat flux is increasing. New, one-of-a-kind missions require new approaches to thermal control. In this research, under vacuum conditions, a pulsed water spray impinged on a small disc, while a high speed data acquisition system recorded the temperature histories of this copper disc. The water droplets froze quickly and accumulated on the disc as the spray continued. After the spray stopped, the frozen water that remained on the disc then sublimated into the vacuum environment and cooled the disc. This paper examines two important aspects of this process: 1) the difference in spray start up and shutdown in a vacuum environment versus in a standard atmospheric pressure environment, and 2) the water utilization efficiency in a vacuum environment due to the effects of drop trajectories and drop bouncing on the surface. Both phenomena play a role during spray cooling in a vacuum. This knowledge should help spacecraft designers plan for spray cooling as an option to cool spacecraft electronics, human metabolic generated heat, and heat from other sources.

  1. Ceramic Materials Selection of Fuel Crucibles based on Plasma Spray Coating for SFR

    Energy Technology Data Exchange (ETDEWEB)

    Song, Hoon; Kim, Jonghwan; Kim, Hyungtae; Ko, Youngmo; Woo, Yoonmyung; Oh, Seokjin; Kim, Kihwan; Lee, Chanbock [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2012-07-01

    The plasma-sprayed coating can provide the crucible with a denser, more friable coating layer, compared with the more friable coating layer formed by slurry-coating, which was used to prevent the interaction between melt and crucibles. Plasma-sprayed coatings are consolidated by mechanical interlocking of the molten particles impacting on the substrate and are dense by the heat applied by the plasma. The increased coating density is advantageous because it should not require frequent re coating and U-Zr melt penetration through the protective layer is more difficult in a dense coating than in a porous coating. In this study, we used Vacuum Plasma Spray method to investigate permanent coatings for re-usable crucibles for melting and casting of metallic fuel onto niobium substrates. Niobium was selected as a substrate because of its refractory nature and the coefficient of thermal expansion is similar to that of many of the candidate materials. After the HfC, ZrC, TiC, TaC, Y{sub 2}O{sub 3}, and 8% YSZ coatings were applied the resulting microstructure and chemical compositions was characterized to find the optimum process conditions for coating. Thermal plasma-sprayed coatings of refractory materials can be applied to develop a re-usable crucible coating for metallic fuel, such as the U-Zr alloy proposed for sodium cooled fast reactors.

  2. Indoor spray measurement of spray drift potential using a spray drift test bench : effect of drift-reducing nozzle types, spray boom height, nozzle spacing and forward speed

    NARCIS (Netherlands)

    Moreno Ruiz, J.R.

    2014-01-01

    In a series of indoor experiments spray drift potential was assessed when spraying over a spray drift testbench with two different driving speeds, 2m/s and 4m/s, two different spray boom heights, 30 cm and 50 cm, and two different nozzle spacing, 25 cm and 50 cm, for six different nozzle types. The

  3. Effect of whey protein agglomeration on spray dried microcapsules containing Saccharomyces boulardii.

    Science.gov (United States)

    Duongthingoc, Diep; George, Paul; Katopo, Lita; Gorczyca, Elizabeth; Kasapis, Stefan

    2013-12-01

    This work investigates the effect of whey protein agglomeration on the survivability of Saccharomyces boulardii within spray dried microcapsules. It attempts to go beyond phenomenological observations by establishing a relationship between physicochemical characteristics of the polymeric matrix and its effect on probiotic endurance upon spray drying. It is well known that this type of thermal shock has lethal consequences on the yeast cells. To avoid such undesirable outcome, we take advantage of the early agglomeration phenomenon observed for whey protein by adjusting the pH value of preparations close to isoelectric point (pH 4-5). During the subsequent process of spray drying, development of whey protein agglomerates induces formation of an early crust, and the protein in this molten globular state creates a cohesive network encapsulating the yeast cells. It appears that the early crust formation at a given sample pH and temperature regime during spray drying benefits the survivability of S. boulardii within microcapsules. Copyright © 2013. Published by Elsevier Ltd.

  4. Comparison of in vitro behavior of as-sprayed, alkaline-treated and collagen-treated bioceramic coatings obtained by high velocity oxy-fuel spray

    Energy Technology Data Exchange (ETDEWEB)

    Melero, H., E-mail: hortensia.melero.correas@gmail.com [Thermal Spray Centre, Universitat de Barcelona, Martí i Franqués, 1, 08028 Barcelona (Spain); Garcia-Giralt, N. [URFOA, IMIM (Institut Hospital del Mar d’Investigacions Mèdiques), RETICEF, Doctor Aiguader, 80, 08003 Barcelona (Spain); Fernández, J. [Thermal Spray Centre, Universitat de Barcelona, Martí i Franqués, 1, 08028 Barcelona (Spain); Díez-Pérez, A. [URFOA, IMIM (Institut Hospital del Mar d’Investigacions Mèdiques), RETICEF, Doctor Aiguader, 80, 08003 Barcelona (Spain); Servei de Medicina Interna, Hospital del Mar, Barcelona (Spain); Guilemany, J.M. [Thermal Spray Centre, Universitat de Barcelona, Martí i Franqués, 1, 08028 Barcelona (Spain)

    2014-07-01

    Hydroxyapatite (HAp)–TiO{sub 2} samples obtained using high velocity oxy-fuel spray (HVOF), that had previously shown excellent mechanical behaviour, were innovatively surface treated in order to improve their biological performance. The chosen treatments were an alkaline treatment to increase –OH radicals density on the surface (especially on TiO{sub 2} zones), and a collagen treatment to bond collagen fibrils to the –OH radicals present in hydroxyapatite. These coatings were analysed using scanning electron microscopy, energy-dispersive X-ray spectroscopy and infrared spectroscopy, and tested for human osteoblast biocompatibility and functionality. In the case of the alkaline treatment, although the –OH radicals density did not increase compared to the as-sprayed coatings, a nanostructured layer of sodium hydroxycarbonate precipitated on the surface, thus improving biological behaviour due to the nanoroughness effect. For the collagen-treated samples, collagen fibrils appeared well-adhered to the surface, and in vitro cell culture tests showed that these surfaces were much more conducive to cell adhesion and differentiation than the as-sprayed and alkaline-treated samples. These results pointed to collagen treatment as a very promising method to improve bioactivity of HAp–TiO{sub 2} thermal-sprayed coatings.

  5. Optimization of Arc-Sprayed Ni-Cr-Ti Coatings for High Temperature Corrosion Applications

    Science.gov (United States)

    Matthews, S.; Schweizer, M.

    2013-04-01

    High Cr content Ni-Cr-Ti arc-spray coatings have proven successful in resisting the high temperature sulfidizing conditions found in black liquor recovery boilers in the pulp and paper industry. The corrosion resistance of the coatings is dependent upon the coating composition, to form chromium sulfides and oxides to seal the coating, and on the coating microstructure. Selection of the arc-spray parameters influences the size, temperature and velocity of the molten droplets generated during spraying, which in turn dictates the coating composition and formation of the critical coating microstructural features—splat size, porosity and oxide content. Hence it is critical to optimize the arc-spray parameters in order to maximize the corrosion resistance of the coating. In this work the effect of key spray parameters (current, voltage, spray distance and gas atomizing pressure) on the coating splat thickness, porosity content, oxide content, microhardness, thickness, and surface profile were investigated using a full factorial design of experiment. Based on these results a set of oxidized, porous and optimized coatings were prepared and characterized in detail for follow-up corrosion testing.

