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

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

International Nuclear Information System (INIS)

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

2011-01-01

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

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

Energy Technology Data Exchange (ETDEWEB)

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

2011-09-15

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

Fat properties during homogenization, spray-drying, and storage affect the physical properties of dairy powders.

Science.gov (United States)

Vignolles, M L; Lopez, C; Madec, M N; Ehrhardt, J J; Méjean, S; Schuck, P; Jeantet, R

2009-01-01

Changes in fat properties were studied before, during, and after the drying process (including during storage) to determine the consequences on powder physical properties. Several methods were combined to characterize changes in fat structure and thermal properties as well as the physical properties of powders. Emulsion droplet size and droplet aggregation depended on the homogenizing pressures and were also affected by spray atomization. Aggregation was usually greater after spray atomization, resulting in greater viscosities. These processes did not have the same consequences on the stability of fat in the powders. The quantification of free fat is a pertinent indicator of fat instability in the powders. Confocal laser scanning microscopy permitted the characterization of the structure of fat in situ in the powders. Powders from unhomogenized emulsions showed greater free fat content. Surface fat was always overrepresented, regardless of the composition and process parameters. Differential scanning calorimetry melting experiments showed that fat was partially crystallized in situ in the powders stored at 20 degrees C, and that it was unstable on a molecular scale. Thermal profiles were also related to the supramolecular structure of fat in the powder particle matrix. Powder physical properties depended on both composition and process conditions. The free fat content seemed to have a greater influence than surface fat on powder physical properties, except for wettability. This study clearly showed that an understanding of fat behavior is essential for controlling and improving the physical properties of fat-filled dairy powders and their overall quality.

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...

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)

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.

Mullite and Mullite/ZrO2-7wt.%Y2O3 Powders for Thermal Spraying of Environmental Barrier Coatings

Science.gov (United States)

Garcia, E.; Mesquita-Guimarães, J.; Miranzo, P.; Osendi, M. I.; Wang, Y.; Lima, R. S.; Moreau, C.

2010-01-01

Mullite and mullite/ZrO2-7wt.%Y2O3 coatings could be thought among the main protective layers for environment barrier coatings (EBCs) to protect Si-based substrates in future gas turbine engines. Considering that feedstock of the compound powder is not commercially available, two powder processing routes Spray Drying (SD) and Flame Spheroidization (FS) were implemented for both types of powders. For each method the particle size, the morphology, and microstructure of the powder particles was determined. In addition, the effect of the heat treatment on the powder crystallinity and microstructure of FS powders was also investigated. To evaluate their suitability as feedstock materials, the powders were plasma sprayed and their in-flight particle characteristics monitored for coatings production. The powder morphology was correlated to the in-flight particle characteristics and splat morphology to gain insight about into the influence of powder characteristics on the coating formation.

Influence of deposition and spray pattern of nasal powders on insulin bioavailability.

Science.gov (United States)

Pringels, E; Callens, C; Vervaet, C; Dumont, F; Slegers, G; Foreman, P; Remon, J P

2006-03-09

The influence of the deposition pattern and spray characteristics of nasal powder formulations on the insulin bioavailability was investigated in rabbits. The formulations were prepared by freeze drying a dispersion containing a physical mixture of drum dried waxy maize starch (DDWM)/Carbopol 974P (90/10, w/w) or a spray-dried mixture of Amioca starch/Carbopol 974P (25/75, w/w). The deposition in the nasal cavity of rabbits and in a silicone human nose model after actuation of three nasal delivery devices (Monopowder, Pfeiffer and experimental system) was compared and related to the insulin bioavailability. Posterior deposition of the powder formulation in the nasal cavity lowered the insulin bioavailability. To study the spray pattern, the shape and cross-section of the emitted powder cloud were analysed. It was concluded that the powder bulk density of the formulation influenced the spray pattern. Consequently, powders of different bulk density were prepared by changing the solid fraction of the freeze dried dispersion and by changing the freezing rate during freeze drying. After nasal delivery of these powder formulations no influence of the powder bulk density and of the spray pattern on the insulin bioavailability was observed.

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.

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.

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.

Nano crystalline high energy milled 5083 Al powder deposited using cold spray

Energy Technology Data Exchange (ETDEWEB)

Rokni, M.R., E-mail: mohammadreza.rokni@mines.sdsmt.edu [Department of Materials and Metallurgical Engineering, Advanced Materials Processing Center, South Dakota School of Mines and Technology (SDSM and T), SD (United States); Widener, C.A. [Department of Materials and Metallurgical Engineering, Advanced Materials Processing Center, South Dakota School of Mines and Technology (SDSM and T), SD (United States); Nardi, A.T. [United Technologies Research Center, East Hartford, CT (United States); Champagne, V.K. [U.S. Army Research Laboratory, Weapons and Materials Research Directorate, Aberdeen Proving Ground, MD (United States)

2014-06-01

Electron microscopy and nanoindentation are used to investigate the relationship between microstructure and nanohardness of a non-cryomilled, nanocrystalline 5083 Al alloy powder before and after being deposited by cold spray. Microstructural investigations observed the presence of nano grains in the powder microstructure, ranging from 20 to 80 nm and with a typical grain size of 40–50 nm. It was also revealed that the nanocrystalline structure of the powder is retained after cold spraying. As a result, almost no change in nanohardness was indicated between the powder and the particles interior in the cold sprayed layer. However, hardness was substantially higher in some regions in the cold sprayed layer, which was attributed to the particle–particle interfaces or other areas with very small nano grain size. The presence of some un-joined particle remnant lines was also found in the deposition and explained through Critical Velocity Ratio (CVR) of powder particles. Although cold spray is a high deformation process, there is little evidence of dislocations within the nanograins of the cold sprayed layer. The latter observation is rationalized through intragranular dislocation slip and recovery mechanisms.

A comparative physico-chemical study of chlorapatite and hydroxyapatite: from powders to plasma sprayed thin coatings.

Science.gov (United States)

Demnati, I; Grossin, D; Combes, C; Parco, M; Braceras, I; Rey, C

2012-10-01

Due to their bioactivity and osteoconductivity, hydroxyapatite (HA) plasma sprayed coatings have been widely developed for orthopedic uses. However, the thermodynamic instability of HA leads frequently to a mixture of phases which limit the functional durability of the coating. This study investigates the plasma spraying of chlorapatite (ClA) powder, known to melt without decomposition, onto pure titanium substrates using a low energy plasma spray system (LEPS). Pure ClA powder was prepared by a solid gas reaction at 950 °C and thermogravimetric analysis showed the good thermal stability of ClA powder in the range 30-1400 °C compared to that of the HA powder. Characterization of ClA coating showed that ClA had a very high crystalline ratio and no other crystalline phase was detected in the coating. HA and ClA coatings composition, microstructure and in vitro bioactivity potential were studied, compared and discussed. In vitro SBF test on HA and ClA coatings revealed the formation of a poorly crystalline apatite on the coating surface suggesting that we could expect a good osteoconductivity especially for the ClA coating prepared by the LEPS system.

Powder processing and spheroidizing with thermal inductively coupled plasma

International Nuclear Information System (INIS)

Nutsch, G.; Linke, P.; Zakharian, S.; Dzur, B.; Weiss, K.-H.

2001-01-01

Processing of advanced powder materials for the spraying industry is one of the most promising applications of the thermal RF inductively coupled plasma. By selecting the feedstock carefully and adjusting the RF plasma parameters, unique materials with high quality can be achieved. Powders injected in the hot plasma core emerge with modified shapes, morphology, crystal structure and chemical composition. Ceramic oxide powders such as Al 2 O 3 , ZrO 2 , SiO 2 are spheroidized with a high spheroidization rate. By using the RF induction plasma spheroidizing process tungsten melt carbide powders are obtained with a high spheroidization rate at high feeding rates by densification of agglomerated powders consisting of di-tungsten carbide and monocarbide with a definite composition. This kind of ball-like powders is particularly suited for wear resistant applications. (author)

Standardization of spray-dried powder of Piper betle hot water extract.

Science.gov (United States)

Arawwawala, Liyanage Dona Ashanthi Menuka; Hewageegana, Horadugoda Gamage Sujatha Pushpakanthi; Arambewela, Lakshmi Sriyani Rajapaksha; Ariyawansa, Hettiarachchige Sami

2011-04-01

The leaves of Piper betle Linn. (Family: Piperaceae) possess several bioactivities and are used in the Traditional Medical systems of Sri Lanka. The present investigation was carried out to standardize the spray-dried powder of P. betle by (a) determination of physicochemical parameters, presence or absence of heavy metals, and microbial contamination; (b) screening for phytochemicals; and (c) development of High Pressure Liquid Chromatography (HPLC) fingerprint and densitogram. The percentages of moisture content, total ash, acid insoluble ash, water-soluble ash, and ethanol extractable matter of spray-dried powder of P. betle were 2.2-2.5, 6.8-7.0, 0.003-0.005, 4.1-4.3, and 15.8-16.2, respectively. The concentrations of all the tested heavy metals were below the WHO acceptable limits and bacterial species, such as Escherichia coli, Salmonella spp, Staphylococcus aureus, and Pseudomonas aeroginosa were not present in the P. betle spray-dried powder. Phenolic compounds, tannins, flavonoids steroids, and alkaloids were found to be present in the spray-dried powder of P. betle and HPLC fingerprint and densitogram clearly demonstrated the proportional differences of these chemical constituents. In conclusion, the results obtained from this study can be used to standardize the spray-dried powder of P. betle.

Standardization of spray-dried powder of Piper betle hot water extract

Science.gov (United States)

Arawwawala, Liyanage Dona Ashanthi Menuka; Hewageegana, Horadugoda Gamage Sujatha Pushpakanthi; Arambewela, Lakshmi Sriyani Rajapaksha; Ariyawansa, Hettiarachchige Sami

2011-01-01

The leaves of Piper betle Linn. (Family: Piperaceae) possess several bioactivities and are used in the Traditional Medical systems of Sri Lanka. The present investigation was carried out to standardize the spray-dried powder of P. betle by (a) determination of physicochemical parameters, presence or absence of heavy metals, and microbial contamination; (b) screening for phytochemicals; and (c) development of High Pressure Liquid Chromatography (HPLC) fingerprint and densitogram. The percentages of moisture content, total ash, acid insoluble ash, water-soluble ash, and ethanol extractable matter of spray-dried powder of P. betle were 2.2-2.5, 6.8-7.0, 0.003-0.005, 4.1-4.3, and 15.8-16.2, respectively. The concentrations of all the tested heavy metals were below the WHO acceptable limits and bacterial species, such as Escherichia coli, Salmonella spp, Staphylococcus aureus, and Pseudomonas aeroginosa were not present in the P. betle spray-dried powder. Phenolic compounds, tannins, flavonoids steroids, and alkaloids were found to be present in the spray-dried powder of P. betle and HPLC fingerprint and densitogram clearly demonstrated the proportional differences of these chemical constituents. In conclusion, the results obtained from this study can be used to standardize the spray-dried powder of P. betle. PMID:21716924

Influence of Powder Injection Parameters in High-Pressure Cold Spray

Science.gov (United States)

Ozdemir, Ozan C.; Widener, Christian A.

2017-10-01

High-pressure cold spray systems are becoming widely accepted for use in the structural repair of surface defects of expensive machinery parts used in industrial and military equipment. The deposition quality of cold spray repairs is typically validated using coupon testing and through destructive analysis of mock-ups or first articles for a defined set of parameters. In order to provide a reliable repair, it is important to not only maintain the same processing parameters, but also to have optimum fixed parameters, such as the particle injection location. This study is intended to provide insight into the sensitivity of the way that the powder is injected upstream of supersonic nozzles in high-pressure cold spray systems and the effects of variations in injection parameters on the nature of the powder particle kinetics. Experimentally validated three-dimensional computational fluid dynamics (3D CFD) models are implemented to study the particle impact conditions for varying powder feeder tube size, powder feeder tube axial misalignment, and radial powder feeder injection location on the particle velocity and the deposition shape of aluminum alloy 6061. Outputs of the models are statistically analyzed to explore the shape of the spray plume distribution and resulting coating buildup.

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.

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...

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.

Powder compression mechanics of spray-dried lactose nanocomposites.

Science.gov (United States)

Hellrup, Joel; Nordström, Josefina; Mahlin, Denny

2017-02-25

The aim of this study was to investigate the structural impact of the nanofiller incorporation on the powder compression mechanics of spray-dried lactose. The lactose was co-spray-dried with three different nanofillers, that is, cellulose nanocrystals, sodium montmorillonite and fumed silica, which led to lower micron-sized nanocomposite particles with varying structure and morphology. The powder compression mechanics of the nanocomposites and physical mixtures of the neat spray-dried components were evaluated by a rational evaluation method with compression analysis as a tool, using the Kawakita equation and the Shapiro-Konopicky-Heckel equation. Particle rearrangement dominated the initial compression profiles due to the small particle size of the materials. The strong contribution of particle rearrangement in the materials with fumed silica continued throughout the whole compression profile, which prohibited an in-depth material characterization. However, the lactose/cellulose nanocrystals and the lactose/sodium montmorillonite nanocomposites demonstrated high yield pressure compared with the physical mixtures indicating increased particle hardness upon composite formation. This increase has likely to do with a reinforcement of the nanocomposite particles by skeleton formation of the nanoparticles. In summary, the rational evaluation of mechanical properties done by applying powder compression analysis proved to be a valuable tool for mechanical evaluation for this type of spray-dried composite materials, unless they demonstrate particle rearrangement throughout the whole compression profile. Copyright © 2016 Elsevier B.V. All rights reserved.

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.

