Influence of velocity and surface temperature of alumina particles on the properties of plasma sprayed coatings

In this paper are described the main characteristics of the plasma spraying process of alumina deposits, i.e., the temperature and flow field of the plasma jets obtained with the classical spraying torches, the injection of the particles into the plasma jet, the particle surface temperature and velocities in the plasma (measured for calibrated alumina particles), and the coating generation. The measurements on the alumina particles are compared with the predictions of a mathematical model. The experimental and computed particle velocities are in rather good agreement. However, this is not the case for the particle surface temperature. Possible reasons for the discrepancy are proposed (influence of the carrier gas, thermophoretic forces, and poor penetration of the particles into the plasma core even for an injection velocity twice that of the optimal calculated one, as shown by recent measurements). Finally the correlations between the particle velocities and surface temperature, and the properties of the alumina coating (porosity, crystal structure, mechanical properties) are studied.     

Heat Generation and Particle Injection in a Thermal Plasma Torch

The operation of plasma guns used for plasma spraying involves a continuous movement of the anode arc root. The resulting fluctuations of voltage and thermal energy input introduce an undesirable element in the spray process. This paper deals with the effects of these arc instabilities on the plasma jet, and the behavior of particles injected in the flow. The first part refers to the formation of the plasma jet. Measurements show that the static behavior of the arc depends strongly upon the plasma-forming gas mixture, especially the mass flow rate, of the heavy gas, injection mode, nozzle diameter, and arc current. These parameters control the electric field in the arc column, the arc length, its stability, and the gas velocity and temperature. The dynamic behavior of the arc is examined to determine how the tempeature and velocity of the plasma gas vary with voltage variations. Relationships between the gas velocity at the nozzle exit and the lifetime of the arc roots, and the independent operating parameters of the gun can be established from a dimensional analysis. The second part discusses the interaction between the plasma jet and the particles injected into the flow. The parameters controlling particle injection and trajectory are examined to determine how injection velocity must vary with particle size and density to achieve a given trajectory. The effect of the transverse injection of the powder carrier gas is investigated using a 3-D computational fluid dynamics code. Finally, the effect of the jet fluctuations on particle trajectory is studied under the assumption that the jet velocity follows the voltage variation. The result is a continuous variation of the particle spray jet position in the flow. Experimental observations confirm the model predictions.     

Effect of a substrate on the temperature distribution in an argon-hydrogen thermal plasma jet

Gas temperature profiles in the plume of an argon-hydrogen thermal plasma jet were determined /torn Rayleigh scattered laser light. Measured profiles were found to be well fitted by a Gaussian curve. Temperature data were compared with values obtained from thermocouples and showed an increasing discrepancy for temperatures higher than 800 K. The presence Q1 a cooled substrate in the flow was observed to increase the center-line temperature by about 22 at the substrate. By, combining the temperature results with calorimetric measurements of heal fox, a heat transfer coefficient to a copper substrate held at 300 K Iras determined to be in the range 400–1000 W/m². K under typical plasma spraying conditions.     

Thermal plasmas

Although many thermal plasma processes have been developed for industrial applications, the wide acceptance as a manufacturing technology is prevented due to economical and competitive reasons, and/or reproducibility and reliability aspects. This paper is devoted to an assessment of the present knowledge in the following topics: (1) plasma torch and performance of blown arc (dc or ac), transferred arc and radio frequency torches; (2) established industrial applications with special emphasis on cutting, welding, spraying, transferred arc reclamation, reheating and purification, reheating metal melts, smelting reduction, chemical operations, and waste destruction; (3) recent developments in the knowledge of fundamental processes in plasma torches with power sources, cathodes (hot and cold), anodes (static and dynamic behavior), and torch components; (4) modeling-thermodynamic and transport properties, plasma flow with and without the Maxwell's equations; (5) measurement techniques including emission and absorption spectroscopy, laser scattering, enthalpy probes, video cameras, spectral analysis, shadowgraphy, and particle diagnostics either in flight with statistical measurements and those giving characteristics of a single particle upon flattening on a substrate; and (6) plasma-processing development in the presently used industrial processes and also in prospective processes with surface hardening, ultrafine powder production, plasma-assisted CVD, and plasma-fluidized or spouted bed reactors     

Temperature and velocity fields in a gas stream exiting a plasma torch. A mathematical model and its experimental verification