  6. Processing line for industrial radiation-thermal synthesis of doped lithium ferrite powders

    Science.gov (United States)

    Surzhikov, A. P.; Galtseva, O. V.; Vasendina, E. A.; Vlasov, V. A.; Nikolaev, E. V.

    2016-02-01

    The paper considers the issues of industrial production of doped lithium ferrite powders by radiation-thermal method. A technological scheme of the processing line is suggested. The radiation-thermal technological scheme enables production of powders with technical characteristics close to the required ones under relatively low temperature annealing conditions without intermediate mixing. The optimal conditions of the radiation-thermal synthesis are achieved isothermally under irradiation by the electron beam with energy of 2.5 MeV in the temperature range of 700-750 0C within- 120 min.

  7. Total-Factor Energy Efficiency (TFEE Evaluation on Thermal Power Industry with DEA, Malmquist and Multiple Regression Techniques

    Directory of Open Access Journals (Sweden)

    Jin-Peng Liu

    2017-07-01

    Full Text Available Under the background of a new round of power market reform, realizing the goals of energy saving and emission reduction, reducing the coal consumption and ensuring the sustainable development are the key issues for thermal power industry. With the biggest economy and energy consumption scales in the world, China should promote the energy efficiency of thermal power industry to solve these problems. Therefore, from multiple perspectives, the factors influential to the energy efficiency of thermal power industry were identified. Based on the economic, social and environmental factors, a combination model with Data Envelopment Analysis (DEA and Malmquist index was constructed to evaluate the total-factor energy efficiency (TFEE in thermal power industry. With the empirical studies from national and provincial levels, the TFEE index can be factorized into the technical efficiency index (TECH, the technical progress index (TPCH, the pure efficiency index (PECH and the scale efficiency index (SECH. The analysis showed that the TFEE was mainly determined by TECH and PECH. Meanwhile, by panel data regression model, unit coal consumption, talents and government supervision were selected as important indexes to have positive effects on TFEE in thermal power industry. In addition, the negative indexes, such as energy price and installed capacity, were also analyzed to control their undesired effects. Finally, considering the analysis results, measures for improving energy efficiency of thermal power industry were discussed widely, such as strengthening technology research and design (R&D, enforcing pollutant and emission reduction, distributing capital and labor rationally and improving the government supervision. Relative study results and suggestions can provide references for Chinese government and enterprises to enhance the energy efficiency level.

  8. Design and optimization of coating structure for the thermal barrier coatings fabricated by atmospheric plasma spraying via finite element method

    Directory of Open Access Journals (Sweden)

    L. Wang

    2014-06-01

    Full Text Available The first prerequisite for fabricating the thermal barrier coatings (TBCs with excellent performance is to find an optimized coating structure with high thermal insulation effect and low residual stress. This paper discusses the design and optimization of a suitable coating structure for the TBCs prepared by atmospheric plasma spraying (APS using the finite element method. The design and optimization processes comply with the rules step by step, as the structure develops from a simple to a complex one. The research results indicate that the suitable thicknesses of the bond-coating and top-coating are 60–120 μm and 300–420 μm, respectively, for the single ceramic layer YSZ/NiCoCrAlY APS-TBC. The embedded interlayer (50 wt.%YSZ + 50 wt.%NiCoCrAlY will further reduce the residual stress without sacrificing the thermal insulation effect. The double ceramic layer was further considered which was based on the single ceramic layer TBC. The embedded interlayer and the upper additional ceramic layer will have a best match between the low residual stress and high thermal insulation effect. Finally, the optimized coating structure was obtained, i.e., the La2Ce2O7(LC/YSZ/Interlayer/NiCoCrAlY coating structure with appropriate layer thickness is the best choice. The effective thermal conductivity of this optimized LC/YSZ/IL/BL TBC is 13.2% lower than that of the typical single ceramic layer YSZ/BL TBC.

  9. Effect of the borax mass and pre-spray medium temperature on droplet size and velocity vector distributions of intermittently sprayed starchy solutions.

    Science.gov (United States)

    Naz, Muhammad Yasin; Sulaiman, Shaharin Anwar; Ariwahjoedi, Bambang

    2015-02-07

    Spray coating technology has demonstrated great potential in the slow release fertilizers industry. The better understanding of the key spray parameters benefits both the environment and low cost coating processes. The use of starch based materials to coat the slow release fertilizers is a new development. However, the hydraulic spray jet breakup of the non-Newtonian starchy solutions is a complex phenomenon and very little known. The aim of this research was to study the axial and radial distributions of the Sauter Mean Diameter (SMD) and velocity vectors in pulsing spray patterns of native and modified tapioca starch solutions. To meet the objective, high speed imaging and Phase Doppler Anemometry (PDA) techniques were employed to characterize the four compositions of the starch-urea-borax complex namely S0, S1, S2 and S3. The unheated solutions exhibited very high viscosities ranging from 2035 to 3030 cP. No jet breakup was seen at any stage of the nozzle operation at an injection pressure of 1-5 bar. However, at 80 °C temperature and 5 bar pressure, the viscosity was reduced to 455 to 638 cP and dense spray patterns emerged from the nozzle obscuring the PDA signals. The axial size distribution revealed a significant decrease in SMD along the spray centreline. The smallest axial SMD (51 to 79 μm) was noticed in S0 spray followed by S1, S2 and S3. Unlikely, the radial SMD in S0 spray did not vary significantly at any stage of the spray injection. This trend was attributed to the continuous growth of the surface wave instabilities on the native starch sheet. However, SMD obtained with S1, S2 and S3 varied appreciably along the radial direction. The mean velocity vector profiles followed the non-Gaussian distribution. The constant vector distributions were seen in the near nozzle regions, where the spray was in the phase of development. In far regions, the velocity vectors were poly-dispersed and a series of ups and downs were seen in the respective radial

  10. Adsorption thermal energy storage for cogeneration in industrial batch processes: Experiment, dynamic modeling and system analysis

    International Nuclear Information System (INIS)

    Schreiber, Heike; Graf, Stefan; Lanzerath, Franz; Bardow, André

    2015-01-01

    Adsorption thermal energy storage is investigated for heat supply with cogeneration in industrial batch processes. The feasibility of adsorption thermal energy storage is demonstrated with a lab-scale prototype. Based on these experiments, a dynamic model is developed and successfully calibrated to measurement data. Thereby, a reliable description of the dynamic behavior of the adsorption thermal energy storage unit is achieved. The model is used to study and benchmark the performance of adsorption thermal energy storage combined with cogeneration for batch process energy supply. As benchmark, we consider both a peak boiler and latent thermal energy storage based on a phase change material. Beer brewing is considered as an example of an industrial batch process. The study shows that adsorption thermal energy storage has the potential to increase energy efficiency significantly; primary energy consumption can be reduced by up to 25%. However, successful integration of adsorption thermal storage requires appropriate integration of low grade heat: Preferentially, low grade heat is available at times of discharging and in demand when charging the storage unit. Thus, adsorption thermal energy storage is most beneficial if applied to a batch process with heat demands on several temperature levels. - Highlights: • A highly efficient energy supply for industrial batch processes is presented. • Adsorption thermal energy storage (TES) is analyzed in experiment and simulation. • Adsorption TES can outperform both peak boilers and latent TES. • Performance of adsorption TES strongly depends on low grade heat temperature.