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

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

Synthesis and characterization of Yb and Er based monosilicate powders and durability of plasma sprayed Yb2SiO5 coatings on C/C–SiC composites

International Nuclear Information System (INIS)

Khan, Zuhair S.; Zou Binglin; Huang Wenzhi; Fan Xizhi; Gu Lijian; Chen Xiaolong; Zeng Shuibing; Wang Chunjie; Cao Xueqiang

2012-01-01

Highlights: ► Ultra-pure rare-earth monosilicate powders based on Er and Yb have been fabricated by solid-state reaction. ► Spray-drying treatment results in powders with free flowing characteristics and rounded surface morphologies. ► CTEs are found to be 7.1 ppm/°C for Yb 2 SiO 5 and 7.5 ppm/°C for Er 2 SiO 5 . ► Plasma spraying has been used to deposit Yb 2 SiO 5 coatings on C/C–SiC substrate. ► Coatings remain strongly intact with the substrate on thermal cycling between ∼400 °C and 1500 °C in gas burner rig experiment. - Abstract: Rare-earth silicates such as Yb 2 SiO 5 and Er 2 SiO 5 are promising environmental barrier coating materials for ceramic matrix composites. In this work, Yb 2 SiO 5 and Er 2 SiO 5 ceramic powders have been synthesized by solid-state reaction using Yb 2 O 3 , Er 2 O 3 and SiO 2 as starting materials. The fabricated powders were subjected to spray drying treatment for subsequent synthesis of coatings by plasma spraying. The spray drying resulted in well-dispersed and spherical powder particles with good flowability. Analytical techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), thermogravimetry and differential scanning calorimetry (TGA/DSC) and dilatometry were applied to study the microstructural and thermal characteristics of the powders. Ultra-high purity monosilicate powders formed as a result of heating treatments at 1400 °C in a box furnace for 20 h. TG/DSC revealed the genesis temperatures of the silicate formation (low temperature polymorphs) and also showed that the solid-state reactions to form Yb and Er based monosilicates proceeded without any weight-loss in the tested temperature range. The values of coefficients of thermal expansion (CTE) of the fabricated compounds are found to be 7.1 ppm/°C for Yb 2 SiO 5 and 7.5 ppm/°C for Er 2 SiO 5 by dilatometric measurements. Besides these studies, coating formation by plasma spraying of spray-dried Yb 2 SiO 5 powders on the ceramic

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.

Processing of Polysulfone to Free Flowing Powder by Mechanical Milling and Spray Drying Techniques for Use in Selective Laser Sintering

Directory of Open Access Journals (Sweden)

Nicolas Mys

2016-04-01

Full Text Available Polysulfone (PSU has been processed into powder form by ball milling, rotor milling, and spray drying technique in an attempt to produce new materials for Selective Laser Sintering purposes. Both rotor milling and spray drying were adept to make spherical particles that can be used for this aim. Processing PSU pellets by rotor milling in a three-step process resulted in particles of 51.8 μm mean diameter, whereas spray drying could only manage a mean diameter of 26.1 μm. The resulting powders were characterized using Differential Scanning Calorimetry (DSC, Gel Permeation Chromatography (GPC and X-ray Diffraction measurements (XRD. DSC measurements revealed an influence of all processing techniques on the thermal behavior of the material. Glass transitions remained unaffected by spray drying and rotor milling, yet a clear shift was observed for ball milling, along with a large endothermic peak in the high temperature region. This was ascribed to the imparting of an orientation into the polymer chains due to the processing method and was confirmed by XRD measurements. Of all processed powder samples, the ball milled sample was unable to dissolve for GPC measurements, suggesting degradation by chain scission and subsequent crosslinking. Spray drying and rotor milling did not cause significant degradation.

Suspension plasma sprayed composite coating using amorphous powder feedstock

International Nuclear Information System (INIS)

Chen Dianying; Jordan, Eric H.; Gell, Maurice

2009-01-01

Al 2 O 3 -ZrO 2 composite coatings were deposited by the suspension plasma spray process using molecularly mixed amorphous powders. X-ray diffraction (XRD) analysis shows that the as-sprayed coating is composed of α-Al 2 O 3 and tetragonal ZrO 2 phases with grain sizes of 26 nm and 18 nm, respectively. The as-sprayed coating has 93% density with a hardness of 9.9 GPa. Heat treatment of the as-sprayed coating reveals that the Al 2 O 3 and ZrO 2 phases are homogeneously distributed in the composite coating

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.)

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

Manufacturing And High Temperature Oxidation Properties Of Electro-Sprayed Fe-24.5% Cr-5%Al Powder Porous Metal

Directory of Open Access Journals (Sweden)

Lee Kee-Ahn

2015-06-01

Full Text Available Fe-Cr-Al based Powder porous metals were manufactured using a new electro-spray process, and the microstructures and high-temperature oxidation properties were examined. The porous materials were obtained at different sintering temperatures (1350°C, 1400°C, 1450°C, and 1500°C and with different pore sizes (500 μm, 450 μm, and 200 μm. High-temperature oxidation experiments (TGA, Thermal Gravimetry Analysis were conducted for 24 hours at 1000°C in a 79% N2+ 21% O2, 100 mL/min. atmosphere. The Fe-Cr-Al powder porous metals manufactured through the electro-spray process showed more-excellent oxidation resistance as sintering temperature and pore size increased. In addition, the fact that the densities and surface areas of the abovementioned powder porous metals had the largest effects on the metal’s oxidation properties could be identified.

Barium strontium titanate powders prepared by spray pyrolysis

International Nuclear Information System (INIS)

Brankovic, G.; Brankovic, Z.; Goes, M.S.; Paiva-Santos, C.O.; Cilense, M.; Varela, J.A.; Longo, E.

2005-01-01

Ultasonic spray pyrolysis (SP) has been investigated for the production of the barium strontium titanate (BST) powders from the polymeric precursors. The processing parameters, such as flux of aerosol and temperature profile inside the furnace, were optimized to obtain single phase BST. The powders were characterized by the methods of X-ray diffraction analysis, SEM, EDS and TEM. The obtained powders were submicronic, consisting of spherical, polycrystalline particles, with internal nanocrystalline structure. Crystallite size of 10 nm, calculated using Rietveld refinement, is in a good agreement with results of HRTEM

Nasal deposition and clearance in man: comparison of a bidirectional powder device and a traditional liquid spray pump.

Science.gov (United States)

Djupesland, Per Gisle; Skretting, Arne

2012-10-01

Delivery of powder formulations to the nose is an attractive alternative for many drugs and vaccines. This study compared the regional nasal deposition and clearance patterns of lactose powder delivered by the OptiNose powder device (Opt-Powder; OptiNose US Inc., Yardley, PA, USA) to that of liquid aerosol administered via a traditional hand-actuated liquid spray pump (Rexam SP270, Rexam Pharma, France). The study was an open-label, crossover design in seven healthy subjects (five females, two males). The regional nasal deposition and clearance patterns of the Opt-Powder device were compared to a traditional liquid spray pump by dynamic gamma camera imaging after administration of either (99m)Tc-labeled lactose powder or liquid (99m)Tc- diethelyne triamine pentaacetic acid-aerosol. The gamma camera images were scaled and aligned with sagittal magnetic resonance images to identify nasal regions. Possible deposition of radiolabeled material in the lungs following both methods of delivery was also evaluated. Both powder and spray were distributed to all of the nasal regions. The Opt-Powder device, however, achieved significantly larger initial deposition in the upper and middle posterior regions of the nose than spray (upper posterior region; Opt-Powder 18.3% ± 11.5 vs. Spray 2.4% ± 1.8, pSpray 15.7% ± 13.8, pdeposition to the lower anterior and posterior regions for spray was three times higher compared to Opt-Powder (Opt-Powder 17.4% ± 24.5 vs. Spray 59.4% ± 18.2, pdeposition was observed. The initial deposition following powder delivery was significantly larger in the ciliated mucosa of the upper and posterior nasal regions, whereas less was deposited in the lower regions. Overall nasal clearance of powder was slower initially, but due to retention in anterior nonciliated regions the overall nasal clearance after spray was slower.

[Research about effect of spray drying conditions on hygroscopicity of spray dry powder of gubi compound's water extract and its mechanism].

Science.gov (United States)

Zong, Jie; Shao, Qi; Zhang, Hong-Qing; Pan, Yong-Lan; Zhu, Hua-Xu; Guo, Li-Wei

2014-02-01

To investigate moisture content and hygroscopicity of spray dry powder of Gubi compound's water extract obtained at different spray drying conditions and laying a foundation for spray drying process of Chinese herbal compound preparation. In the paper, on the basis of single-factor experiments, the author choose inlet temperature, liquid density, feed rate, air flow rate as investigated factors. The experimental absorption rate-time curve and scanning electron microscopy results showed that under different spray drying conditions the spray-dried powders have different morphology and different adsorption process. At different spray-dried conditions, the morphology and water content of the powder is different, these differences lead to differences in the adsorption process, at the appropriate inlet temperature and feed rate with a higher sample density and lower air flow rate, in the experimental system the optimum conditions is inlet temperature of 150 degrees C, feed density of 1.05 g x mL(-1), feed rate of 20 mL x min(-1) air flow rate of 30 m3 x h(-1).

Heat Treatment of Gas-Atomized Powders for Cold Spray Deposition

Science.gov (United States)

Story, William A.; Brewer, Luke N.

2018-02-01

This communication demonstrates the efficacy of heat treatment on the improved deposition characteristics of aluminum alloy powders. A novel furnace was constructed for solutionizing of feedstock powders in an inert atmosphere while avoiding sintering. This furnace design achieved sufficiently high cooling rates to limit re-precipitation during powder cooling. Microscopy showed homogenization of the powder particle microstructures after heat treatment. Cold spray deposition efficiency with heat-treated powders substantially increased for the alloys AA2024, AA6061, and AA7075.

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.

Development of granular powder manufacturing technology by spray pyrolysis

International Nuclear Information System (INIS)

Katoh, Yoshiyuki; Kawase, Keiichi; Takahashi, Yoshiharu; Todokoro, Akio

1996-01-01

For shortening of mixed-oxide (MOX) fuel manufacturing process and improvement in treatment of MOX-powder, we have been developing the granular powder production technology. Since the granular powders have excellent fluidity owing to the spherical shape, there is the possibility of modifying scattering and adcering of the powder in the process equipment. In this paper, spray pyrolysis process in adopted as the process of manufacturing the granular powders and the basic feasibility study has been carried out. The experimental results show that the manufactured granular powders have excellent fluidity and the diameter of the powders is controllable. Furthermore, high density pellets are formed by sintering the powders. Thus, it is clarified that this process is promising for the actual MOX fuel fabrication. (author)

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%

Preparation and in vivo absorption evaluation of spray dried powders containing salmon calcitonin loaded chitosan nanoparticles for pulmonary delivery

Science.gov (United States)

Sinsuebpol, Chutima; Chatchawalsaisin, Jittima; Kulvanich, Poj

2013-01-01

Purpose The aim of the present study was to prepare inhalable co-spray dried powders of salmon calcitonin loaded chitosan nanoparticles (sCT-CS-NPs) with mannitol and investigate pulmonary absorption in rats. Methods The sCT-CS-NPs were prepared by the ionic gelation method using sodium tripolyphosphate (TPP) as a cross-linking polyion. Inhalable dry powders were obtained by co-spray drying aqueous dispersion of sCT-CS-NPs and mannitol. sCT-CS-NPs co-spray dried powders were characterized with respect to morphology, particle size, powder density, aerodynamic diameter, protein integrity, in vitro release of sCT, and aerosolization. The plasmatic sCT levels following intratracheal administration of sCT-CS-NPs spray dried powders to the rats was also determined. Results sCT-CS-NPs were able to be incorporated into mannitol forming inhalable microparticles by the spray drying process. The sCT-CS-NPs/mannitol ratios and spray drying process affected the properties of the microparticles obtained. The conformation of the secondary structures of sCTs was affected by both mannitol content and spray dry inlet temperature. The sCT-CS-NPs were recovered after reconstitution of spray dried powders in an aqueous medium. The sCT release profile from spray dried powders was similar to that from sCT-CS-NPs. In vitro inhalation parameters measured by the Andersen cascade impactor indicated sCT-CS-NPs spray dried powders having promising aerodynamic properties for deposition in the deep lung. Determination of the plasmatic sCT levels following intratracheal administration to rats revealed that the inhalable sCT-CS NPs spray dried powders provided higher protein absorption compared to native sCT powders. Conclusion The sCT-CS-NPs with mannitol based spray dried powders were prepared to have appropriate aerodynamic properties for pulmonary delivery. The developed system was able to deliver sCT via a pulmonary route into the systemic circulation. PMID:24039397

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

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.

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

OpenAIRE

Sasidharan Pillai, Rahul

2015-01-01

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

Tribological properties of thermally sprayed TiAl-Al2O3 composite coating

Science.gov (United States)

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

2009-08-01

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

Tribological properties of thermally sprayed TiAl-Al2O3 composite coating

International Nuclear Information System (INIS)

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

2009-01-01

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

The Production of a Stable Infliximab Powder: The Evaluation of Spray and Freeze-Drying for Production

Science.gov (United States)

Kanojia, Gaurav; Have, Rimko ten; Bakker, Arjen; Wagner, Koen; Frijlink, Henderik W.; Kersten, Gideon F. A.; Amorij, Jean-Pierre

2016-01-01

In prospect of developing an oral dosage form of Infliximab, for treatment of Crohn’s disease and rheumatoid arthritis, freeze-drying (vial vs Lyoguard trays) and spray-drying were investigated as production method for stable powders. Dextran and inulin were used in combination with sucrose as stabilizing excipients. The drying processes did not affect Infliximab in these formulations, i.e. both the physical integrity and biological activity (TNF binding) were retained. Accelerated stability studies (1 month at 60°C) showed that the TNF binding ability of Infliximab was conserved in the freeze-dried formulations, whereas the liquid counterpart lost all TNF binding. After thermal treatment, the dried formulations showed some chemical modification of the IgG in the dextran-sucrose formulation, probably due to Maillard reaction products. This study indicates that, with the appropriate formulation, both spray-drying and freeze-drying may be useful for (bulk) powder production of Infliximab. PMID:27706175

A comparison between spray drying and spray freeze drying to produce an influenza subunit vaccine powder for inhalation

NARCIS (Netherlands)

Saluja, V.; Amorij, J-P.; Kapteyn, J. C.; de Boer, A. H.; Frijlink, H. W.; Hinrichs, W. L. J.