A mathematical model was developed to predict the velocity and temperature fields in a free plasma jet issuing from a D.C. plasma torch. It was assumed that the temperature and velocity at the torch nozzle were specified and the turbulent Navier-Stokes equations were solved in conjunction with a two-equation model of turbulence and the energy transport equation. The model was formulated in terms of the two-dimensional elliptic equations to facilitate its future extension to nonparabolic problems. The predictions of the model were compared with experimental measurements obtained from laser Doppler and spectroscopic techniques. Good overall agreement was found between the theoretical predictions and the experimental measurements for two sets of initial conditions corresponding to nitrogen/hydrogen and argon/hydrogen plasmas. Radiation was found to have a small effect on the overall heat transfer process, and it is suggested that the assumption of an optically thin radiation loss per unit volume is sufficiently accurate for most engineering applications. The significance of this work lies in the fact that, for the first time, it is possible to test the assumptions of the current model against a reliable set of experimental measurements.Notation C ₁,C ₂,C _D constants inK- turbulence model, Table III - C _P average specific heat of plasma at constant pressure - h ₁ length of integration region - h ₂ width of integration region - K turbulent kinetic energy per unit mass - P pressure - r radial coordinate - R ₀ internal radius of anode - S _K source term forK equation - S _R radiation loss per unit volume - S source term for equation - T ₀ temperature of plasma atz=0 - T temperature of plasma - T _a ambient temperature - u velocity inz direction - u ₀ velocity of plasma atz=0 - v radial velocity of plasma - z axial coordinate - dissipation rate of turbulence energy - , _eff, _t molecular, effective, and turbulent viscosities, respectively - density - _K, _T, Prandtl numbers forK, T, and, respectively     

Experimental investigation of powder vaporization in thermal plasma jets

An experimental study of the vaporization of metallic and ceramic particles in a thermal do plasma jet has been initiated and two series of experiments have been performed: (1) measurement of the vapor concentration within the plasma jet by absorption spectroscopy. (2) Investigation of the vapor cloud surrounding a single particle in flight by emission spectroscopy. The temperature within this cloud is determined by the intensity ratio of two lines which are simultaneously measured. The cloud radius is deduced /torn measurement of the particle velocity by laser doppler anemometry, and the vapor concentration is calculated from the line intensity profile, once the temperature is known. Results on iron and alumina particles injected in argon or argon-hydrogen plasma jets are given and discussed.     

Sol-gel synthesis of yttrium aluminum garnet (YAG): effects of the precursor nature and concentration on the crystallization

Journal of Sol-Gel Science and Technology - The sol–gel synthesis of yttrium aluminum garnet (YAG) was performed using different metal precursors (salts and alkoxides of aluminum and yttrium)...     

Main Issues for a Fully Predictive Plasma Spray Torch Model and Numerical Considerations

Plasma spray is one of the most versatile and established techniques for the deposition of thick coatings that provide functional surfaces to protect or improve the performance of the substrate material. However, a greater understanding of plasma spray torch operation will result in improved control of process and coating properties and in the development of novel plasma spray processes and applications. The operation of plasma torches is controlled by coupled dynamic, thermal, chemical, electromagnetic, and acoustic phenomena that take place at different time and space scales. Computational modeling makes it possible to gain important insight into torch characteristics that are not practically accessible to experimental observations, such as the dynamics of the arc inside the plasma torch. This article describes the current main issues in carrying out plasma spray torch numerical simulations at a high level of fidelity. These issues encompass the use of non-chemical and non-thermodynamic equilibrium models, incorporation of electrodes with sheath models in the computational domain, and resolution of rapid transient events, including the so-called arc reattachment process. Practical considerations regarding model implementation are also discussed, particularly the need for the model to naturally reproduce the observed torch operation modes in terms of voltage and pressure fluctuations.     

An efficient access to new Tröger’s bases using superacidic chemistry

In the superacidic media HF/SbF₅, hydroxylation of several Tröger’s bases was performed using sodium persulfate as a hydroperoxonium H₃ precursor. The obtained products are selectively hydroxylated in good yields on unusual positions of the aromatic rings.     

Parameters controlling the generation and properties of plasma sprayed zirconia coatings

D.C. plasma jets temperature and velocity distributions as well as the arc root fluctuations at the anode were studied for Ar-H₂ (25 vol%) plasma forming gases. The parameters were the arc current up to 700 A, the total gas flow rate up to 100 slm, and the nozzle diameter which was varied from 6 to 10 mm. The trajectories of partially stabilized zirconia particles into the jet were studied by a 2D laser imaging technique and two fast (100 ns) two color pyrometers. The results have revealed the difficulty to inject small particles into the plasma flow since most were found to by-pass the jet rather than penetrate it. The results also show the broad trajectory distribution within the jet and the influence of the arc root fluctuations on the mean particle trajectory distribution within the jet. Beside the measurements of the particle surface temperature and velocity distributions in flight, the particle flattening and the cooling of the resulting splats were studied statistically for single particles all over the spray cone. Such studies have emphasized the drastic influence of the substrates or previously deposited layers temperature on the contact between them and the splats. At 200–300°C this contact is excellent (cooling rates of the order of 100 K/μs for 1 μm thick splats) and it results in a columnar growth within the splats and the layered splats of a bead (up to 500 layered splats). This growth can be observed through passes provided the bead surface temperature has not cooled too much (a few tens of K) before the next bead covers it. A/C values up to 60 MPa were achieved with PSZ coatings. The effect of impact velocity of the particles, of substrate preheating temperature, of relative movments torch to substrate, of substrate oxidation on A/C values and splat formation were also studied.