  11. TGO growth and crack propagation in a thermal barrier coating

    Energy Technology Data Exchange (ETDEWEB)

    Chen, W.R.; Archer, R.; Huang, X. [National Research Council of Canada, Ottawa, ON (Canada); Marple, B.R. [National Research Council of Canada, Boucherville, PQ (Canada)

    2008-07-01

    In thermal barrier coating (TBC) systems, a continuous alumina layer developed at the ceramic topcoat/bond coat interface helps to protect the metallic bond coat from further oxidation and improve the durability of the TBC system under service conditions. However, other oxides such as spinel and nickel oxide, formed in the oxidizing environment, are believed to be detrimental to TBC durability during service at high temperatures. It was shown that in an air-plasma-sprayed (APS) TBC system, post-spraying heat treatments in low-pressure oxygen environments could suppress the formation of the detrimental oxides by promoting the formation of an alumina layer at the ceramic topcoat/bond coat interface, leading to an improved TBC durability. This work presents the influence of post-spraying heat treatments in low-pressure oxygen environments on the oxidation behaviour and durability of a thermally sprayed TBC system with high-velocity oxy-fuel (HVOF)-produced Co-32Ni-21Cr-8Al-0.5Y (wt.%) bond coat. Oxidation behaviour of the TBCs is evaluated by examining their microstructural evolution, growth kinetics of the thermally grown oxide (TGO) layers, as well as crack propagation during low frequency thermal cycling at 1050 C. The relationship between the TGO growth and crack propagation will also be discussed. (orig.)

  12. Effects of spray parameters on the microstructure and property of Al2O3 coatings sprayed by a low power plasma torch with a novel hollow cathode

    International Nuclear Information System (INIS)

    Li Changjiu; Sun Bo

    2004-01-01

    Al 2 O 3 coating is deposited using a low power plasma torch with a novel hollow cathode through axial powder injection under a plasma power up to several kilowatts. The effects of the main processing parameters including plasma arc power, operating gas flow and spray distance on particle velocity during spraying, and the microstructure and property of the coating are investigated. The microstructure of the Al 2 O 3 coating is examined using optical microscopy and X-ray diffraction analysis. The property of the coating is characterized by dry rubber wheel abrasive wear test. The velocity of in-flight particle is measured using a velocity/temperature measurement system for spray particle based on thermal radiation from the particle. The dependency of the microstructure and property of the coating on spray particle conditions are examined by comparing the particle velocity, and microstructure and abrasive wear weight loss of subsequent coating deposited by low power plasma spray with those of the coating by conventional plasma spray at a power one order higher. X-ray diffraction analysis of the coating revealed that Al 2 O 3 particles during low power plasma spraying reach to sufficiently melting state prior to impact on the substrate with a velocity comparable to that in conventional plasma spraying. The experiment results have shown that processing parameters have significant influence on the particle conditions and performance of deposited Al 2 O 3 coating. The coating of comparable microstructure and properties to that deposited by conventional plasma spray can be produced under a power one order lower. From the present study, it can be suggested that a comparable coating can be produced despite plasma power level if the comparable particle velocity and molten state are achieved

  13. Vapor generator steam drum spray heat

    International Nuclear Information System (INIS)

    Fasnacht, F.A. Jr.

    1978-01-01

    A typical embodiment of the invention provides a combination feedwater and cooldown water spray head that is centrally disposed in the lower portion of a nuclear power plant steam drum. This structure not only discharges the feedwater in the hottest part of the steam drum, but also increases the time required for the feedwater to reach the steam drum shell, thereby further increasing the feedwater temperature before it contacts the shell surface, thus reducing thermal shock to the steam drum structure

  14. Spray Drying of High Sugar Content Foods: Improving of Product Yield and Powder Properties

    Directory of Open Access Journals (Sweden)

    Mehmet Koç

    2016-05-01

    Full Text Available Spray drying is the most preferred drying method to produce powdered food in the food industry and it is also widely used to convert sugar-rich liquid foods to a powder form. During and/or after spray drying process of sugar-rich products, undesirable situation was appeared such as stickiness, high moisture affinity (hygroscopicity and low solubility due to low molecular weight monosaccharides that found naturally in the structure. The basis of these problems was formed by low glass transition temperature of sugar-rich products. This review gives information about the difficulties in drying of sugar-rich products via spray dryer, actions need to be taken against these difficulties and drying of sugar-rich honey and fruit juices with spray drying method.

  15. Measurement of the non-thermal properties of a low pressure spraying plasma by electric and spectroscopic methods

    International Nuclear Information System (INIS)

    Jung, Yong Ho

    2003-02-01

    For the case of an atmospheric plasma, the local thermodynamic equilibrium (LTE) model can be applied to plasmas at a nozzle entrance and to those on the axis of the plasma flame, but it is not easy to justify applying the LTE model to off-center plasma and to a low-pressure spraying plasma. Although the energy distribution of the electrons is assumed to be Maxwellian for the most of spraying plasmas, the non-Maxwellian distribution is possible for the case of low-pressure spaying plasma and edge plasma of atmospheric spraying plasma. In this work, the non-Maxwellian distribution of electrons was measured by using an electric probe installed on the fast scanning probe system, and non-LTE effects were measured by using the optical emission spectroscopy system. Distribution of the electrons of a low-pressure spraying plasma is observed not as Maxwellian but as bi-Maxwellian by the measurement of the single probe. Bi-Maxwellian distribution appears in the edge of a low pressure spraying plasma and seems to be due to the reduction of the collisonality by the drastic variation of the plasma density. Non-LTE characteristics of a low-pressure spraying plasma can be deuced from the measured results of the optical emission spectroscopy and is analyzed by the collisional radiative equilibrium (CRE) model, where the Maxwellian and the non-Maxwellian distributions are assumed for comparison. For the electron temperature, the results from optical emission spectroscopy were similar to the results from the single probe (3∼5 % in error)

  16. Spray boom for selectively spraying a herbicidal composition onto dicots

    DEFF Research Database (Denmark)

    2012-01-01

    There is provided a method and spray boom for discriminating cereal crop (monocot) and weeds (dicots). The spray boom includes means for digitally recording an image of a selected area to be treated by a nozzle on the spray boom, whereby a plant material is identified based on a segmentation proc...

  17. Understanding Factors that Influence Protective Glove Use among Automotive Spray Painters

    Science.gov (United States)

    Ceballos, Diana; Reeb-Whitaker, Carolyn; Glazer, Patricia; Murphy-Robinson, Helen; Yost, Michael

    2017-01-01

    Dermal contact with isocyanate-based coatings may lead to systemic respiratory sensitization. The most common isocyanates found in sprayed automotive coatings are monomeric and oligomeric 1,6-hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI). Most spray painters use thin (4–5 mil) latex gloves that are not effective at preventing dermal exposures when spraying isocyanate paints. Personal interviews with collision repair industry personnel and focus groups with spray painters were held to characterize risk awareness, to examine perceptions and challenges concerning protective glove use and selection, and to generate ideas for protective glove use interventions. The most popular gloves among spray painters were thin (4–5 mil) and thick (14 mil) latex. We found that medium to thick (6–8 mil) nitrile were not always perceived as comfortable and were expected to be more expensive than thin (4–5 mil) latex gloves. Of concern is the users’ difficulty to distinguish between nitrile and latex gloves; latex gloves are now sold in different colors including blue, which has traditionally been associated with nitrile gloves. Even though spray painters were familiar with the health hazards related to working with isocyanate paints; most were not always aware that dermal exposure to isocyanates could contribute to the development of occupational asthma. There is a need for more research to identify dermal materials that are protective against sprayed automotive coatings. Automotive spray painters and their employers need to be educated in the selection and use of protective gloves, specifically on attributes such as glove material, color, and thickness. PMID:24215135