2010-01-01

The aim of this study was to investigate two different processes to produce a stable influenza subunit vaccine powder for pulmonary immunization i.e. spray drying (SD) and spray freeze drying (SFD). The formulations were analyzed by proteolytic assay, single radial immunodiffusion assay (SRID),

Plasma spraying of beryllium and beryllium-aluminum-silver alloys

International Nuclear Information System (INIS)

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

1994-01-01

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

Plasma spraying of beryllium and beryllium-aluminum-silver alloys

International Nuclear Information System (INIS)

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

1993-01-01

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

Characterization of Ce0.9Gd0.1O1.95 powders synthesized by spray drying

DEFF Research Database (Denmark)

Blennow Tullmar, Peter; Chen, Weiwu; Lundberg, Mats

2009-01-01

Ce0.9Gd0.1O1.95 powders were synthesized by spray drying and successive calcinations. The phase purity, BET surface area, and particle morphology of as-sprayed and calcined powders were characterized. After calcination above 300 °C, the powders were single phase and showed a BET surface area of 68...

Physicochemical and Antioxidant Activities of Spray-dried Pitaya Fruit Powder

Science.gov (United States)

Li, Guopeng; Liu, Yangyang; Lin, Lijing; Li, Jihua

2018-01-01

Pitaya commonly known as dragon fruit is very popular in China due to its intense color, constituent minerals, vitamins, and antioxidant properties. In the present study, physiochemical properties and antioxidant activities of fruit powder from two pitaya cultivars (namely red flesh and white flesh) and fruit peel were observed. Compared with the fruit powder of fruit flesh, the fruit powder made from fruit peel showed a higher antioxidant activity. The current study provides insights to produce spray-dried pitaya fruit powders that could potentially be used as functional food ingredients in various food fields.

Direct synthesis of nano-sized glass powders with spherical shape by RF (radio frequency) thermal plasma

International Nuclear Information System (INIS)

Seo, J.H.; Kim, J.S.; Lee, M.Y.; Ju, W.T.; Nam, I.T.

2011-01-01

A new route for obtaining very small, spheroid glass powders is demonstrated using an RF (radio frequency) thermal plasma system. During the process, four kinds of chemicals, here SiO 2 , B 2 O 3 , BaCO 3 , and K 2 CO 3 , were mixed at pre-set weight ratios, spray-dried, calcined at 250 deg. C for 3 h, and crushed into fragments. Then, they were successfully reformed into nano-sized amorphous powders (< 200 nm) with spherical shape by injecting them along the centerline of an RF thermal plasma reactor at ∼ 24 kW. The as-synthesized powders show negligible (< 1%) composition changes when compared with the injected precursors of raw material compounds.

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.

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

Science.gov (United States)

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

2011-03-01

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

Manufacture of SOFC electrodes by wet powder spraying

Energy Technology Data Exchange (ETDEWEB)

Wilkenhoener, R.; Mallener, W.; Buchkremer, H.P. [Forschungszentrum Juelich GmbH (Germany)] [and others

1996-12-31

The reproducible and commercial manufacturing of electrodes with enhanced electrochemical performance is of central importance for a successful technical realization of Solid Oxide Fuel Cell (SOFC) systems. The route of electrode fabrication for the SOFC by Wet Powder Spraying (WPS) is presented. Stabilized suspensions of the powder materials for the electrodes were sprayed onto a substrate by employing a spray gun. After drying of the layers, binder removal and sintering are performed in one step. The major advantage of this process is its applicability for a large variety of materials and its flexibility with regard to layer shape and thickness. Above all, flat or curved substrates of any size can be coated, thus opening up the possibility of {open_quotes}up-scaling{close_quotes} SOFC technology. Electrodes with an enhanced electrochemical performance were developed by gradually optimizing the different process steps. For example an optimized SOFC cathode of the composition La{sub 0.65}Sr{sub 0.3}MnO{sub 3} with 40% 8YSZ showed a mean overpotential of about -50 mV at a current density of -0.8 A/cm{sup 2}, with a standard deviation amounting to 16 mV (950{degrees}C, air). Such optimized electrodes can be manufactured with a high degree of reproducibility, as a result of employing a computer-controlled X-Y system for moving the spray gun. Several hundred sintered composites, comprising the substrate anode and the electrolyte, of 100x 100 mm{sup 2} were coated with the cathode by WPS and used for stack integration. The largest manufactured electrodes were 240x240 mm{sup 2}, and data concerning their thickness homogeneity and electrochemical performance are given.

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.

Processamento de achocolatado de cupuaçu por spray-dryer Cupuassu chocolate drink powder processed by spray-dryer

Directory of Open Access Journals (Sweden)

Suzana Caetano da Silva Lannes

2003-03-01

Full Text Available O achocolatado de cupuaçu é uma mistura do pó de cupuaçu, açúcar, aroma e outros ingredientes constantes da formulação. Este produto formulado foi processado por spray-dryer, gerando um produto seco, pulverizado e instantaneizado. O achocolatado acrescido de água (concentrado passa pelo spray-dryer formando glóbulos de pequeno diâmetro que são arrastados por uma corrente de ar quente. A rápida evaporação de líquido permite manter baixa a temperatura do ar na secagem, não afetando o produto. O pó de cupuaçu não dispersa prontamente em água devido ao seu conteúdo de óleo. Conseqüentemente, necessita-se de uma forma desengordurada para se obter instantaneização. A secagem por spray-dryer reúne as melhores condições de rendimento técnico em comparação com outros processos. Obtiveram rendimentos de processo acima de 20% e a instantaneização completa do produto.Cupuassu chocolate drink powder is a mixture of cupuassu powder, sugar, flavour and other ingredients of formulation. The product was processed by spray-dryer, leading a dry, pulverized and instantised product. The chocolate drink powder with water (concentrated pass through spray-dryer forming small diameter globules that are arrested by a hot air stream. The rapid evaporation allows keeping low temperature at drying air, and no affecting the product. The process is a set of better conditions of technique and economical efficiency in comparison to other process. Cupuassu powder does not disperse readily in water owing to its oil content. Consequently, a form of cocoa with the oil removed is needed to produce an acceptably instant drink. The results obtained were satisfactory, due to the complete instantisation of the product after processing.

The effect of YBa2Cu3O7-x powder characteristics on thick coatings prepared by atmospheric plasma spraying

International Nuclear Information System (INIS)

Georgiopoulos, E.; Tsetsekou, A.

2000-01-01

The development of superconducting YBa 2 Cu 3 O 7-x plasma sprayed coatings on metal substrates can be very useful for applications such as targets for thin-film deposition techniques (sputtering, laser ablation, ion assisted deposition) or magnetic shielding, due to the brittle nature of bulk superconductors. The plasma spraying technique is very flexible and can be used for manufacturing components with a large variety of geometries. This technique requires the use of powders with good rheological characteristics. In this study, YBa 2 Cu 3 O 7-x powders were produced by using the conventional solid-state reaction route and also by spray drying a solution of nitrate precursors. Both powders, as well as mixtures of them, were plasma sprayed to develop coatings on stainless-steel substrates, with the aim of studying the effect of the feedstock powder characteristics on the coating properties. It was found that by optimizing the plasma spraying conditions, good quality coatings could be obtained. However, the powder morphology and homogeneity significantly affect the coating quality. More homogeneous powders lead to better results, the spray-dried powder being the best because of its enhanced rheological properties and good morphology. (author)

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

International Nuclear Information System (INIS)

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

2011-01-01

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

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.

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...

Combined control of morphology and polymorph in spray drying of mannitol for dry powder inhalation

Science.gov (United States)

Lyu, Feng; Liu, Jing J.; Zhang, Yang; Wang, Xue Z.

2017-06-01

The morphology and polymorphism of mannitol particles were controlled during spray drying with the aim of improving the aerosolization properties of inhalable dry powders. The obtained microparticles were characterized using scanning electron microscopy, infrared spectroscopy, differential scanning calorimetry, powder X-ray diffraction and inhaler testing with a next generation impactor. Mannitol particles of varied α-mannitol content and surface roughness were prepared via spray drying by manipulating the concentration of NH4HCO3 in the feed solution. The bubbles produced by NH4HCO3 led to the formation of spheroid particles with a rough surface. Further, the fine particle fraction was increased by the rough surface of carriers and the high α-mannitol content. Inhalable dry powders with a 29.1 ± 2.4% fine particle fraction were obtained by spray-drying using 5% mannitol (w/v)/2% NH4HCO3 (w/v) as the feed solution, proving that this technique is an effective method to engineer particles for dry powder inhalation.

Plasma spraying of Fe-Cr-Al alloy powder

Czech Academy of Sciences Publication Activity Database

Voleník, Karel; Leitner, J.; Kolman, Blahoslav Jan; Písačka, Jan; Schneeweiss, Oldřich

2008-01-01

Roč. 46, č. 1 (2008), s. 17-25 ISSN 0023-432X R&D Projects: GA AV ČR IAA1041404 Institutional research plan: CEZ:AV0Z20430508; CEZ:AV0Z20410507 Keywords : Fe-Cr-Al alloy powder * plasma spraying * oxidation * vaporization * composition changes Subject RIV: JK - Corrosion ; Surface Treatment of Materials Impact factor: 1.345, year: 2007

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

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

OpenAIRE

Mehmet Koç; Figen Kaymak-Ertekin

2016-01-01

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 transiti...

Spray Drying of Honey: The Effect of Drying Agents on Powder Properties

Directory of Open Access Journals (Sweden)

Samborska Katarzyna

2015-06-01

Full Text Available The aim of this study was to investigate the possibility of honey spray drying with addition of maltodextrin and gum Arabic as drying agents. The influence of the concentration of the solution subjected to drying, the type and content of the drying agents upon the physical properties of obtained powders was examined. An attempt was undertaken to obtain powder with a honey content of more than 50% d.b. Spray drying of multifloral honey with the addition of maltodextrin and gum Arabic was carried out at inlet air temperature of 180°C, feed rate of 1 mL/s and rotational speed of a disc atomizer of 39,000 rpm. The properties of obtained powders were quantified in terms of moisture content, bulk density, Hausner ratio, apparent density, hygroscopicity and wettability. Using gum Arabic it was possible to obtain a product with a higher content of honey (67% solids than in the case of maltodextrin (50% d.b.. However, the powders obtained with gum Arabic were characterised by worse physical properties: higher hygroscopicity and cohesion, and longer wetting time.

Characterisation of spray dried soy sauce powders made by adding crystalline carbohydrates to drying carrier.

Science.gov (United States)

Wang, Wei; Zhou, Weibiao

2015-02-01

This study aimed to reduce stickiness and caking of spray dried soy sauce powders by introducing a new crystalline structure into powder particles. To perform this task, soy sauce powders were formulated by using mixtures of cellulose and maltodextrin or mixtures of waxy starch and maltodextrin as drying carriers, with a fixed carrier addition rate of 30% (w/v) in the feed solution. The microstructure, crystallinity, solubility as well as stickiness and caking strength of all the different powders were analysed and compared. Incorporating crystalline carbohydrates in the drying carrier could significantly reduce the stickiness and caking strength of the powders when the ratio of crystalline carbohydrates to maltodextrin was above 1:5 and 1:2, respectively. X-ray Diffraction (XRD) results showed that adding cellulose or waxy starch could induce the crystallinity of powders. Differential Scanning Calorimetry (DSC) results demonstrated that the native starch added to the soy sauce powders did not fully gelatinize during spray drying. Copyright © 2014 Elsevier Ltd. All rights reserved.

Plasma sprayed samarium--cobalt permanent magnets

International Nuclear Information System (INIS)

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

1975-01-01

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

Plasma sprayed samarium--cobalt permanent magnets

International Nuclear Information System (INIS)

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

1975-01-01

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

Anti-inflammatory, antiallodynic effects and quantitative analysis of gallic acid in spray dried powders from Phyllanthus niruri leaves, stems, roots and whole plant

Directory of Open Access Journals (Sweden)

Angélica G. Couto

2012-11-01

Full Text Available The anti-inflammatory and antiallodynic effects of spray dried powders starting from leaves, stems, roots, the mixture of leaves and stems, as well as the whole plant aqueous solutions of Phyllanthus niruri L., Phyllanthaceae, were assessed. Gallic acid, used as chemical marker, was quantified by HPLC in the spray dried powders. Carrageenan-induced inflammatory and allodynic responses in the mouse paw were used as pharmacological models. Quantitative and qualitative differences among chemical composition of different herb parts were observed. The oral administration of leaves or leaves plus stems spray dried powders (100 mg/kg significantly inhibited the carrageenan-induced allodynic effect (42±5 and 54±3%, respectively. Additionally, the spray dried powders of leaves significantly reduced carrageenan-induced paw oedema (35±6%. The spray dried powders of roots, stems, or the mixture of leaves, stems and roots (100 mg/kg, p.o. did not exhibit antiallodynic or antioedematogenic effect in the same model. In conclusion, differences in the chemical composition of spray dried powders from P. niruri are reflected in their in vivo pharmacological actions. Despite of a direct relationship of anti-inflammatory and antiallodynic effects with the gallic acid content had been observed, especially in the spray dried powders of leaves, the use of spray dried powders of leaves plus stems showed to be more effective, suggesting a synergic effect between their constituents.

Anti-inflammatory, antiallodynic effects and quantitative analysis of gallic acid in spray dried powders from Phyllanthus niruri leaves, stems, roots and whole plant

Directory of Open Access Journals (Sweden)

Angélica G. Couto

2013-02-01

Full Text Available The anti-inflammatory and antiallodynic effects of spray dried powders starting from leaves, stems, roots, the mixture of leaves and stems, as well as the whole plant aqueous solutions of Phyllanthus niruri L., Phyllanthaceae, were assessed. Gallic acid, used as chemical marker, was quantified by HPLC in the spray dried powders. Carrageenan-induced inflammatory and allodynic responses in the mouse paw were used as pharmacological models. Quantitative and qualitative differences among chemical composition of different herb parts were observed. The oral administration of leaves or leaves plus stems spray dried powders (100 mg/kg significantly inhibited the carrageenan-induced allodynic effect (42±5 and 54±3%, respectively. Additionally, the spray dried powders of leaves significantly reduced carrageenan-induced paw oedema (35±6%. The spray dried powders of roots, stems, or the mixture of leaves, stems and roots (100 mg/kg, p.o. did not exhibit antiallodynic or antioedematogenic effect in the same model. In conclusion, differences in the chemical composition of spray dried powders from P. niruri are reflected in their in vivo pharmacological actions. Despite of a direct relationship of anti-inflammatory and antiallodynic effects with the gallic acid content had been observed, especially in the spray dried powders of leaves, the use of spray dried powders of leaves plus stems showed to be more effective, suggesting a synergic effect between their constituents.

Improvement of deposition efficiency and control of hardness for cold-sprayed coatings using high carbon steel/mild steel mixture powder

International Nuclear Information System (INIS)

Ogawa, Kazuhiro; Amao, Satoshi; Yokoyama, Nobuyuki; Ootaki, Kousuke

2011-01-01

In this study, in order to make high carbon steel coating by cold spray technique, spray conditions such as carrier gas temperature and pressure etc. were investigated. And also, in order to improve deposition efficiency and control coating hardness of cold-sprayed high carbon steel, high carbon and mild steel mixed powder and its mechanical milled powder were developed and were optimized. By using the cold-spray technique, particle deposition of a high carbon steel was successful. Moreover, by applying mixed and mechanical milled powders, the porosity ratio was decreased and deposition efficiency was improved. Furthermore, using these powders, it is possible to control the hardness value. Especially, when using mechanical milled powder, it is very difficult to identify the interface between the coating and the substrate. The bonding between the coating and the substrate is thus considered to be excellent. (author)

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

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

Production of spray-dried honey jackfruit (Artocarpus heterophyllus) powder from enzymatic liquefied puree.

Science.gov (United States)

Wong, Chen Wai; Tan, Hong Hock

2017-02-01

This paper presents the enzymatic liquefaction process for honey jackfruit optimized with Pectinex ® Ultra SP-L and Celluclast ® 1.5 L individually or in combinations at different concentrations (0-2.5% v/w) and incubation time (0-2.5 h). Treatment with combinations of enzymes showed a greater effect in the reduction of viscosity (83.9-98.8%) as compared to single enzyme treatment (64.8-87.3%). The best parameter for enzymatic liquefaction was obtained with 1.0% (v/w) Pectinex ® Ultra SP-L and 0.5% (v/w) Celluclast ® 1.5 L for 1.5 h. Spray drying process was carried out using different inlet temperatures (140-180 °C) and maltodextrin concentrations (10-30% w/w). Results indicated that the spray-dried honey jackfruit powder produced at 160 °C with 30% w/w maltodextrin gave the highest product yield (66.90%) with good powder qualities in terms of water activity, solubility, moisture content, hygroscopicity, color and bulk density. The spray-dried honey jackfruit powder could potentially be incorporated into various food products.

Supercritical fluid molecular spray thin films and fine powders

Science.gov (United States)

Smith, Richard D.

1988-01-01

Solid films are deposited, or fine powders formed, by dissolving a solid material into a supercritical fluid solution at an elevated pressure and then rapidly expanding the solution through a short orifice into a region of relatively low pressure. This produces a molecular spray which is directed against a substrate to deposit a solid thin film thereon, or discharged into a collection chamber to collect a fine powder. The solvent is vaporized and pumped away. Solution pressure is varied to determine, together with flow rate, the rate of deposition and to control in part whether a film or powder is produced and the granularity of each. Solution temperature is varied in relation to formation of a two-phase system during expansion to control porosity of the film or powder. A wide variety of film textures and powder shapes are produced of both organic and inorganic compounds. Films are produced with regular textural feature dimensions of 1.0-2.0 .mu.m down to a range of 0.01 to 0.1 .mu.m. Powders are formed in very narrow size distributions, with average sizes in the range of 0.02 to 5 .mu.m.

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.  

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.

Computational Simulation on a Coaxial Substream Powder Feeding Laval Nozzle of Cold Spraying

Directory of Open Access Journals (Sweden)

Guosheng HUANG

2014-09-01

Full Text Available In this paper, a substream coaxial powder feeding nozzle was investigated for use in cold spraying. The relationship between nozzle structure and gas flow, the acceleration behavior of copper particles were examined by computational simulation method. Also, one of the nozzle was used to spray copper coating on steel substrate. The simulation results indicate that: the velocity of gas at the center of the nozzle is lower than that of the conventional nozzle. Powders are well restrained near the central line of the nozzle, no collision occurred between the nozzle wall and the powders. This type of nozzle with expansion 3.25 can successfully deposit copper coating on steel substrate, the copper coating has low porosity about 3.1 % – 3.8 % and high bonding strength about 23.5 MPa – 26.8 MPa. DOI: http://dx.doi.org/10.5755/j01.ms.20.3.4244

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.)

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.

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

Doped nanocrystalline ZnO powders for non-linear resistor applications by spray pyrolysis method.

Science.gov (United States)

Hembram, Kaliyan; Vijay, R; Rao, Y S; Rao, T N

2009-07-01

Homogeneous and doped nanocrystalline ZnO powders (30-200 nm) were synthesized by spray pyrolysis technique. The spray pyrolysed powders were calcined in the temperature range of 500-750 degrees C. Formation of insulating pyrochlore phase started from 700 degrees C during the calcination itself. The calcined powders were compacted and sintered at different temperatures ranging from 900-1200 degrees C for 0.5-4 h. The densification behavior was found to be dependent on calcination temperature of the nanopowder. The resulting discs were found to have density (5.34-5.62 g/cc) in the range of 96-99% of theoretical density. The breakdown voltage value obtained for the nanopowder based non-linear resistor is 10.3 kV/cm with low leakage current density of 0.7 microA/cm2 and coefficient of nonlinearity as high as 193. The activation energy for grain growth of the doped ZnO nanopowder powders is 449.4 +/- 15 kJ/mol.

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.

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.

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.)

Designing CAF-adjuvanted dry powder vaccines: spray drying preserves the adjuvant activity of CAF01.

Science.gov (United States)

Ingvarsson, Pall Thor; Schmidt, Signe Tandrup; Christensen, Dennis; Larsen, Niels Bent; Hinrichs, Wouter Leonardus Joseph; Andersen, Peter; Rantanen, Jukka; Nielsen, Hanne Mørck; Yang, Mingshi; Foged, Camilla

2013-05-10

Dry powder vaccine formulations are highly attractive due to improved storage stability and the possibility for particle engineering, as compared to liquid formulations. However, a prerequisite for formulating vaccines into dry formulations is that their physicochemical and adjuvant properties remain unchanged upon rehydration. Thus, we have identified and optimized the parameters of importance for the design of a spray dried powder formulation of the cationic liposomal adjuvant formulation 01 (CAF01) composed of dimethyldioctadecylammonium (DDA) bromide and trehalose 6,6'-dibehenate (TDB) via spray drying. The optimal excipient to stabilize CAF01 during spray drying and for the design of nanocomposite microparticles was identified among mannitol, lactose and trehalose. Trehalose and lactose were promising stabilizers with respect to preserving liposome size, as compared to mannitol. Trehalose and lactose were in the glassy state upon co-spray drying with the liposomes, whereas mannitol appeared crystalline, suggesting that the ability of the stabilizer to form a glassy matrix around the liposomes is one of the prerequisites for stabilization. Systematic studies on the effect of process parameters suggested that a fast drying rate is essential to avoid phase separation and lipid accumulation at the surface of the microparticles during spray drying. Finally, immunization studies in mice with CAF01 in combination with the tuberculosis antigen Ag85B-ESAT6-Rv2660c (H56) demonstrated that spray drying of CAF01 with trehalose under optimal processing conditions resulted in the preservation of the adjuvant activity in vivo. These data demonstrate the importance of liposome stabilization via optimization of formulation and processing conditions in the engineering of dry powder liposome formulations. Copyright © 2013 Elsevier B.V. All rights reserved.

Spray dried amikacin powder for inhalation in cystic fibrosis patients: a quality by design approach for product construction.

Science.gov (United States)

Belotti, Silvia; Rossi, Alessandra; Colombo, Paolo; Bettini, Ruggero; Rekkas, Dimitrios; Politis, Stavros; Colombo, Gaia; Balducci, Anna Giulia; Buttini, Francesca

2014-08-25

An amikacin product for convenient and compliant inhalation in cystic fibrosis patients was constructed by spray-drying in order to produce powders of pure drug having high respirability and flowability. An experimental design was applied as a statistical tool for the characterization of amikacin spray drying process, through the establishment of mathematical relationships between six Critical Quality Attributes (CQAs) of the finished product and five Critical Process Parameters (CPPs). The surface-active excipient, PEG-32 stearate, studied for particle engineering, in general did not benefit the CQAs of the spray dried powders for inhalation. The spray drying feed solution required the inclusion of 10% (v/v) ethanol in order to reach the desired aerodynamic performance of powders. All desirable function solutions indicated that the favourable concentration of amikacin in the feed solution had to be kept at 1% w/v level. It was found that when the feed rate of the sprayed solution was raised, an increase in the drying temperature to the maximum value (160 °C) was required to maintain good powder respirability. Finally, the increase in drying temperature always led to an evident increase in emitted dose (ED) without affecting the desirable fine particle dose (FPD) values. The application of the experimental design enabled us to obtain amikacin powders with both ED and FPD, well above the regulatory and scientific references. The finished product contained only the active ingredient, which keeps low the mass to inhale for dose requirement. Copyright © 2014 Elsevier B.V. All rights reserved.

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.

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.

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.

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.

Cold Spraying of Armstrong Process Titanium Powder for Additive Manufacturing

Science.gov (United States)

MacDonald, D.; Fernández, R.; Delloro, F.; Jodoin, B.

2017-04-01

Titanium parts are ideally suited for aerospace applications due to their unique combination of high specific strength and excellent corrosion resistance. However, titanium as bulk material is expensive and challenging/costly to machine. Production of complex titanium parts through additive manufacturing looks promising, but there are still many barriers to overcome before reaching mainstream commercialization. The cold gas dynamic spraying process offers the potential for additive manufacturing of large titanium parts due to its reduced reactive environment, its simplicity to operate, and the high deposition rates it offers. A few challenges are to be addressed before the additive manufacturing potential of titanium by cold gas dynamic spraying can be reached. In particular, it is known that titanium is easy to deposit by cold gas dynamic spraying, but the deposits produced are usually porous when nitrogen is used as the carrier gas. In this work, a method to manufacture low-porosity titanium components at high deposition efficiencies is revealed. The components are produced by combining low-pressure cold spray using nitrogen as the carrier gas with low-cost titanium powder produced using the Armstrong process. The microstructure and mechanical properties of additive manufactured titanium components are investigated.

Tungsten oxide coatings deposited by plasma spray using powder and solution precursor for detection of nitrogen dioxide gas

Energy Technology Data Exchange (ETDEWEB)

Zhang, Chao, E-mail: zhangc@yzu.edu.cn [College of Mechanical Engineering, Yangzhou University, Yangzhou 225127 (China); Wang, Jie [College of Mechanical Engineering, Yangzhou University, Yangzhou 225127 (China); Geng, Xin [College of Mechanical Engineering, Yangzhou University, Yangzhou 225127 (China); College of Chemistry and Chemical Engineering, Yangzhou University, Yangzhou 225002 (China)

2016-05-25

Increasing attention has been paid on preparation methods for resistive-type gas sensors based on semiconductor metal oxides. In this work, tungsten oxide (WO{sub 3}) coatings were prepared on alumina substrates and used as gas sensitive layers. The coatings were deposited by atmospheric plasma spray using powder, solution precursor, or a combination of both. Tungsten oxide powder through a powder port and ammonium tungstate aqueous solution through a liquid port were injected into plasma stream respectively or together to deposit WO{sub 3} coatings. Phase structures in the coatings were characterized by X-ray diffraction analyzer. The field-emission scanning electron microscopy images confirmed that the coatings were in microstructure, nanostructure or micro-nanostructure. The sensing properties of the sensors based on the coatings exposed to 1 ppm nitrogen dioxide gas were characterized in a home-made instrument. Sensing properties of the coatings were compared and discussed. The influences of gas humidity and working temperature on the sensor responses were further studied. - Highlights: • Porous gas sensitive coatings were deposited by plasma spray using powder and solution precursor. • Crystallized WO{sub 3} were obtained through hybrid plasma spray plus a pre-conditioned step. • Plasma power had an important influence on coating microstructure. • The particle size of atmospheric plasma-sprayed microstructured coating was stable. • Solution precursor plasma-sprayed WO{sub 3} coatings had nanostructure and showed good responses to 1 ppm NO{sub 2}.

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

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.

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)

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.

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.

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.

Effect of Storage Temperature on the Stability of Spray Dried Bacteriophage Powders.

Science.gov (United States)

Leung, Sharon S Y; Parumasivam, Thaigarajan; Nguyen, An; Gengenbach, Thomas; Carter, Elizabeth A; Carrigy, Nicholas B; Wang, Hui; Vehring, Reinhard; Finlay, Warren H; Morales, Sandra; Britton, Warwick J; Kutter, Elizabeth; Chan, Hak-Kim

2018-02-24

This study aimed to assess the robustness of using a spray drying approach and formulation design in producing inhalable phage powders. Two types of Pseudomonas phages, PEV2 (Podovirus) and PEV40 (Myovirus) in two formulations containing different amounts of trehalose (70% and 60%) and leucine (30% and 40%) were studied. Most of the surface of the produced powders was found to be covered in crystalline leucine. The powders were stored at 4°C and 20 °C under vacuum. The phage stability and in vitro aerosol performance of the phage powders were examined on the day of production and after 1, 3 and 12 months of storage. A minor titer loss during production was observed for both phages (0.2 - 0.8 log 10 pfu/ml). The storage stability of the produced phage powders was found to be phage and formulation dependent. No further reduction in titer occurred for PEV2 powders stored at 4 °C across the study. The formulation containing 30% leucine maintained the viability of PEV2 at 20 °C, while the formulation containing 40% leucine gradually lost titer over time with a storage reduction of ∼0.9 log 10 pfu/ml measured after 12 months. In comparison, the PEV40 phage powders generally had a ∼ 0.5 log 10 pfu/ml loss upon storage regardless of temperature. When aerosolized, the total in vitro lung doses of PEV2 were of the order of 10 7 pfu, except the formulation containing 40% leucine stored at 20 °C which had a lower lung dose. The PEV40 powders also had lung doses of 10 6 - 10 7 pfu. The results demonstrate that spray dried Myoviridae and Podoviridae phage in a simple formulation of leucine and trehalose can be successfully stored for one year at 4 °C and 20 °C with vacuum packaging. Copyright © 2018. Published by Elsevier B.V.