  18. Nanosilver conductive lines made by spray coating and aerosol jet printing technique

    Science.gov (United States)

    Krzeminski, Jakub; Wroblewski, Grzegorz; Dybowska-Sarapuk, Lucja; Lepak, Sandra; Jakubowska, Malgorzata

    2017-08-01

    Printing electronics even though the printing techniques are known for a long time, are gaining in importance. The possibility of making the electronic circuits on flexible, big-area substrates with efficient and cheap technology make it attractive for the electronic industry. Spray coating, as a one of printing methods, additionally provide the chance to print on the non-flat, complicated shaped substrates. Despite the spray coating is mostly used to print a big pads, it is reachable to spray the separate conductive lines both as a quickly-produced prototype and as a fully manufactured circuit. Our work presents the directly printed lines with spray coating technique. For the printing process self-made ink was used. We tested three different approaches to line formation and compare them in the terms of line edge, resistivity and thickness. Line profiles provide the information about the roughness and the line size. In the end we showed the aerosol jet printed meander to give an overview of this similar to spray coating but more sophisticated technique.

  19. New trends in the kitchen: propellants assessment of edible food aerosol sprays used on food.

    Science.gov (United States)

    Varlet, V; Smith, F; Augsburger, M

    2014-01-01

    New products available for food creations include a wide variety of "supposed" food grade aerosol sprays. However, the gas propellants used cannot be considered as safe. The different legislations available did not rule any maximum residue limits, even though these compounds have some limits when used for other food purposes. This study shows a preliminary monitoring of propane, butane and dimethyl ether residues, in cakes and chocolate after spraying, when these gases are used as propellants in food aerosol sprays. Release kinetics of propane, butane and dimethyl ether were measured over one day with sprayed food, left at room temperature or in the fridge after spraying. The alkanes and dimethyl ether analyses were performed by headspace-gas chromatography-mass spectrometry/thermal conductivity detection, using monodeuterated propane and butane generated in situ as internal standards. According to the obtained results and regardingthe extrapolations of the maximum residue limits existing for these substances, different delays should be respected according to the storage conditions and the gas propellant to consume safely the sprayed food. Copyright © 2013 Elsevier Ltd. All rights reserved.

  20. Mathematical modelling of heat absorption capacity of containment spray system in a 700 MWe PHWR

    International Nuclear Information System (INIS)

    Kota, Sampath Bharadwaj; Ali, Seik Mansoor; Balasubramaniyan, V.

    2015-01-01

    This paper presents a mathematical model for estimating the heat removal by containment spray system in the post Loss of Coolant Accident (LOCA) environment. The procedure involves firstly, the calculation of heat removal rates by droplets of spray dispersed in the air-steam mixture by an appropriate direct contact condensation model accounting for the presence of non-condensable gas (air). Parametric influence of droplet size, ambient pressure and temperature on heat flux is brought out. It was found that the heat flux is inversely proportional to the ambient pressure and diameter. A spray module was subsequently developed and incorporated into an in-house containment thermal hydraulics code. The pressure and temperature transients in a 700 MWe PHWR containment building following a Large Break LOCA was obtained using this code. The efficacy of the spray in condensing the steam is shown by comparing the transients with and without the operation of spray system. Parametric studies are also conducted with respect to droplet size and flow rate of water droplet spray. The details of the investigation are presented and discussed in this paper. (author)

  1. Reduction of spray pressure leads to less emission and better deposition of spray liquid at high-volume spraying in greenhouse tomato

    NARCIS (Netherlands)

    Os, van E.A.; Michielsen, J.M.G.P.; Corver, F.J.M.; Berg, van den J.V.; Bruins, M.A.; Porskamp, H.A.J.; Zande, van de J.C.

    2005-01-01

    In an experimental greenhouse, growing a tomato crop, it was investigated if a reduction in spray pressure could improve the spray result, while, simultaneously, emission to the ground could be reduced. Spray deposition on the leaves and the emission to the ground was evaluated at different spray

  2. Testing of Flame Sprayed Al2O3 Matrix Coatings Containing TiO2

    Directory of Open Access Journals (Sweden)

    Czupryński A.

    2016-09-01

    Full Text Available The paper presents the results of the properties of flame sprayed ceramic coatings using oxide ceramic materials coating of a powdered aluminium oxide (Al2O3 matrix with 3% titanium oxide (TiO2 applied to unalloyed S235JR grade structural steel. A primer consisting of a metallic Ni-Al-Mo based powder has been applied to plates with dimensions of 5×200×300 mm and front surfaces of Ø40×50 mm cylinders. Flame spraying of primer coating was made using a RotoTec 80 torch, and an external coating was made with a CastoDyn DS 8000 torch. Evaluation of the coating properties was conducted using metallographic testing, phase composition research, measurement of microhardness, substrate coating adhesion (acc. to EN 582:1996 standard, erosion wear resistance (acc. to ASTM G76-95 standard, and abrasive wear resistance (acc. to ASTM G65 standard and thermal impact. The testing performed has demonstrated that flame spraying with 97% Al2O3 powder containing 3% TiO2 performed in a range of parameters allows for obtaining high-quality ceramic coatings with thickness up to ca. 500 µm on a steel base. Spray coating possesses a structure consisting mainly of aluminium oxide and a small amount of NiAl10O16 and NiAl32O49 phases. The bonding primer coat sprayed with the Ni-Al-Mo powder to the steel substrate and external coating sprayed with the 97% Al2O3 powder with 3% TiO2 addition demonstrates mechanical bonding characteristics. The coating is characterized by a high adhesion to the base amounting to 6.5 MPa. Average hardness of the external coating is ca. 780 HV. The obtained coatings are characterized by high erosion and abrasive wear resistance and the resistance to effects of cyclic thermal shock.

  3. Microstructure Evolution and Impedance Spectroscopy Characterization of Thermal Barrier Coating Exposed to Gas Thermal-shock Environment

    Directory of Open Access Journals (Sweden)

    CHEN Wen-long

    2017-10-01

    Full Text Available Gas thermal-shock experiment of thermal barrier coatings (TBCs was carried out in air up to 1250℃ in order to simulate the thermal cycling process of the engine blades during the start heating and shut down cooling. The growth of thermal growth oxide (TGO layer and microstructure evolution of YSZ layer during thermal cycling process were investigated systematically by electrochemical impedance spectroscopy testing and SEM. The results show that the thickness of TGO layer increases when increasing the frequency of thermal cycling, and the impedance response of middle frequencies is more and more remarkable. Meanwhile, initiation and growth of micro-cracks occur in YSZ layer during the gas thermal-shock experiment. The corresponding impedance characterization of YSZ layer after 100 cycles is similar to the as-sprayed sample, indicating that micro-cracks in short time could heal since the YSZ micro-cracks sinter at high temperature. But after 300 cycles, the impedance spectroscopy of YSZ layer is quite different to the as-sprayed sample, with the corresponding impedance of particle-gap of YSZ more and more remarkable with the increase of the thermal-shock times, indicating that non-healing micro-cracks form in the YSZ layer, which may be the main reason to induce the failure of YSZ layer.

  4. Assessment of the thermal performance and energy conservation opportunities of a cement industry in Indonesia

    International Nuclear Information System (INIS)

    Rasul, M.G.; Widianto, W.; Mohanty, B.