Preparation of ultra-fine powders from polysaccharide-coated solid lipid nanoparticles and nanostructured lipid carriers by innovative nano spray drying technology.

Science.gov (United States)

Wang, Taoran; Hu, Qiaobin; Zhou, Mingyong; Xue, Jingyi; Luo, Yangchao

2016-09-10

In this study, five polysaccharides were applied as natural polymeric coating materials to prepare solid lipid nanoparticles (SLN) and nanostructure lipid carriers (NLC), and then the obtained lipid colloidal particles were transformed to solid powders by the innovative nano spray drying technology. The feasibility and suitability of this new technology to generate ultra-fine lipid powder particles were evaluated and the formulation was optimized. The spray dried SLN powder exhibited the aggregated and irregular shape and dimension, but small, uniform, well-separated spherical powder particles of was obtained from NLC. The optimal formulation of NLC was prepared by a 20-30% oleic acid content with carrageenan or pectin as coating material. Therefore, nano spray drying technology has a potential application to produce uniform, spherical, and sub-microscale lipid powder particles when the formulation of lipid delivery system is appropriately designed. Copyright © 2016 Elsevier B.V. All rights reserved.

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.

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.)

An analytical methodology to predict the coating characteristics of plasma-sprayed ceramic powders

International Nuclear Information System (INIS)

Varacalle, D.J. Jr.

1990-01-01

Experimental and analytical studies have been conducted at the Idaho National Engineering Laboratory (INEL) to investigate gas, particle, and coating dynamics in the plasma spray process. Nine experiments were conducted using a Taguchi statistical parametric approach. The thermal plasma produced by the commercial plasma spray torch and the related plasma/particle interaction were then numerically modeled from the cathode tip to varied standoff distances in the free plume for the nine experiments, which ranged in power from 28 to 43 kW. The flow and temperature fields in the plasma were solved using the governing conservation equations with suitable boundary conditions. This information was then used as boundary conditions to solve the plasma/particle interaction problem for the nine experiments. The particle dynamics (10- to 75-μm particles) for a yttria-stabilized zirconia powder were then simulated by computer. Particle morphology is discussed with respect to the changes in the process parameters. The predicted temperature and velocity of the zirconia particles were then used as initial conditions to a coating dynamics code. The code predicts the thickness and porosity of the zirconia coatings for the specific process parameters. The predicted coating characteristics exhibit reasonable correlation with the actual characteristics obtained from the Taguchi experimental studies. 12 refs., 7 figs., 6 tabs

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)

Supercritical fluid molecular spray film deposition and powder formation

Science.gov (United States)

Smith, Richard D.

1986-01-01

Solid films are deposited, or fine powders formed, by dissolving a solid material into a supercritical fluid solution at an elevated pressure and then rapidly expanding the solution through a short orifice into a region of relatively low pressure. This produces a molecular spray which is directed against a substrate to deposit a solid thin film thereon, or discharged into a collection chamber to collect a fine powder. Upon expansion and supersonic interaction with background gases in the low pressure region, any clusters of solvent are broken up and the solvent is vaporized and pumped away. Solute concentration in the solution is varied primarily by varying solution pressure to determine, together with flow rate, the rate of deposition and to control in part whether a film or powder is produced and the granularity of each. Solvent clustering and solute nucleation are controlled by manipulating the rate of expansion of the solution and the pressure of the lower pressure region. Solution and low pressure region temperatures are also controlled.

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)

Wear of Flame-Sprayed Ni-Cr-B-Si Powder Coating on Journal for Seal Contact

Directory of Open Access Journals (Sweden)

Hu Sheng-Yen

2016-01-01

Full Text Available Flame-sprayed techniques is used in this paper to coat Ni-Cr-B-Si powder on low-carbon steel or bearing steel materials of the journal surface. The wear tester is used to explore material properties of the binding capability, surface hardness, wear and friction within each layer depth. The normal force is applied in addition to the cladding layer by not only using bearing ball but also oil seal pieces, to explore rubber material of oil seal contact journal. In experiments to explore the material and processing conditions affect the microstructure and hardness of the cladding layer, and at the same hardness, surface roughness to affect the performance of the mill run.The results showed that spraying Ni-Cr-B-Si alloy powder in mild steel sheet to melt and run, cladding layer and the substrate has a uniform distribution of fine abrasive particles and binding effect, causing the substrate surface hardness (HRC about promotion 10 times. While, if sprayed Ni-Cr-B-Si alloy powder to steel panels bearing surface because the surface coated compact structure, can reduce the surface roughness and the coefficient of friction, and more improve the wear resistance of the cladding layer.

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

Stability to oxidation of spray-dried fish oil powder microencapsulated using milk ingredients

DEFF Research Database (Denmark)

Keogh, M.K.; O'Kennedy, B.T.; Kelly, J.

2001-01-01

Microencapsulation of fish oil was achieved by spray-drying homogenized emulsions of fish oil using 3 different types of casein as emulsifier and lactose as filler. As the degree of aggregation of the casein emulsifier increased, the vacuole volume of the microencapsulated powders decreased...

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.

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)

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.

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

Comparison of blueberry powder produced via foam-mat freeze-drying versus spray-drying: evaluation of foam and powder properties.

Science.gov (United States)

Darniadi, Sandi; Ho, Peter; Murray, Brent S

2018-03-01

Blueberry juice powder was developed via foam-mat freeze-drying (FMFD) and spray-drying (SD) via addition of maltodextrin (MD) and whey protein isolate (WPI) at weight ratios of MD/WPI = 0.4 to 3.2 (with a fixed solids content of 5 wt% for FMFD and 10 wt% for SD). Feed rates of 180 and 360 mL h -1 were tested in SD. The objective was to evaluate the effect of the drying methods and carrier agents on the physical properties of the corresponding blueberry powders and reconstituted products. Ratios of MD/WPI = 0.4, 1.0 and 1.6 produced highly stable foams most suitable for FMFD. FMFD gave high yields and low bulk density powders with flake-like particles of large size that were also dark purple with high red values. SD gave low powder recoveries. The powders had higher bulk density and faster rehydration times, consisting of smooth, spherical and smaller particles than in FMFD powders. The SD powders were bright purple but less red than FMFD powders. Solubility was greater than 95% for both FMFD and SD powders. The FMFD method is a feasible method of producing blueberry juice powder and gives products retaining more characteristics of the original juice than SD. © 2017 Society of Chemical Industry. © 2017 Society of Chemical Industry.

The influence of raw material, added emulsifying salt and spray drying on cheese powder structure and hydration properties

DEFF Research Database (Denmark)

Felix da Silva, Denise; Larsen, Flemming Hofmann; Hougaard, Anni Bygvrå

2017-01-01

The present work has evaluated how raw material, addition of emulsifying salts (ES) and drying technology affect particle characteristics, structure, and hydration of cheese powders. In this context the spray drying technology induced the strongest effect on morphology and swelling of cheese powder...

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)

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

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.

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.

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)

A study on the decontamination of insoles colonized by Trichophyton rubrum: effect of terbinafine spray powder 1% and terbinafine spray solution 1%.

Science.gov (United States)

Feuilhade de Chauvin, M

2012-07-01

Shoes worn with bare feet function as a fungal reservoir and lead to persistent dermatophytosis. This study was designed to evaluate two formulations of terbinafine (1% spray powder or solution) to treat the insoles of shoes colonized by skin scales infected with Trichophyton rubrum and to determine the contact time necessary to achieve decontamination. Infected skin scales weighing 0.5 g, taken from the feet of patients with confirmed T. rubrum infection, was dispersed onto insoles pre-moistened with sterile saline solution (to mimic perspiration). Three types of insole were tested (felt, latex, leather). After inoculation, insoles were placed separately in new cardboard boxes at ambient temperature, and re-humidified with sterile normal saline solution for 48 h before being treated; untreated insoles served as controls. Scales were scraped off at 48 h or 96 h, and dropped into tubes of Sabouraud agar, incubated at 27°C and examined at 3 and 6 weeks. Cultures from all control insoles showed numerous T. rubrum colonies. In contrast, cultures from all insoles treated with a single application of terbinafine 1% spray solution or powder, and taken after 48 h or 96 h contact with the product, remained sterile at 3 weeks and 6 weeks. This study demonstrated the successful treatment of insoles colonized by T. rubrum-infected skin scales. Terbinafine 1% spray solution and powder showed good efficacy; the dermatophyte could no longer be cultured 48 h after a single application of terbinafine. © 2011 The Author. Journal of the European Academy of Dermatology and Venereology © 2011 European Academy of Dermatology and Venereology.

Testing of Flame Sprayed Al2O3 Matrix Coatings Containing TiO2

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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.

Understanding plasma spraying process and characteristics of DC-arc plasma gun (PJ-100

Directory of Open Access Journals (Sweden)

Jovana Ružić

2012-12-01

Full Text Available The thermal spray processes are a group of coating processes used to apply metallic or non-metallic coatings. In these processes energy sources are used to heat the coating material (in the form of powder, wire, or rod form to a molten or semi-molten state and accelerated towards a prepared surface by either carrier gases or atomization jets. In plasma spraying process, the spraying material is generally in the form of powder and requires a carrier gas to feed the powder into the plasma jet, which is passing between the hot cathode and the cylindrical nozzle-shaped anode. The design of DC plasma gun (PJ - 100 is designed and manufactured in Serbia. Plasma spaying process, the powder injection with the heat, momentum and mass transfers between particles and plasma jet, and the latest developments related to the production of DC plasma gun are described in this article.

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

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

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

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

Design, characterization, and aerosolization of organic solution advanced spray-dried moxifloxacin and ofloxacin dipalmitoylphosphatidylcholine (DPPC) microparticulate/nanoparticulate powders for pulmonary inhalation aerosol delivery

Science.gov (United States)

Duan, Jinghua; Vogt, Frederick G; Li, Xiaojian; Hayes, Don; Mansour, Heidi M

2013-01-01

The aim of this study was to design and develop respirable antibiotics moxifloxacin (MOXI) hydrochloride and ofloxacin (OFLX) microparticles and nanoparticles, and multifunctional antibiotics particles with or without lung surfactant 1,2-dipalmitoyl-sn-glycero-3-phosphocholine (DPPC) for targeted dry powder inhalation delivery as a pulmonary nanomedicine. Particles were rationally designed and produced by advanced spray-drying particle engineering from an organic solution in closed mode (no water) from dilute solution. Scanning electron microscopy indicated that these particles had both optimal particle morphology and surface morphology, and the particle size distributions were suitable for pulmonary delivery. Comprehensive and systematic physicochemical characterization and in vitro aerosol dispersion performance revealed significant differences between these two fluoroquinolone antibiotics following spray drying as drug aerosols and as cospray-dried antibiotic drug: DPPC aerosols. Fourier transform infrared spectroscopy and confocal Raman microspectroscopy were employed to probe composition and interactions in the solid state. Spray-dried MOXI was rendered noncrystalline (amorphous) following organic solution advanced spray drying. This was in contrast to spray-dried OFLX, which retained partial crystallinity, as did OFLX:DPPC powders at certain compositions. Aerosol dispersion performance was conducted using inertial impaction with a dry powder inhaler device approved for human use. The present study demonstrates that the use of DPPC offers improved aerosol delivery of MOXI as cospray-dried microparticulate/nanoparticulate powders, whereas residual partial crystallinity influenced aerosol dispersion of OFLX and most of the compositions of OFLX:DPPC inhalation powders. PMID:24092972

Spray freeze drying to produce a stable Delta(9)-tetrahydrocannabinol containing inulin-based solid dispersion powder suitable for inhalation

NARCIS (Netherlands)

van Drooge, Dirk-Jan; Hinrichs, Wouter L J; Dickhoff, Bastiaan H J; Elli, Marco N A; Visser, Marinella R; Zijlstra, Gerrit S; Frijlink, Henderik W

2005-01-01

The purpose of this study is to investigate whether spray freeze drying produces an inhalable solid dispersion powder in which Delta(9)-tetrahydrocannabinol (THC) is stabilised. Solutions of THC and inulin in a mixture of tertiary butanol (TBA) and water were spray freeze dried. Drug loads varied

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.

PRELIMINARY RESULTS USING ANEW METHOD TO OPTIMIZE A SPRAY DRYER PROCESS FOR PRODUCING HIGH QUALITY MILK POWDER FROM COW, GOAT AND SHE-ASS MILK CONCENTRATES

Directory of Open Access Journals (Sweden)

Giuseppe Altieri

2008-12-01

Full Text Available As quality is a very important factor in milk powder produced by drying, the optimal process must protect both nutritional and sensorial properties. Although heat damage indices (namely the insolubility index (IINS, thermal damage (IDT, protein denaturation could be used to evaluate the correct processing of milk, they are very time-consuming. Hence a chemical marker, like vitamin C, is proposed for rapid assessment of the overall damage to the quality of the produced milk powder. Trials were carried out on milk concentrates from cow, goat and she-ass so as to optimize the process performance of the spray dryer, for each kind of milk, at three inlet temperatures (120, 150, 185 °C; the feed flow rate was set at 0.5 dm3/h with outlet air RH% in the range 10-40%; raw milk was concentrated using a low pressure evaporator until an average level of 23% dry matter was reached. As expected, the thermal damage of the milk powder increased as the inlet air temperature increased; the outlet powder RH% was 96-98% poorly correlated with the mass flow rate of the concentrate inlet. Moreover, the destruction kinetic of vitamin C was found highly correlated with the thermal damage to the milk powder. At 175 °C inlet air temperature the overall thermal treatment on the she-ass milk concentrate, which is very heat-sensitive due to its high lactose content, was “weak” (IDT<80 and the milk powder of “premium or extra” quality (IINS<1.25ml and lactic acid = 0.07% < 0.15% ADMI. The titratable acidity values are uncorrelated with the process air temperature but depend uniquely from the raw milk freshness.