    2005-01-01

    A simple model is presented to assess the thermal performance of a cement industry with an integrated view to improve the productivity of the plant. The model is developed on the basis of mass, energy and exergy balance and is applied to an existing Portland cement industry in Indonesia. The data obtained from industry show that the burning efficiency and the second law efficiency of the kiln system are 52.07% and 57.07% respectively. Cooler efficiency and heat recovery efficiency are 47.75% and 51.2% respectively. The unaccounted loss at kiln system was found to be 1.85% and that of cooler system was 19%. The high loss at cooler was mainly due to the convection and radiation losses from the uninsulated cooler. Irreversibility of the system was found to be about 20%, which is due to the conversion from chemical to thermal energy. The thermal energy conservation opportunities are identified. This study show that by replacing industrial diesel oil (IDO) with waste heat recovery from kiln and cooler exhaust for drying of raw meal and fuel, and preheating of combustion air, a cement industry in Indonesia can save about 1.264 x 10 5 US dollars per year

  5. Protection of Reinforced Concrete Structures of Waste Water Treatment Reservoirs with Stainless Steel Coating Using Arc Thermal Spraying Technique in Acidified Water

    Directory of Open Access Journals (Sweden)

    Han-Seung Lee

    2016-09-01

    Full Text Available Waste water treatment reservoirs are contaminated with many hazardous chemicals and acids. Reservoirs typically comprise concrete and reinforcement steel bars, and the main elements responsible for their deterioration are hazardous chemicals, acids, and ozone. Currently, a variety of techniques are being used to protect reservoirs from exposure to these elements. The most widely used techniques are stainless steel plating and polymeric coating. In this study, a technique known as arc thermal spraying was used. It is a more convenient and economical method for protecting both concrete and reinforcement steel bar from deterioration in waste water treatment reservoirs. In this study, 316L stainless steel coating was applied to a concrete surface, and different electrochemical experiments were performed to evaluate the performance of coatings in different acidic pH solutions. The coating generated from the arc thermal spraying process significantly protected the concrete surface from corrosion in acidic pH solutions, owing to the formation of a double layer capacitance—a mixture of Cr3+ enriched with Cr2O3 and Cr-hydroxide in inner and Fe3+ oxide on the outer layer of the coating. The formation of this passive film is defective owing to the non-homogeneous 316L stainless steel coating surface. In the pH 5 solution, the growth of a passive film is adequate due to the presence of un-dissociated water molecules in the aqueous sulfuric acid solution. The coated surface is sealed with alkyl epoxide, which acts as a barrier against the penetration of acidic solutions. This coating exhibits higher impedance values among the three studied acidic pH solutions.

  6. Measuring water ingestion from spray exposures.

    Science.gov (United States)

    Sinclair, Martha; Roddick, Felicity; Nguyen, Thang; O'Toole, Joanne; Leder, Karin

    2016-08-01

    Characterisation of exposure levels is an essential requirement of health risk assessment; however for water exposures other than drinking, few quantitative exposure data exist. Thus, regulatory agencies must use estimates to formulate policy on treatment requirements for non-potable recycled water. We adapted the use of the swimming pool chemical cyanuric acid as a tracer of recreational water ingestion to permit detection of small water volumes inadvertently ingested from spray exposures. By using solutions of 700-1000 mg/L cyanuric acid in an experimental spray exposure scenario, we were able to quantify inadvertent water ingestion in almost 70% of participants undertaking a 10 min car wash activity using a high pressure spray device. Skin absorption was demonstrated to be negligible under the experimental conditions, and the measured ingestion volumes ranged from 0.06 to 3.79 mL. This method could be applied to a range of non-potable water use activities to generate exposure data for risk assessment processes. The availability of such empirical measurements will provide greater assurance to regulatory agencies and industry that potential health risks from exposure to non-potable water supplies are well understood and adequately managed to protect public health. Copyright © 2016 Elsevier Ltd. All rights reserved.

  7. Cold Spray Deposition of Freestanding Inconel Samples and Comparative Analysis with Selective Laser Melting

    Science.gov (United States)

    Bagherifard, Sara; Roscioli, Gianluca; Zuccoli, Maria Vittoria; Hadi, Mehdi; D'Elia, Gaetano; Demir, Ali Gökhan; Previtali, Barbara; Kondás, Ján; Guagliano, Mario

    2017-10-01

    Cold spray offers the possibility of obtaining almost zero-porosity buildups with no theoretical limit to the thickness. Moreover, cold spray can eliminate particle melting, evaporation, crystallization, grain growth, unwanted oxidation, undesirable phases and thermally induced tensile residual stresses. Such characteristics can boost its potential to be used as an additive manufacturing technique. Indeed, deposition via cold spray is recently finding its path toward fabrication of freeform components since it can address the common challenges of powder-bed additive manufacturing techniques including major size constraints, deposition rate limitations and high process temperature. Herein, we prepared nickel-based superalloy Inconel 718 samples with cold spray technique and compared them with similar samples fabricated by selective laser melting method. The samples fabricated using both methods were characterized in terms of mechanical strength, microstructural and porosity characteristics, Vickers microhardness and residual stresses distribution. Different heat treatment cycles were applied to the cold-sprayed samples in order to enhance their mechanical characteristics. The obtained data confirm that cold spray technique can be used as a complementary additive manufacturing method for fabrication of high-quality freestanding components where higher deposition rate, larger final size and lower fabrication temperatures are desired.

  8. Optimasi Proses Spray Drying Pada Enkapsulasi Antosianin Ubi Ungu

    Directory of Open Access Journals (Sweden)

    Retno Yunilawati

    2018-04-01

    Full Text Available Teknologi proses spray drying banyak dilakukan pada enkapsulasi zat warna alam untuk aplikasi di industri. Pada penelitian ini dilakukan enkapsulasi antosianin ubi ungu dengan teknik spray drying. Tujuan dari penelitian ini adalah optimasi proses spray drying pada enkapsulasi antosianin ubi ungu. Optimasi proses dilakukan pada kondisi berbagai suhu inlet (150 °C sampai dengan 180 °C dan jumlah maltodekstrin sebagai carrier (5% sampai dengan 15%. Sebagai respon dilakukan pengukuran kadar air, absorbansi, dan kadar antosianin. Response Surface Methodology (RSM dengan metode Central Composite Design (CCD digunakan untuk analisis data optimasi. Hasil analisis menunjukkan bahwa suhu inlet dan persentase maltodekstrin berpengaruh secara signifikan terhadap kadar air, absorbansi, dan kadar antosianin total. Kondisi optimal didapatkan pada suhu inlet 166,96 °C dan maltodekstrin sebesar 5%. Pada kondisi ini dihasilkan serbuk antosianin ubi ungu dengan kadar air 4,79%; absorbansi 0,8827; dan kadar antosianin total 968,65 mg/kg.

  9. A central solar-industrial waste heat heating system with large scale borehole thermal storage

    NARCIS (Netherlands)

    Guo, F.; Yang, X.; Xu, L.; Torrens, I.; Hensen, J.L.M.

    2017-01-01

    In this paper, a new research of seasonal thermal storage is introduced. This study aims to maximize the utilization of renewable energy source and industrial waste heat (IWH) for urban district heating systems in both heating and non-heating seasons through the use of large-scale seasonal thermal

  10. Comparison of three control strategies for optimization of spray dryer operation

    DEFF Research Database (Denmark)

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

    2017-01-01

    controllers for operation of a four-stage spray dryer. The three controllers are a proportional-integral (PI) controller that is used in industrial practice for spray dryer operation, a linear model predictive controller with real-time optimization (MPC with RTO, MPC-RTO), and an economically optimizing...... nonlinear model predictive controller (E-NMPC). The MPC with RTO is based on the same linear state space model in the MPC and the RTO layer. The E-NMPC consists of a single optimization layer that uses a nonlinear system of ordinary differential equations for its predictions. The PI control strategy has...... the production rate, while minimizing the energy consumption, keeping the residual moisture content of the powder below a maximum limit, and avoiding that the powder sticks to the chamber walls. We use an industrially recorded disturbance scenario in order to produce realistic simulations and conclusions...

  11. Spray-Dried Cellulose Nanofibril-Reinforced Polypropylene Composites for Extrusion-Based Additive Manufacturing: Nonisothermal Crystallization Kinetics and Thermal Expansion

    Directory of Open Access Journals (Sweden)

    Lu Wang

    2018-02-01

    Full Text Available Isotactic polypropylene (iPP is a versatile polymer. It accounts for the second-largest polymer consumption worldwide. However, iPP is difficult to 3D print via extrusion-based processing. This is attributable to its rapid crystallization rate. In this study, spray-dried cellulose nanofibrils (SDCNF and maleic anhydride polypropylene (MAPP were investigated to reveal their effects on the nonisothermal crystallization kinetics and thermal expansion of iPP. SDCNF at 3 wt % and 30 wt % accelerated the crystallization rate of iPP, while SDCNF at 10 wt % retarded the crystallization rate by restricting crystal growth and moderately increasing the nucleation density of iPP. Additionally, adding MAPP into iPP/SDCNF composites accelerated the crystallization rate of iPP. The effective activation energy of iPP increased when more than 10 wt % SDCNF was added. Scanning electron microscopy and polarized light microscopy results indicated that high SDCNF content led to a reduced gap size among SDCNF, which hindered the iPP crystal growth. The coefficient of thermal expansion of iPP/SDCNF10% was 11.7% lower than the neat iPP. In summary, SDCNF, at 10 wt %, can be used to reduce the warping of iPP during extrusion-based additive manufacturing.

  12. 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.

  13. Characteristics of wetting temperature during spray cooling

    International Nuclear Information System (INIS)

    Mitsutake, Yuichi; Monde, Masanori; Hidaka, Shinichirou

    2006-01-01

    An experimental study has been done to elucidate the effects of mass flux and subcooling of liquid and thermal properties of solid on the wetting temperature during cooling of a hot block with spray. A water spray was impinged at one of the end surfaces of a cylindrical block initially heated at 400 or 500degC. The experimental condition was mass fluxes G=1-9 kg/m 2 s and degrees of subcooling ΔT sub =20, 50, 80 K. Three blocks of copper, brass and carbon steel were prepared. During spray cooling internal block temperature distribution and sputtering sound pressure level were recorded and the surface temperature and heat flux were evaluated with 2D inverse heat conducting analysis. Cooling process on cooling curves is divided into four regimes categorized by change in a flow situation and the sound level. The wetting temperature defined as the wall temperature at a minimum heat flux point was measured over an extensive experimental range. The wetting wall temperature was correlated well with the parameter of GΔT sub . The wetting wall temperature increases as GΔT sub increases and reaches a constant value depending on the material of the surface at higher region of GΔT sub . (author)

  14. Challenges in thermal design of industrial single-phase power inverter

    Directory of Open Access Journals (Sweden)

    Ninković Predrag

    2016-01-01

    Full Text Available This paper presents the influence of thermal aspects in design process of an industrial single-phase inverter, choice of its topology and components. Stringent design inputs like very high overload level, demand for natural cooling and very wide input voltage range have made conventional circuit topology inappropriate therefore asking for alternative solution. Different power losses calculations in semiconductors are performed and compared, outlining the guidelines how to choose the final topology. Some recommendations in power magnetic components design are given. Based on the final project, a 20kVA single-phase inverter for thermal power plant supervisory and control system is designed and commissioned.

  15. Numerical study of the spray impingement onto a solid wall

    OpenAIRE

    Rodrigues, Christian Michel Gomes

    2011-01-01

    The modelling of turbulent multiphase flows has been gathering high interest in the last decades in the scientific community due to its relevance in several applications, such as in industrial and environmental processes or for chemical and biomedical purposes. In fact, regarding the industrial applications, the impingement of liquid fuel sprays onto engine surfaces has become a subject of interest due to its influence on the mixture preparation prior to combustion and, consequently, engine p...

  16. 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

  17. Robust aggregator design for industrial thermal energy storages in smart grid

    DEFF Research Database (Denmark)

    Rahnama, Samira; Bendtsen, Jan Dimon; Stoustrup, Jakob

    2017-01-01

    Exploitation of flexible consumption in the future smart grid requires new actors and infrastructure. In this paper, we propose a hierarchical setup in which a central controller, a so-called “aggregator,” is responsible for managing the flexibilities of industrial thermal loads via a contract...

  18. In-situ observation of crack propagation in thermally sprayed coatings

    Czech Academy of Sciences Publication Activity Database

    Mušálek, R.; Kovářík, O.; Matějíček, Jiří

    2010-01-01

    Roč. 205, č. 7 (2010), s. 1807-1811 ISSN 0257-8972 R&D Projects: GA MŠk ME 901 Institutional research plan: CEZ:AV0Z20430508 Keywords : coating fracture * in-situ observation * alumina * stainless steel * plasma spraying Subject RIV: JL - Materials Fatigue, Friction Mechanics Impact factor: 2.135, year: 2010 http://www.sciencedirect.com/science?_ob=GatewayURL&_method=citationSearch&_uoikey=B6TVV-4YTFBCY-5&_origin=SDEMFRHTML&_version=1&md5=896533bcc989ebaa374ff209558fbcf1

  19. Simultaneous Polymerization and Polypeptide Particle Production via Reactive Spray-Drying.

    Science.gov (United States)

    Glavas, Lidija; Odelius, Karin; Albertsson, Ann-Christine

    2016-09-12

    A method for producing polypeptide particles via in situ polymerization of N-carboxyanhydrides during spray-drying has been developed. This method was enabled by the development of a fast and robust synthetic pathway to polypeptides using 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) as an initiator for the ring-opening polymerization of N-carboxyanhydrides. The polymerizations finished within 5 s and proved to be very tolerant toward impurities such as amino acid salts and water. The formed particles were prepared by mixing the monomer, N-carboxyanhydride of l-glutamic acid benzyl ester (NCAGlu) and the initiator (DBU) during the atomization process in the spray-dryer and were spherical with a size of ∼1 μm. This method combines two steps; making it a straightforward process that facilitates the production of polypeptide particles. Hence, it furthers the use of spray-drying and polypeptide particles in the pharmaceutical industry.

  20. Numerical investigation of micro-pore formation during substrate impact of molten droplets in spraying processes

    International Nuclear Information System (INIS)

    Liu, H.; Lavernia, E.J.; Rangel, R.H.; Muehlberger, E.; Sickinger, A.