Designing CAF-adjuvanted dry powder vaccines: Spray drying preserves the adjuvant activity of CAF01

DEFF Research Database (Denmark)

Ingvarsson, Pall Thor; Schmidt, Signe Tandrup; Christensen, Dennis

2013-01-01

spray drying. The optimal excipient to stabilize CAF01 during spray drying and for the design of nanocomposite microparticles was identified among mannitol, lactose and trehalose. Trehalose and lactose were promising stabilizers with respect to preserving liposome size, as compared to mannitol...... parameters suggested that a fast drying rate is essential to avoid phase separation and lipid accumulation at the surface of the microparticles during spray drying. Finally, immunization studies in mice with CAF01 in combination with the tuberculosis antigen Ag85B-ESAT6-Rv2660c (H56) demonstrated that spray...... drying of CAF01 with trehalose under optimal processing conditions resulted in the preservation of the adjuvant activity in vivo. These data demonstrate the importance of liposome stabilization via optimization of formulation and processing conditions in the engineering of dry powder liposome...

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

Oxide Dispersion Strengthened Iron Aluminide by CVD Coated Powders

Energy Technology Data Exchange (ETDEWEB)

Asit Biswas Andrew J. Sherman

2006-09-25

This I &I Category2 program developed chemical vapor deposition (CVD) of iron, aluminum and aluminum oxide coated iron powders and the availability of high temperature oxidation, corrosion and erosion resistant coating for future power generation equipment and can be used for retrofitting existing fossil-fired power plant equipment. This coating will provide enhanced life and performance of Coal-Fired Boilers components such as fire side corrosion on the outer diameter (OD) of the water wall and superheater tubing as well as on the inner diameter (ID) and OD of larger diameter headers. The program also developed a manufacturing route for readily available thermal spray powders for iron aluminide coating and fabrication of net shape component by powder metallurgy route using this CVD coated powders. This coating can also be applid on jet engine compressor blade and housing, industrial heat treating furnace fixtures, magnetic electronic parts, heating element, piping and tubing for fossil energy application and automotive application, chemical processing equipment , heat exchanger, and structural member of aircraft. The program also resulted in developing a new fabrication route of thermal spray coating and oxide dispersion strengthened (ODS) iron aluminide composites enabling more precise control over material microstructures.

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

Experience of high-nitrogenous steel powder application in repairs and surface hardening of responsible parts for power equipment by plasma spraying

Science.gov (United States)

Kolpakov, A. S.; Kardonina, N. I.

2016-02-01

The questions of the application of novel diffusion-alloying high-nitrogenous steel powders for repair and surface hardening of responsible parts of power equipment by plasma spraying are considered. The appropriateness of the method for operative repair of equipment and increasing its service life is justified. General data on the structure, properties, and manufacture of nitrogen-, aluminum-, and chromium-containing steel powders that are economically alloyed using diffusion are described. It is noted that the nitrogen release during the decomposition of iron nitrides, when heating, protects the powder particles from oxidation in the plasma jet. It is shown that the coating retains 50% of nitrogen that is contained in the powder. Plasma spraying modes for diffusion-alloying high-nitrogenous steel powders are given. The service properties of plasma coatings based on these powders are analyzed. It is shown that the high-nitrogenous steel powders to a nitrogen content of 8.9 wt % provide the necessary wear resistance and hardness of the coating and the strength of its adhesion to the substrate and corrosion resistance to typical aggressive media. It is noted that increasing the coating porosity promotes stress relaxation and increases its thickness being limited with respect to delamination conditions in comparison with dense coatings on retention of the low defectiveness of the interface and high adhesion to the substrate. The examples of the application of high-nitrogenous steel powders in power engineering during equipment repairs by service companies and overhaul subdivisions of heat power plants are given. It is noted that the plasma spraying of diffusion-alloyed high-nitrogenous steel powders is a unique opportunity to restore nitrided steel products.

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.

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

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.

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.

Thermal conductivity model for powdered materials under vacuum based on experimental studies

Directory of Open Access Journals (Sweden)

N. Sakatani

2017-01-01

Full Text Available The thermal conductivity of powdered media is characteristically very low in vacuum, and is effectively dependent on many parameters of their constituent particles and packing structure. Understanding of the heat transfer mechanism within powder layers in vacuum and theoretical modeling of their thermal conductivity are of great importance for several scientific and engineering problems. In this paper, we report the results of systematic thermal conductivity measurements of powdered media of varied particle size, porosity, and temperature under vacuum using glass beads as a model material. Based on the obtained experimental data, we investigated the heat transfer mechanism in powdered media in detail, and constructed a new theoretical thermal conductivity model for the vacuum condition. This model enables an absolute thermal conductivity to be calculated for a powder with the input of a set of powder parameters including particle size, porosity, temperature, and compressional stress or gravity, and vice versa. Our model is expected to be a competent tool for several scientific and engineering fields of study related to powders, such as the thermal infrared observation of air-less planetary bodies, thermal evolution of planetesimals, and performance of thermal insulators and heat storage powders.

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.

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

The Measurement of Thermal Conductivities of Silica and Carbon Black Powders at Different pressures by Thermal COnductivity Probe

Institute of Scientific and Technical Information of China (English)

X.G.Liang; X.S.Ge; 等

1992-01-01

This investigation was done to study the gas filled powder insulation and thermal conductivity probe for the measurent of thermal conductivity of powders.The mathematical analysis showed that the heat capacity of the probe itself and the thermal rsistance between the probe and powder must be considered .The authors developed a slender probe and measured the effective thermal conductivity of sillca and carbon black powders under a variety of conditions.

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.

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.

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

Directory of Open Access Journals (Sweden)

Raimonda Lukauskaitė

2012-12-01

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

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

Directory of Open Access Journals (Sweden)

Raimonda Lukauskaitė

2013-02-01

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

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

Influence of a powder feed rate on the properties of the plasma sprayed chromium carbide- 25% nickel chromium coating

Directory of Open Access Journals (Sweden)

Mihailo R. Mrdak

2014-04-01

Full Text Available Normal 0 false false false MicrosoftInternetExplorer4 The plasma spray process is a leading technology of powder depositing in the production of coatings widely used in the aerospace industry for the protection of new parts and for the repair of worn ones. Cermet 75Cr3C2 - 25Ni(Cr coatings based on Cr3C2 carbides are widely used to protect parts as they retain high values of hardness, strength and resistance to wear up to a temperature of 850°C. This paper discusses the influence of the parameters of the plasma spray deposition of 75Cr3C2 - 25Ni(Cr powder on the structure and mechanical properties of the coating. The powder is deposited using plasma spraying at atmospheric pressure (APS. The plasma gas is He, which is an inert gas and does not react with the powder; it produces dense plasma with lower heat content and less incorporated ambient air in the plasma jet thus reducing temperature decomposition and decarburization of Cr3C2 carbide.. In this study, three groups of coatings were deposited with three different powder feed rates of: 30, 45 and 60 g/min. The  coating with the best properties was deposited on the inlet flange parts of the turbo - jet engine TV2-117A to reduce the influence of vibrations and wear. The structures and the mechanical properties of 75Cr3C2 - 25Ni(Cr coatings are analyzed in accordance with the Pratt & Whitney standard. Studies have shown that powder feed rates have an important influence on the mechanical properties and structures of 75Cr3C2 - 25Ni(Cr coatings. 

Uniform-droplet spray forming

Energy Technology Data Exchange (ETDEWEB)

Blue, C.A.; Sikka, V.K. [Oak Ridge National Lab., TN (United States); Chun, Jung-Hoon [Massachusetts Institute of Technology, Cambridge, MA (United States); Ando, T. [Tufts Univ., Medford, MA (United States)

1997-04-01

The uniform-droplet process is a new method of liquid-metal atomization that results in single droplets that can be used to produce mono-size powders or sprayed-on to substrates to produce near-net shapes with tailored microstructure. The mono-sized powder-production capability of the uniform-droplet process also has the potential of permitting engineered powder blends to produce components of controlled porosity. Metal and alloy powders are commercially produced by at least three different methods: gas atomization, water atomization, and rotating disk. All three methods produce powders of a broad range in size with a very small yield of fine powders with single-sized droplets that can be used to produce mono-size powders or sprayed-on substrates to produce near-net shapes with tailored microstructures. The economical analysis has shown the process to have the potential of reducing capital cost by 50% and operating cost by 37.5% when applied to powder making. For the spray-forming process, a 25% savings is expected in both the capital and operating costs. The project is jointly carried out at Massachusetts Institute of Technology (MIT), Tuffs University, and Oak Ridge National Laboratory (ORNL). Preliminary interactions with both finished parts and powder producers have shown a strong interest in the uniform-droplet process. Systematic studies are being conducted to optimize the process parameters, understand the solidification of droplets and spray deposits, and develop a uniform-droplet-system (UDS) apparatus appropriate for processing engineering alloys.

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)

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

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.

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...

Synthesis and property of powders of oxide superconductor by the spray drying and the mist pyrolysis method

Energy Technology Data Exchange (ETDEWEB)

Awano, M.; Takagi, H.; Torii, Y.; Tsuzuki, A.; Murayama, N.; Ishii, E. (Government Industrial Research Inst., Nagoya (Japan)); Sudo, E. (Tokyo Kokyu Rozai Co. Ltd., Fukuoka (Japan))

1989-01-01

Powders of oxide superconductor (Ba-Y-Cu-O and Bi-Pb-Sr-Ca-Cu-O systems) were synthesized by the spray drying and the mist pyrolysis methods. Fine Ba{sub 2}YCu{sub 3}O{sub 7-y} particles with diameter of 0.1-0.3 {mu}m were produced by the spray drying of the oxalates coprecipitated slurry and following calcination at 800deg C. By the pyrolyzing of nitrates mist containing Ba{sup 2+},Y{sup 3+},Cu{sup 2+} ions in the reaction zone heated at 950-980deg C fine particles were also produced. For Bi-Pb-Sr-Ca-Cu-O system, above mentioned methods were effective to produce fine homogeneous particles of compound at intermediate stage to high Tc phase. Sintered body made from these fine homogeneous powders were densified to about 95-98% of theoretical densitiy. (orig.).

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.

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.

Thermally induced phase transformation of pearl powder

International Nuclear Information System (INIS)

Zhang, Guoqing; Guo, Yili; Ao, Ju; Yang, Jing; Lv, Guanglie; Shih, Kaimin

2013-01-01

The polymorphic phase transformation of thermally treated pearl powder was investigated by X-ray diffraction and thermoanalytical techniques. The phase transformation was based on quantification of the calcite content at various temperatures using Rietveld refinement analysis. The results show that the phase transformation of pearl aragonite occurred within a temperature range of 360–410 °C, which is 50–100 °C lower than the range for non-biomineralized aragonite. These thermoanalytical results suggest that the phase transformation of pearl aragonite may occur immediately after the thermal decomposition of the organic matrix in the pearl powder. An important finding is that decomposition of the organic matrix may greatly facilitate such transformation by releasing additional space for an easier structural reconstruction during the phase transformation process. - Highlights: ► Providing a new method to describe the polymorphic transition of pearl powder ► The phase transition sketch was exhibited by XRD phase quantitative analysis. ► There are dozens of degrees in advance comparing to natural aragonite. ► The phase transition occurs following the thermal decomposition of organism

Synthesis of mullite-based coatings from alumina and zircon powder mixtures by plasma spraying and laser remelting

International Nuclear Information System (INIS)

Hazra, S.; Das, J.; Bandyopadhyay, P.P.

2015-01-01

A mechanical mixture of alumina and pulverized zircon sand in 3:2 M ratio has been plasma sprayed to obtain mullite coating. Thereafter, the top layer of the coating has been remelted using laser. The presence of a mullite phase in the as-sprayed and laser remelted coatings has been confirmed qualitatively using X-ray diffraction. Both as-sprayed and laser remelted coatings have been characterized for their microstructure, hardness and porosity. The ultrafine grain structure of the coating produced by rapid quenching has been analyzed using transmission electron microscope. Presence of a mullite phase in the coatings has also been confirmed using small angle electron diffraction. Laser remelting has resulted in an appreciable reduction in porosity and increase in hardness in the coatings. - Highlights: • Mullite has been produced by plasma spraying of alumina–zircon powder mixture. • As sprayed coating shows good integrity. • Laser remelting reduced porosity and increased coating hardness

Synthesis of mullite-based coatings from alumina and zircon powder mixtures by plasma spraying and laser remelting

Energy Technology Data Exchange (ETDEWEB)

Hazra, S. [Integrated Test Range, Chandipur, Balasore, Odisha 756025 (India); Das, J. [Department of Metallurgical and Materials Engineering, IIT Kharagpur, 721302 (India); Bandyopadhyay, P.P., E-mail: ppb@mech.iitkgp.ernet.in [Department of Mechanical Engineering, IIT Kharagpur, 721302 (India)

2015-03-15

A mechanical mixture of alumina and pulverized zircon sand in 3:2 M ratio has been plasma sprayed to obtain mullite coating. Thereafter, the top layer of the coating has been remelted using laser. The presence of a mullite phase in the as-sprayed and laser remelted coatings has been confirmed qualitatively using X-ray diffraction. Both as-sprayed and laser remelted coatings have been characterized for their microstructure, hardness and porosity. The ultrafine grain structure of the coating produced by rapid quenching has been analyzed using transmission electron microscope. Presence of a mullite phase in the coatings has also been confirmed using small angle electron diffraction. Laser remelting has resulted in an appreciable reduction in porosity and increase in hardness in the coatings. - Highlights: • Mullite has been produced by plasma spraying of alumina–zircon powder mixture. • As sprayed coating shows good integrity. • Laser remelting reduced porosity and increased coating hardness.

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.

Mathematical modelling of powder material motion and transportation in high-temperature flow core during plasma coatings application

Science.gov (United States)

Bogdanovich, V. I.; Giorbelidze, M. G.

2018-03-01

A problem of mathematical modelling of powder material motion and transportation in gas thermal flow core has been addressed. Undertaken studies indicate significant impact on dynamics of motion of sprayed particles of phenomenological law for drag coefficient and accounting momentum loss of a plasma jet upon acceleration of these particles and their diameter. It is determined that at great dispersion of spraying particles, they reach detail surface at different velocity and significant particles separation takes place at spraying spot. According to the results of mathematical modelling, requirements for admissible dispersion of diameters of particles used for spraying have been formulated. Research has also allowed reducing separation of particles at the spraying spot due to the selection of the method of powder feed to the anode channel of the plasma torch.

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.

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.

Downstream processing of a ternary amorphous solid dispersion: The impacts of spray drying and hot melt extrusion on powder flow, compression and dissolution.

Science.gov (United States)

Davis, Mark T; Potter, Catherine B; Walker, Gavin M

2018-06-10

Downstream processing aspects of a stable form of amorphous itraconazole exhibiting enhanced dissolution properties were studied. Preparation of this ternary amorphous solid dispersion by either spray drying or hot melt extrusion led to significantly different powder processing properties. Particle size and morphology was analysed using scanning electron microscopy. Flow, compression, blending and dissolution were studied using rheometry, compaction simulation and a dissolution kit. The spray dried material exhibited poorer flow and reduced sensitivity to aeration relative to the milled extrudate. Good agreement was observed between differing forms of flow measurement, such as Flow Function, Relative flow function, Flow rate index, Aeration rate, the Hausner ratio and the Carr index. The stability index indicated that both powders were stable with respect to agglomeration, de-agglomeration and attrition. Tablet ability and compressibility studies showed that spray dried material could be compressed into stronger compacts than extruded material. Blending of the powders with low moisture, freely-flowing excipients was shown to influence both flow and compression. Porosity studies revealed that blending could influence the mechanism of densification in extrudate and blended extrudate formulations. Following blending, the powders were compressed into four 500 mg tablets, each containing a 100 mg dose of amorphous itraconazole. Dissolution studies revealed that the spray dried material released drug faster and more completely and that blending excipients could further influence the dissolution rate. Copyright © 2018 Elsevier B.V. All rights reserved.

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.

[Use of powder metallurgy for development of implants of Co-Cr-Mo alloy powder].

Science.gov (United States)

Dabrowski, J R

2001-04-01

This paper discusses the application of powder metallurgy for the development of porous implantation materials. Powders obtained from Co-Cr-Mo alloy with different carbon content by water spraying and grinding, have been investigated. Cold pressing and rotary re-pressing methods were used for compressing the powder. It was found that the sintered materials obtained from water spraying have the most advantageous properties.

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.

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.

Thermal analysis, X-ray powder diffraction and electron microscopy data related with the production of 1:1 Caffeine:Glutaric Acid cocrystals

Directory of Open Access Journals (Sweden)

Íris Duarte

2016-09-01

Full Text Available The data presented in this article are related to the production of 1:1 Caffeine:Glutaric Acid cocrystals as part of the research article entitled “Green production of cocrystals using a new solvent-free approach by spray congealing” (Duarte et al., 2016 [1]. More specifically, here we present the thermal analysis and the X-ray powder diffraction data for pure Glutaric Acid, used as a raw material in [1]. We also include the X-ray powder diffraction and electron microscopy data obtained for the 1:1 Caffeine:Glutaric Acid cocrystal (form II produced using the cooling crystallization method reported in “Operating Regions in Cooling Cocrystallization of Caffeine and Glutaric Acid in Acetonitrile” (Yu et al., 2010 [2]. Lastly, we show the X-ray powder diffraction data obtained for assessing the purity of the 1:1 Caffeine:Glutaric cocrystals produced in [1].

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)

Controlling of Nitriding Process on Reactive Plasma Spraying of Al Particles

International Nuclear Information System (INIS)

Shahien, Mohammed; Yamada, Motohiro; Yasui, Toshiaki; Fukumoto, Masahiro

2011-01-01

Reactive plasma spraying (RPS) has been considered as a promising technology for in-situ formation of aluminum nitride (AlN) thermally sprayed coatings. To fabricate thick A lN coatings in RPS process, controlling and improving the in-flight nitriding reaction of Al particles is required. In this study, it was possible to control the nitriding reaction by using ammonium chloride (NH 4 Cl) powders. Thick and dense AlN coating (more than 300 μm thickness) was successfully fabricated with small addition of NH 4 Cl powders. Thus, addition of NH 4 Cl prevented the Al aggregation by changing the reaction pathway to a mild way with no explosive mode (relatively low heating rates) and it acts as a catalyst, nitrogen source and diluent agent.

Gas-thermal coating of powdered materials. Communication 2

International Nuclear Information System (INIS)

Ermakov, S.S.

1986-01-01

This paper investigates the microstructure, microhardness, chemical composition of the transition zone, and also the strength characteristics of gas-thermal coatings including their adhesive power to the substrate (iron brand NC 100.24) and the residual stresses in the coatings. The microstructure of the transition zone was investigated; it was established that on the side of the substrate its density is greater than the mean density of both types of coating. It is shown that the porosity of the substrate has a competing effect on the thermal interaction of materials. Discovered regularities lead to the conclusion that the process of gas-thermal coating of powdered materials is more effective than when compact materials are coated; most effective is the combination of gas-thermal coating with processes of heat treatment of powder-metallurgy products

Effects of pressure on thermal transport in plutonium oxide powder

International Nuclear Information System (INIS)

Bielenberg, Patricia; Prenger, F. Coyne; Veirs, Douglas Kirk; Jones, Jerry

2004-01-01

Radial temperature profiles in plutonium oxide (PuO 2 ) powder were measured in a cylindrical vessel over a pressure range of 0.055 to 334.4 kPa with two different fill gases, helium and argon. The fine PuO 2 powder provides a very uniform self-heating medium amenable to relatively simple mathematical descriptions. At low pressures ( 2 powder has small particle sizes (on the order of 1 to 10 μm), random particle shapes, and high porosity so a more general model was required for this system. The model correctly predicts the temperature profiles of the powder over the wide pressure range for both argon and helium as fill gases. The effective thermal conductivity of the powder bed exhibits a pressure dependence at higher pressures because the pore sizes in the interparticle contact area are relatively small (less than 1 μm) and the Knudsen number remains above the continuum limit at these conditions for both fill gases. Also, the effective thermal conductivity with argon as a fill gas is higher than expected at higher pressures because the solid pathways account for over 80% of the effective powder conductivity. The results obtained from this model help to bring insight to the thermal conductivity of very fine ceramic powders with different fill gases.

Plasma spraying process of disperse carbides for spraying and facing

International Nuclear Information System (INIS)

Blinkov, I.V.; Vishnevetskaya, I.A.; Kostyukovich, T.G.; Ostapovich, A.O.

1989-01-01

A possibility to metallize carbides in plasma of impulsing capacitor discharge is considered. Powders granulation occurs during plasma spraying process, ceramic core being completely capped. X-ray phase and chemical analyses of coatings did not show considerable changes of carbon content in carbides before and after plasma processing. This distinguishes the process of carbides metallization in impulsing plasma from the similar processing in arc and high-frequency plasma generator. Use of powder composites produced in the impulsing capacitor discharge, for plasma spraying and laser facing permits 2-3 times increasing wear resistance of the surface layer as against the coatings produced from mechanical powders mixtures

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.

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

Advanced oxide powders processing based on cascade plasma

International Nuclear Information System (INIS)

Solonenko, O P; Smirnov, A V

2014-01-01

Analysis of the potential advantages offered to thermal spraying and powder processing by the implementation of plasma torches with inter-electrode insert (IEI) or, in other words, cascade plasma torches (CPTs) is presented. The paper provides evidence that the modular designed single cathode CPT helps eliminate the following major disadvantages of conventional plasma torches: plasma parameters drifting, 1-5 kHz pulsing of plasma flow, as well as excessive erosion of electrodes. More stable plasma results in higher quality, homogeneity and reproducibility of plasma sprayed coatings and powders treated. In addition, CPT offers an extremely wide operating window, which allows better control of plasma parameters, particle dwell time and, consequently, particle temperature and velocity within a wide range by generating high enthalpy quasi-laminar plasmas, medium enthalpy transient plasmas, as well as relatively low enthalpy turbulent plasmas. Stable operation, flexibility with plasma gases as well as wide operating window of CPT should help significantly improve the existing plasma spraying processes and coatings, and also help develop new advanced technologies

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.

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.

Influence of Feedstock Powder Modification by Heat Treatments on the Properties of APS-Sprayed Al2O3-40% TiO2 Coatings

Science.gov (United States)

Berger, Lutz-Michael; Sempf, Kerstin; Sohn, Yoo Jung; Vaßen, Robert

2018-04-01

The formation and decomposition of aluminum titanate (Al2TiO5, tialite) in feedstock powders and coatings of the binary Al2O3-TiO2 system are so far poorly understood. A commercial fused and crushed Al2O3-40%TiO2 powder was selected as the feedstock for the experimental series presented in this paper, as the composition is close to that of Al2TiO5. Part of that powder was heat-treated in air at 1150 and 1500 °C in order to modify the phase composition, while not influencing the particle size distribution and processability. The powders were analyzed by thermal analysis, XRD and FESEM including EDS of metallographically prepared cross sections. Only a maximum content of about 45 wt.% Al2TiO5 was possible to obtain with the heat treatment at 1500 °C due to inhomogeneous distribution of Al and Ti in the original powder. Coatings were prepared by plasma spraying using a TriplexPro-210 (Oerlikon Metco) with Ar-H2 and Ar-He plasma gas mixtures at plasma power levels of 41 and 48 kW. Coatings were studied by XRD, SEM including EDS linescans of metallographically prepared cross sections, and microhardness HV1. With the exception of the powder heat-treated at 1500 °C an Al2TiO5-Ti3O5 (tialite-anosovite) solid solution Al2- x Ti1+ x O5 instead of Al2TiO5 existed in the initial powder and the coatings.

Microstructural features and heat flow analysis of atomized and spray-formed Al-Fe-V-Si alloy

International Nuclear Information System (INIS)

Srivastava, A.K.; Ranganathan, S.; Ojha, S.N.

1998-01-01

Microstructural features of rapidly solidified powders and preforms of Al 80 Fe 10 V 4 Si 6 alloy produced by spray forming process have been studied. The atomization and spray deposition were carried out using a confined gas atomization process and the microstructural features were characterized using scanning electron microscopy and transmission electron microscopy (TEM) and X-ray diffraction (XRD) techniques. The microstructure of a wide size range of atomized powders invariably revealed cellular and dendritic morphology. The extent of dendritic region and the dendritic arm spacing were observed to increase with power particle size. The TEM investigations indicated the presence of ultrafine second-phase particles in the intercellular or interdendritic regions. In contrast, the spray deposits of the alloy showed considerable variation in microstructure and size and dispersion of the second-phase particles at specific distances from the deposit-substrate interface and the exterior regions of the deposit. Nevertheless, considerable homogeneity was observed in the microstructure toward the center of the spray deposit. The formation and distribution of a cubic phase α-Al(Fe, V)Si has been characterized in both atomized powders and spray deposits. A one-dimensional heat flow model has been used to analyze the evolution of microstructure during atomization and also during spray deposition processing of this alloy. The results indicate that thermal history of droplets in the spray on deposition surface and their solidification behavior considerably influence the microstructural features of the spray deposits

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

Science.gov (United States)

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

2018-02-01

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

Laser Processing of Multilayered Thermal Spray Coatings: Optimal Processing Parameters

Science.gov (United States)

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

2017-12-01

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

Thermal spray coatings replace hard chrome

International Nuclear Information System (INIS)

Schroeder, M.; Unger, R.

1997-01-01

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

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.

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

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.)

One-Pot Synthesis of CoSex -rGO Composite Powders by Spray Pyrolysis and Their Application as Anode Material for Sodium-Ion Batteries.

Science.gov (United States)

Park, Gi Dae; Kang, Yun Chan

2016-03-14

A simple one-pot synthesis of metal selenide/reduced graphene oxide (rGO) composite powders for application as anode materials in sodium-ion batteries was developed. The detailed mechanism of formation of the CoSe(x)-rGO composite powders that were selected as the first target material in the spray pyrolysis process was studied. The crumple-structured CoSe(x)-rGO composite powders prepared by spray pyrolysis at 800 °C had a crystal structure consisting mainly of Co0.85 Se with a minor phase of CoSe2. The bare CoSe(x) powders prepared for comparison had a spherical shape and hollow structure. The discharge capacities of the CoSe(x)-rGO composite and bare CoSe(x) powders in the 50th cycle at a constant current density of 0.3 A g(-1) were 420 and 215 mA h g(-1), respectively, and their capacity retentions measured from the second cycle were 80 and 46%, respectively. The high structural stability of the CoSe(x)-rGO composite powders for repeated sodium-ion charge and discharge processes resulted in superior sodium-ion storage properties compared to those of the bare CoSe(x) powders. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Spray forming and mechanical properties of a new type powder metallurgy superalloy

International Nuclear Information System (INIS)

Jia Chong-Lin; Ge Chang-Chun; Xia Min; Gu Tian-Fu

2015-01-01

The deposited billet of a new type powder metallurgy (PM) superalloy FGH4095M for use in turbine disk manufacturing has been fabricated using spray forming technology. The metallurgical quality of the deposited billet was analyzed in terms of density, texture, and grain size. Comparative research was done on the microstructure and mechanical properties between the flat disk preform prepared with hot isostatic pressing (HIP) and the same alloy forgings prepared with HIP followed by isothermal forging (IF). The results show that the density of the spray-formed and nitrogen-atomized deposit billet is above 99% of the theoretical density, indicating a compact structure. The grains are uniform and fine. The billet has weak texture with a random distribution in the spray deposition direction and perpendicular to the direction of deposition. A part of atomizing nitrogen exists in the preform in the form of carbonitride. Nitrogen-induced microporosity causes the density reduction of the preform. Compared with the process of HIP+IF, the superalloy FGH4095M after HIP has better mechanical properties at both room temperature and high temperature. The sizes of the γ′ phase are finer in microstructure of the preform after HIP in comparison with the forgings after HIP+IF. This work shows that SF+HIP is a viable processing route for FGH4095M as a turbine-disk material. (paper)

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.

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.