    1994-01-01

    The porosity that is commonly associated with discrete droplet processes, such as plasma spraying and spray deposition, effectively degrades the quality of the sprayed material. In the present study, micro-pore formation during the deformation and interaction of molten tungsten droplets impinging onto a flat substrate in spraying processes is numerically investigated. The numerical simulation is accomplished on the basis of the full Navier-Stokes equations and the Volume Of Fluid (VOF) function by using a 2-domain method for the thermal field and solidification problem and a two-phase flow continuum model for the flow problem with a growing solid layer. The possible mechanisms governing the formation of micro-pores are discussed. The effects of important processing parameters, such as droplet impact velocity, droplet temperature, substrate temperature, and droplet viscosity, on the micro-pore formation are addressed

  1. The corrosion resistance of 140MXC, 530AS and 560AS coatings produced by thermal spraying

    Directory of Open Access Journals (Sweden)

    Edwin Alexis López Covaleda

    2013-01-01

    Full Text Available Three commercial materials were deposited using electric arc thermal spraying: 140MXC (with Fe, W, Cr, Nb, 530AS (AISI 1015 steel and 560AS (AISI 420 steel on AISI 4340 steel. The aim of this paper was to evaluate the best strategy for improving a coating-substrate system’s corrosion resistance, using the following combinations: homogeneous single coatings, bilayers consisting of 530AS or 560AS under 140MXC and 140MXC + 530AS and 140MXC + 560AS coatings deposited simultaneously. The coatings were characterised using optical microscopy, scanning electron microscopy and X-ray diffraction. Corrosion resistance was evaluated through potentiodynamic polarisation and hardness by using the Vickers test. Corrosion resistance depends on the amount of microstructure defects, the deposition strategy and the alloy elements. However, corrosion resistance was similar in single coatings of 140MXC and bilayers, having -630 V corrosion potential and 708 nA corrosion current. The details and corrosion mechanism of the coatings so produced are described in this paper.

  2. 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.

  3. 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.

  4. Metastable phases in yttrium oxide plasma spray deposits and their effect on coating properties

    International Nuclear Information System (INIS)

    Gourlaouen, V.; Schnedecker, G.; Boncoeur, M.; Lejus, A.M.; Collongues, R.

    1993-01-01

    Yttrium oxide coatings were obtained by plasma spray. Structural investigations on these deposits show that, due to the drastic conditions of this technique, a minor monoclinic B phase is formed in the neighborhood of the major cubic C form. The authors discuss here the influence of different plasma spray parameters on the amount of the B phase formed. They describe also the main properties of Y 2 O 3 B and C phases in these deposits such as structural characteristics, thermal stability and mechanical behavior

  5. Arrhenius activation energy of damage to catalase during spray-drying.

    Science.gov (United States)

    Schaefer, Joachim; Lee, Geoffrey

    2015-07-15

    The inactivation of catalase during spray-drying over a range of outlet gas temperatures could be closely represented by the Arrhenius equation. From this an activation energy for damage to the catalase could be calculated. The close fit to Arrhenius suggests that the thermally-induced part of inactivation of the catalase during the complex drying and particle-formation processes takes place at constant temperature. These processes are rapid compared with the residence time of the powder in the collecting vessel of the cyclone where dried catalase is exposed to a constant temperature equal to approximately the drying gas outlet temperature. A lower activation energy after spray drying with the ultrasonic nozzle was found than with the 2-fluid nozzle under otherwise identical spray drying conditions. It is feasible that the ultrasonic nozzle when mounted in the lid of the spray dryer heats up toward the drying gas inlet temperature much more that the air-cooled 2-fluid nozzle. Calculation of the Arrhenius activation energy also showed how the stabilizing efficacy of trehalose and mannitol on the catalase varies in strength across the range of drying gas inlet and outlet temperatures examined. Copyright © 2015 Elsevier B.V. All rights reserved.

  6. Investigating Tribological Characteristics of HVOF Sprayed AISI 316 Stainless Steel Coating by Pulsed Plasma Nitriding

    Science.gov (United States)

    Mindivan, H.

    2018-01-01

    In this study, surface modification of aluminum alloy using High-Velocity Oxygen Fuel (HVOF) thermal spray and pulsed plasma nitriding processes was investigated. AISI 316 stainless steel coating on 1050 aluminum alloy substrate by HVOF process was pulsed plasma nitrided at 793 K under 0.00025 MPa pressure for 43200 s in a gas mixture of 75 % N2 and 25 % H2. The results showed that the pulse plasma nitriding process produced a surface layer with CrN, iron nitrides (Fe3N, Fe4N) and expanded austenite (γN). The pulsed plasma nitrided HVOF-sprayed coating showed higher surface hardness, lower wear rate and coefficient of friction than the untreated HVOF-sprayed one.

  7. The design and scale-up of spray dried particle delivery systems.

    Science.gov (United States)

    Al-Khattawi, Ali; Bayly, Andrew; Phillips, Andrew; Wilson, David

    2018-01-01

    The rising demand for pharmaceutical particles with tailored physicochemical properties has opened new markets for spray drying especially for solubility enhancement, improving inhalation medicines and stabilization of biopharmaceuticals. Despite this, the spray drying literature is scattered and often does not address the principles underpinning robust development of pharmaceuticals. It is therefore necessary to present clearer picture of the field and highlight the factors influencing particle design and scale-up. Areas covered: The review presents a systematic analysis of the trends in development of particle delivery systems using spray drying. This is followed by exploring the mechanisms governing particle formation in the process stages. Particle design factors including those of equipment configurations and feed/process attributes were highlighted. Finally, the review summarises the current industrial approaches for upscaling pharmaceutical spray drying. Expert opinion: Spray drying provides the ability to design particles of the desired functionality. This greatly benefits the pharmaceutical sector especially as product specifications are becoming more encompassing and exacting. One of the biggest barriers to product translation remains one of scale-up/scale-down. A shift from trial and error approaches to model-based particle design helps to enhance control over product properties. To this end, process innovations and advanced manufacturing technologies are particularly welcomed.

  8. 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.

  9. Energy efficiency and pollution control for thermal units in the Egyptian industry

    International Nuclear Information System (INIS)

    Said Abdel-wahab; Ismail, W.M.

    1999-01-01

    Energy conservation and environmental protection project (ECEP) is a Usaid sponsored project. Its main objective is to promote energy conservation and pollution protection in the egyptian industry through a group of demonstrated projects. One of the implemented activities is the boilers and furnaces tune-up program, which aims to increase energy efficiency and reduce pollution. To achieve this objective. (ECEP) distributed 100 electronic portable exhaust gas analyzers to cover eight industrial sectors at six different geographical locations in egypt. These analyzers were used to measure the contents of exhaust gases to help operators tune up their equipment on regular basis. The result is that the firing thermal units operate at the highest possible combustion efficiency to reduce the amount of fuel consumption as well as pollution emissions. The analyzer used measures two types of temperature, five different stack gases, draft and smoke density. moreover it computes the efficiency of combustion as well as Co2 and excess air percentage. Thermal units that rested by these analyzers were consuming a huge amount of fossil fuel from different types. The average combustion efficiency for thermal units tested was improved by 14%, 15% and 28% for boilers, furnaces and diesel respectively

  10. Plasma spraying of hard magnetic coatings based on Sm-Co alloys

    International Nuclear Information System (INIS)

    KrasnoyarskiyRabochiy prospect, Krasnoyarsk, 660014 (Russian Federation))" data-affiliation=" (Siberian State Aerospace University named after Academician M.F. Reshetnev 31 KrasnoyarskiyRabochiy prospect, Krasnoyarsk, 660014 (Russian Federation))" >Saunin, V N; KrasnoyarskiyRabochiy prospect, Krasnoyarsk, 660014 (Russian Federation))" data-affiliation=" (Siberian State Aerospace University named after Academician M.F. Reshetnev 31 KrasnoyarskiyRabochiy prospect, Krasnoyarsk, 660014 (Russian Federation))" >Telegin, S V

    2015-01-01

    Our research is focused on the formation of hard magnetic coatings by plasma spraying an arc-melted Sm-Co powder. We have studied basic magnetic characteristics depending on the components ratio in the alloy. A sample with a 40 wt.% Sm coating exhibits the highest coercive force (63 kOe) as compared to near-to-zero coercive force in the starting powder. X-ray structure analysis of the starting alloy and the coating reveals that the amount of SmCo 5 phase in the sprayed coating increases occupying up to 2/3 of the sample. We have also studied temperature dependence of the coating and have been able to obtain plasma sprayed permanent magnets operating within the temperature range from -100 to +500 °C. The technique used does not involve any additional thermal treatment and allows a coating to be formed right on the magnetic conductor surface irrespective of the conductor geometry

  11. 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.