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

Directory of Open Access Journals (Sweden)

Ungyu Paik

2013-08-01

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

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

International Nuclear Information System (INIS)

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

1996-01-01

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

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

Science.gov (United States)

Vackel, Andrew; Dwivedi, Gopal; Sampath, Sanjay

2015-07-01

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

Controlling of Nitriding Process on Reactive Plasma Spraying of Al Particles

Energy Technology Data Exchange (ETDEWEB)

Shahien, Mohammed [Graduate Student, Toyohashi University of Technology (Japan); Yamada, Motohiro; Yasui, Toshiaki; Fukumoto, Masahiro, E-mail: mo.shahien@yahoo.com [Toyohashi University of Technology (Japan)

2011-10-29

Reactive plasma spraying (RPS) has been considered as a promising technology for in-situ formation of aluminum nitride (AlN) thermally sprayed coatings. To fabricate thick A lN coatings in RPS process, controlling and improving the in-flight nitriding reaction of Al particles is required. In this study, it was possible to control the nitriding reaction by using ammonium chloride (NH{sub 4}Cl) powders. Thick and dense AlN coating (more than 300 {mu}m thickness) was successfully fabricated with small addition of NH{sub 4}Cl powders. Thus, addition of NH{sub 4}Cl prevented the Al aggregation by changing the reaction pathway to a mild way with no explosive mode (relatively low heating rates) and it acts as a catalyst, nitrogen source and diluent agent.

Effect of powder compaction on radiation-thermal synthesis of lithium-titanium ferrites

Science.gov (United States)

Surzhikov, A. P.; Lysenko, E. N.; Vlasov, V. A.; Malyshev, A. V.; Korobeynikov, M. V.; Mikhailenko, M. A.

2017-01-01

Effect of powder compaction on the efficiency of thermal and radiation-thermal synthesis of lithium-substituted ferrites was investigated by X-Ray diffraction and specific magnetization analysis. It was shown that the radiation-thermal heating of compacted powder reagents mixture leads to an increase in efficiency of lithium-titanium ferrites synthesis.

The development of heterogeneous materials based on Ni and B4C powders using a cold spray and stratified selective laser melting technologies

Science.gov (United States)

Filippov, A. A.; Fomin, V. M.; Buzyurkin, A. E.; Kosarev, V. F.; Malikov, A. G.; Orishich, A. M.; Ryashin, N. S.

2018-01-01

The work is dedicated to the creation of new ceramic-composite materials based on boron carbide, nickel and using a laser welding in order to obtain three dimensional objects henceforth. The perspective way of obtaining which has been suggested by the authors combined two methods: cold spray technology and subsequent laser post-treatment. At this stage, the authors focused on the interaction of the laser with the substance, regardless of the multi-layer object development. The investigated material of this work was the metal-ceramic mixture based on boron carbide, which has high physical and mechanical characteristics, such as hardness, elastic modulus, and chemical resistance. The nickel powder as a binder and different types of boron carbide were used. The ceramic content varied from 30 to 70% by mass. Thin ceramic layers were obtained by the combined method and cross-sections of different seams were studied. It was shown that the most perspective layers for additive manufacturing could be obtained from cold spray coatings with ceramic concentrations more than 50% by weight treated when laser beam was defocused (thermal-conductive laser mode).

Radio-frequency plasma spraying of ceramics

International Nuclear Information System (INIS)

Okada, T.; Hamatani, H.; Yoshida, T.

1989-01-01

This study was aimed at developing a novel spraying process using a radio-frequency (rf) plasma. Experiments of Al 2 O 3 and ZrO 2 - 8 wt% Y 2 O 3 spraying showed that the initial powder size was the most important parameter for depositing dense coatings. The optimum powder sizes of Al 2 O 3 and ZrO 2 - 8 wt% Y 2 O 3 were considered to be around 100 and 80 μm, respectively. The use of such large-size powders compared with those used by conventional dc plasma spraying made it possible to deposit adherent ceramics coatings of 150 to 300 μm on as-rolled SS304 substrates. It was also shown that low particle velocity of about 10 m/s, which is peculiar to rf plasma spraying, was sufficient for particle deformation, though it imposed a severe limitation on the substrate position. These experimental results prove that rf plasma spraying is an effective process and a strong candidate to open new fields of spraying applications

Spray drying of fenofibrate loaded nanostructured lipid carriers

DEFF Research Database (Denmark)

Xia, Dengning; Shrestha, Neha; van de Streek, Jacco

2016-01-01

into dry, easily reconstitutable powder using spray drying. A central composite face centered design (CCFD) was used to investigate the influence of the ratio of lipid to protectant (mannitol and trehalose) and crystallinity of spray-dried powder on the particle size, yield and residual moisture content...... of the dried powder. A linear relationship (R2 = 0.9915) was established between the crystalline content of the spray-dried powders against the ratio of mannitol to trehalose from 3:7 to 10:0 (w/w). Spray drying of NLC aqueous dispersion using a mannitol and trehalose mixture resulted in an increase...... in particle size of the NLCs after reconstitution in water as compared to that in the initial aqueous dispersion. The decrease in crystallinity of the dry powder by reducing the ratio of mannitol to trehalose could improve the reconstitution of the NLCs in water. However the yield and residual moisture...

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.

Influence of Starting Powders on Hydroxyapatite Coatings Fabricated by Room Temperature Spraying Method.

Science.gov (United States)

Seo, Dong Seok; Lee, Jong Kook; Hwang, Kyu Hong; Hahn, Byung Dong; Yoon, Seog Young

2015-08-01

Three types of raw materials were used for the fabrication of hydroxyapatite coatings by using the room temperature spraying method and their influence on the microstructure and in vitro characteristics were investigated. Starting hydroxyapatite powders for coatings on titanium substrate were prepared by a heat treatment at 1100 °C for 2 h of bovine bone, bone ash, and commercial hydroxyapatite powders. The phase compositions and Ca/P ratios of the three hydroxyapatite coatings were similar to those of the raw materials without decomposition or formation of a new phase. All hydroxyapatite coatings showed a honeycomb structure, but their surface microstructures revealed different features in regards to surface morphology and roughness, based on the staring materials. All coatings consisted of nano-sized grains and had dense microstructure. Inferred from in vitro experiments in pure water, all coatings have a good dissolution-resistance and biostability in water.

Preparation of Al2O3/Mo nanocomposite powder via chemical route and spray drying

International Nuclear Information System (INIS)

Lo, M.; Cheng, F.; Wei, W.J.

1996-01-01

A route to prepare nanometer-sized Mo particulates in Al 2 O 3 was attempted by a combination of solution reactions in molecular scale and forcing precipitation by a spray-drying technique. MoO 3 was first dissolved in ammonia water and then added in the slurry with high purity, submicrometer Al 2 O 3 powder. Mixed suspension was spray-dried, and then the dried granules were reduced by hydrogen gas and further hot-pressing to a bulky composite at various temperatures. Dissolution of Mo oxide, adsorption reactions on alumina surface, and surface potential of alumina particles in homogeneous ammonia suspension were studied. Characterization of the granules, including compactability, flowing properties, surface morphology, grain growth of Mo and Al 2 O 3 , and mixing homogeneity, were examined. Homogeneity of the spray-dried granules was determined by the calculation of mixing index and the observation of the microstructure of sintered body. The existence of intergranular, intragranular, and nanosized Mo particulates within Al 2 O 3 grains was observed by transmission electron microscopy (TEM). All the evidences revealed that homogeneous composites with nanometer-sized Mo had been successfully prepared by this attempt with the proposed chemical route and following spray-drying process. copyright 1996 Materials Research Society

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.

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.

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...

Microstructural and electrical characterizations of tungsten-doped La₂Mo₂O₉ prepared by spray pyrolysis

DEFF Research Database (Denmark)

Baqué, Laura; Vega-Castillo, Jesús; Georges, Samuel

2013-01-01

La2Mo2 − xWxO9 (x=0, 0.5, 1.0, and 1.3) nanocrystalline powders were synthesized by spray pyrolysis (SP) assisted by an ultrasonic atomizer. Microstructure, sinterability and thermal stability of the prepared powders were investigated. Spherical particles of 430 to 530 nm in diameter and crystall......La2Mo2 − xWxO9 (x=0, 0.5, 1.0, and 1.3) nanocrystalline powders were synthesized by spray pyrolysis (SP) assisted by an ultrasonic atomizer. Microstructure, sinterability and thermal stability of the prepared powders were investigated. Spherical particles of 430 to 530 nm in diameter...... by applying different sintering programs starting from La2Mo2 − xWxO9 powders (x=0 and 1.3) obtained by SP and SSR processes. The electrical properties of these ionic conductors were analyzed by Electrochemical Impedance Spectroscopy (EIS) and correlated with microstructural observations. No significant...... variation of the electrical properties of these ionic conductors was found as compared to conventional ceramics with remarkable microstructural differences....

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.

Plasma spheroidization of iron powders in a non-transferred DC thermal plasma jet

International Nuclear Information System (INIS)

Kumar, S.; Selvarajan, V.

2008-01-01

In this paper, the results of plasma spheroidization of iron powders using a DC non-transferred plasma spray torch are presented. The morphology of the processed powders was characterized through scanning electron microscopy (SEM) and optical microscopy (OM). The percentages of spheroidized powders were calculated by the shape factors such as the Irregularity Parameter (IP) and Roundness (RN). A maximum of 83% of spheroidization can be achieved. The spheroidization results are compared with the theoretical estimation and they are found to be in good agreement. The phase composition of the spheroidized powder was analyzed by XRD. The effect of plasma jet temperature and plasma gas flow rate on spheroidization is discussed. At low plasma gas flow rates and at high plasma jet temperatures, the percentage of spheroidization is high

Epitaxial Growth and Cracking Mechanisms of Thermally Sprayed Ceramic Splats

Science.gov (United States)

Chen, Lin; Yang, Guan-jun

2018-02-01

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

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

NARCIS (Netherlands)

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

2018-01-01

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

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.)

Method of making supercritical fluid molecular spray films, powder and fibers

Science.gov (United States)

Smith, Richard D.

1988-01-01

Solid films are deposited, or fine powders formed, by dissolving a solid material into a supercritical fluid solution at an elevated pressure and then rapidly expanding the solution through a heated nozzle having a short orifice into a region of relatively low pressure. This produces a molecular spray which is directed against a substrate to deposit a solid thin film thereon, or discharged into a collection chamber to collect a fine powder. In another embodiment, the temperature of the solution and nozzle is elevated above the melting point of the solute, which is preferably a polymer, and the solution is maintained at a pressure such that, during expansion, the solute precipitates out of solution within the nozzle in a liquid state. Alternatively, a secondary solvent mutually soluble with the solute and primary solvent and having a higher critical temperature than that of primary solvent is used in a low concentration (<20%) to maintain the solute in a transient liquid state. The solute is discharged in the form of long, thin fibers. The fibers are collected at sufficient distance from the orifice to allow them to solidify in the low pressure/temperature region.

Improvement of the Oxidation Resistance of CoNiCrAlY Bond Coats Sprayed by High Velocity Oxygen-Fuel onto Nickel Superalloy Substrate

Directory of Open Access Journals (Sweden)

Alessio Fossati

2010-11-01

Full Text Available CoNiCrAlY powders with similar granulometry and chemical composition, but different starting reactivity toward oxygen, were sprayed onto superalloy substrates by High Velocity Oxygen-Fuel producing coatings of similar thicknesses. After spraying, samples were maintained at 1,273 K in air for different test periods of up to 5,000 hours. Morphological, microstructural, compositional and electrochemical analyses were performed on the coated samples in order to assess the high temperature oxidation resistance provided by the two different powders. The powder with higher starting reactivity towards oxygen improves the oxidation resistance of the coated samples by producing thinner and more adherent thermally grown oxide layers.

Nano spray drying for encapsulation of pharmaceuticals.

Science.gov (United States)

Arpagaus, Cordin; Collenberg, Andreas; Rütti, David; Assadpour, Elham; Jafari, Seid Mahdi

2018-05-17

Many pharmaceuticals such as pills, capsules, or tablets are prepared in a dried and powdered form. In this field, spray drying plays a critical role to convert liquid pharmaceutical formulations into powders. In addition, in many cases it is necessary to encapsulate bioactive drugs into wall materials to protect them against harsh process and environmental conditions, as well as to deliver the drug to the right place and at the correct time within the body. Thus, spray drying is a common process used for encapsulation of pharmaceuticals. In view of the rapid progress of nanoencapsulation techniques in pharmaceutics, nano spray drying is used to improve drug formulation and delivery. The nano spray dryer developed in the recent years provides ultrafine powders at nanoscale and high product yields. In this paper, after explaining the concept of nano spray drying and understanding the key elements of the equipment, the influence of the process parameters on the final powders properties, like particle size, morphology, encapsulation efficiency, drug loading and release, will be discussed. Then, numerous application examples are reviewed for nano spray drying and encapsulation of various drugs in the early stages of product development along with a brief overview of the obtained results and characterization techniques. Copyright © 2018 Elsevier B.V. All rights reserved.

In Situ Fabrication of AlN Coating by Reactive Plasma Spraying of Al/AlN Powder

Directory of Open Access Journals (Sweden)

Mohammed Shahien

2011-10-01

Full Text Available Reactive plasma spraying is a promising technology for the in situ formation of aluminum nitride (AlN coatings. Recently, it became possible to fabricate cubic-AlN-(c-AlN based coatings through reactive plasma spraying of Al powder in an ambient atmosphere. However, it was difficult to fabricate a coating with high AlN content and suitable thickness due to the coalescence of the Al particles. In this study, the influence of using AlN additive (h-AlN to increase the AlN content of the coating and improve the reaction process was investigated. The simple mixing of Al and AlN powders was not suitable for fabricating AlN coatings through reactive plasma spraying. However, it was possible to prepare a homogenously mixed, agglomerated and dispersed Al/AlN mixture (which enabled in-flight interaction between the powder and the surrounding plasma by wet-mixing in a planetary mill. Increasing the AlN content in the mixture prevented coalescence and increased the nitride content gradually. Using 30 to 40 wt% AlN was sufficient to fabricate a thick (more than 200 µm AlN coating with high hardness (approximately 1000 Hv. The AlN additive prevented the coalescence of Al metal and enhanced post-deposition nitriding through N₂ plasma irradiation by allowing the nitriding species in the plasma to impinge on a larger Al surface area. Using AlN as a feedstock additive was found to be a suitable method for fabricating AlN coatings by reactive plasma spraying. Moreover, the fabricated coatings consist of hexagonal (h-AlN, c-AlN (rock-salt and zinc-blend phases and certain oxides: aluminum oxynitride (Al₅O₆N, cubic sphalerite Al₂₃O₂₇N₅ (ALON and Al₂O₃. The zinc-blend c-AlN and ALON phases were attributed to the transformation of the h-AlN feedstock during the reactive plasma spraying. Thus, the zinc-blend c