  12. Influence of process parameters on the cavitation resistance of arc thermally sprayed cobalt stainless steel; Influencia dos parametros de processo na resistencia a cavitacao de uma liga inoxidavel com cobalto aspergido a arco

    Energy Technology Data Exchange (ETDEWEB)

    Pukasiewicz, A. [Universidade Tecnologica Federal do Parana (UTFPR), Curitiba, PR (Brazil); Capra, A.R.; Chandelier, J. da L. [Instituto de Tecnologia para o Desenvolvimento (LACTEC), Curitiba, PR (Brazil)], e-mail: anderson.geraldo@lactec.org.br; Paredes, R.S.C. [Universidade Federal do Parana (UFPR), Curitiba, PR (Brazil). Dept. de Engenharia Mecanica

    2006-07-01

    In this work the influence of the arc thermal spraying process on the microstructure, oxide volumetric fraction, porosity and cavitation resistance was studied. The characterization was performed by optical and electrical microscopy, microhardness and ultrasonic cavitation test, ASTM G32-96 in AS895HY cobalt stainless steel. The increase in air pressure, 280 to 410 kPa, modified the oxide fraction from 17,2 +- 3,6% to 10,9 +-1,8%, in the samples without pre-heating treatment. With 120 deg C pre-heating treatment the oxide fraction increase from 24,1 +- 2,8% to 12,8 +- 1,9% when the air pressure was modified from 280 to 550 kPa. The mass loss in vibration-induced cavitation were 1,55 and 1,42 mg/h for 410 kPa AS895HY samples, with and without pre heating treatment, and 2,12 mg/h for 280 kPa samples without pre heating treatment. The results showed that the process parameters modified the microstructure and the cavitation resistance of the arc thermal spraying coatings. (author)

  13. 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

  14. Survey of active solar thermal collectors, industry and markets in Canada : final report

    International Nuclear Information System (INIS)

    2005-08-01

    A survey of the solar thermal industry in Canada was presented. The aim of the survey was to determine the size of the Canadian solar thermal industry and market. Data were used to derive thermal energy output as well as avoided greenhouse gas (GHG) emissions from solar thermal systems. The questionnaire was distributed to 268 representatives. Results revealed annual sales of 24.2, 26.4 and 37.5 MW TH in 2002, 2003, and 2004 respectively, which represented over 50 per cent growth in the operating base during the 3 year survey period. Sales of all collector types grew substantially during the 3 year period, and survey respondents anticipated 20 per cent growth in both 2005 and 2006. Approximately 10 per cent of all sales were exported during 2002-2004. Unglazed liquid collectors constituted the majority of collector types sold in Canada, almost all of which were sold into the residential sector for swimming pool heating. The majority of air collectors were sold into the industrial/commercial and institutional (I/CI) sectors for use in space heating. Sales of liquid glazed and evacuated tube collectors were split between the residential and I/CI sectors. Residential sales were primarily for domestic water heating. In 2004, 23 per cent of sales in the residential sector were for combination domestic hot water and space heating applications, an indication of strong growth. Results of the survey indicated that the solar thermal market in Quebec differed from other regions, with more than double the annual per capita revenue of any other region as a result of greater market penetration of unglazed air collectors. Calculations of the GHG emissions avoided due to active solar thermal systems were made based on historical estimates of solar thermal installations. A model was developed to calculate an operating base by collector type from 1979 to the present. The model showed that many of the systems installed during the 1980s were decommissioned during the 1990s, and that

  15. Establishing empirical relationships to predict porosity level and corrosion rate of atmospheric plasma-sprayed alumina coatings on AZ31B magnesium alloy

    Directory of Open Access Journals (Sweden)

    D. Thirumalaikumarasamy

    2014-06-01

    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. In this work, empirical relationships were developed to predict the porosity and corrosion rate of alumina coatings by incorporating independently controllable atmospheric plasma spray operational parameters (input power, stand-off distance and powder feed rate using response surface methodology (RSM. A central composite rotatable design with three factors and five levels was chosen to minimize the number of experimental conditions. Within the scope of the design space, the input power and the stand-off distance appeared to be the most significant two parameters affecting the responses among the three investigated process parameters. A linear regression relationship was also established between porosity and corrosion rate of the alumina coatings. Further, sensitivity analysis was carried out and compared with the relative impact of three process parameters on porosity level and corrosion rate to verify the measurement errors on the values of the uncertainty in estimated parameters.

  16. Use of cheese whey for biomass production and spray drying of probiotic lactobacilli.

    Science.gov (United States)

    Lavari, Luisina; Páez, Roxana; Cuatrin, Alejandra; Reinheimer, Jorge; Vinderola, Gabriel

    2014-08-01

    The double use of cheese whey (culture medium and thermoprotectant for spray drying of lactobacilli) was explored in this study for adding value to this wastewater. In-house formulated broth (similar to MRS) and dairy media (cheese and ricotta whey and whey permeate) were assessed for their capacity to produce biomass of Lactobacillus paracasei JP1, Lb. rhamnosus 64 and Lb. gasseri 37. Simultaneously, spray drying of cheese whey-starch solution (without lactobacilli cells) was optimised using surface response methodology. Cell suspensions of the lactobacilli, produced in in house-formulated broth, were spray-dried in cheese whey-starch solution and viability monitored throughout the storage of powders for 2 months. Lb. rhamnosus 64 was able to grow satisfactorily in at least two of the in-house formulated culture media and in the dairy media assessed. It also performed well in spray drying. The performance of the other strains was less satisfactory. The growth capacity, the resistance to spray drying in cheese whey-starch solution and the negligible lost in viability during the storage (2 months), makes Lb. rhamnosus 64 a promising candidate for further technological studies for developing a probiotic dehydrated culture for foods, utilising wastewaters of the dairy industry (as growth substrate and protectant) and spray drying (a low-cost widely-available technology).

  17. Thermal Shock Property of Al/Ni-ZrO2 Gradient Thermal Barrier Coatings

    Institute of Scientific and Technical Information of China (English)

    FANJin-juan; WANGQuan-sheng; ZHANGWei-fang

    2004-01-01

    Al/Ni-ZrO2 gradient thermal barrier coatings are made on aluminum substrate using plasma spraying method and one direction thermal shock properties of the coatings are studied in this paper. The results show that pores in coatings link to form cracks vertical to coating surface. They go through the whole ZrO2 coating once vertical cracks form. When thermal shock cycles increase, horizontal cracks that result in coatings failure forms in the coatings and interface. And vertical cracks delay appearance of horizontal cracks and enhance thermal shock property of coatings. Failure mechanisms of coating thermal shock are discussed using experiments and finite element method.

  18. An overview of high thermal conductive hot press forming die material development

    Directory of Open Access