Optimal design of a convergent-barrel cold spray nozzle by numerical method

A convergent-barrel (CB) cold spray nozzle was designed through numerical simulation. It was found that the main factors influencing significantly particle velocity and temperature include the length and diameter of the barrel section, the nature of the accelerating gas and its pressure and temperature, and the particle size. Particles can achieve a relatively low velocity but a high temperature under the same gas pressure using a CB nozzle compared to a convergent-divergent (CD) nozzle. The experiment results with Cu powder using the designed CB nozzle confirmed that particle deposition can be realized under a lower gas pressure with a CB nozzle.     

Mössbauer and X-ray diffraction characterization of Fe60Al40 coatings prepared by thermal spraying

Microstructured (atomized) and nanostructured (milled) Fe₆₀Al₄₀ powders together with their corresponding coatings synthesized by High Velocity Oxy-fuel (HVOF) or Atmospheric Plasma Spray (APS) thermal spraying techniques have been characterized by Mössbauer Spectroscopy (MS) and X-ray Diffraction (XRD). The evolution of the microstructure and the atomic ordering degree in the powders and coatings are discussed at the light of the various processing conditions. The operational correlation between the parameters of the duplex morphology of coatings and the processing parameters is discussed.     

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.     

Particle velocity measurements in induction plasma spraying

Laser Dopple anemometry (LDA) measurements of the particle velocity are carried out during an induction plasma spraying operation. The velocity of nickel alloy particles, or molten droplets, at the exit of an induction plasma torch prior to impact on the substrate is shown to vary with the plasma and powder injection conditions. Plasma spraying under soft vacuum (150–450 Torr) gives rise to substantially higher particle velocities (40–60 m/sec) compared to those attained at atmospheric pressure (10–20 m/sec).     

Three-Dimensional Modeling of the Turbulent Plasma Jet Impinging upon a Flat Plate and with Transverse Particle and Carrier-Gas Injection

Modeling results are presented concerning the turbulent thermal plasma jet impinging normally on a substrate and with transverse injection of feedstock particles and their carrier gas from a single injection tube. The k- two-equation model is employed to model the turbulence, and particle dispersion is studied considering the interaction between the moving particles and turbulent eddies and considering the effect on particle trajectories of the random variation of the turbulent fluctuating velocities in their magnitude and direction. A well-validated three-dimensional (3-D) computer code is used in the modeling. The 3-D effects due to the carrier gas injection on the jet flow field and thus on the particle trajectories and heating histories are shown to be appreciable. The radial location of the injection tube with respect to the plasma jet is shown to be a critical parameter for the study of 3-D effects, besides the carrier-gas/plasma stream mass flux ratio. Particle dispersion considerably widens the distribution of the particle trajectories and heating histories. In addition, although pertinent swirl number is often rather small, swirling may also affect the modeling results.     

Industrial Application of Hybrid Sol-Gel Coatings for the Decoration of Crystal Glassware

The coloration of glass via melting techniques presents some unique problems with respect to the reproducibility, toxicology and economics of certain colors, especially if the market demands are highly variable. This is also the case for consumer products such as crystal glass and tableware. Traditionally, the decoration of crystal glasses is performed by laborious manual techniques, which are costly and do not meet modern market requirements. Alternatively, spraying of colored lacquers is a highly flexible and valuable tool for the development of new products. Sol-gel type hybrid coatings provide several advantages compared to conventional organic systems like high abrasion resistance, almost perfect adhesion, refractive index matching and sufficient stability in dishwashing procedures. The solubility of organic dyes in the hybrid matrix is sufficient for intense colors even at rather low layer thicknesses, which on the other hand convey the high brilliance of the base material. The development of transparent, translucent and opaque hybrid coatings for crystal glass has been completed in the last few years and the production of partially coated articles has started recently. The synthesis and properties of the coating material are reviewed and the industrial process and first market results are also outlined.     

Effect of flame-sprayed Al–12Si coatings on the failure behaviour of pressurized fibre-reinforced composite tubes

Internal pressurization testing at room temperature was performed to evaluate the effect of flame-spraying aluminum-12silicon on the leakage behavior of fibre-reinforced composite tubes fabricated by filament winding, and covered with garnet sand. A group of specimens were completely coated with flame-sprayed metal particles and another set remained uncoated. t-tests were conducted at a significance level of α = 0.05 to analyze the effect of the coating on the leakage behavior of the specimens. Ultraviolet imaging was used to illustrate a characteristic leakage pattern of the composite tubes. Coated specimens exhibited slightly higher mean leakage and burst pressures than the uncoated specimens. The t-test results provided strong statistical evidence that the flame spraying process employed did not damage the filament wound tubes covered with garnet sand.     

Co3O4/UiO-66@α-Al2O3陶瓷膜对VOCs废气的分离催化性能

以α-Al₂O₃为支撑层, UiO-66为分离层, Co₃O₄为催化层, 构建了Co₃O₄/UiO-66@α-Al₂O₃陶瓷膜.对其形貌结构进行了表征, 并研究了其对挥发性有机物(VOCs)的分离催化性能. 结果表明, 该陶瓷膜对喷涂行业废气中苯与吡啶两种主要成分体现出良好的分离性, 透过侧的气体中吡啶与苯的摩尔浓度比值可由给料侧的1提高至17; 体系中引入臭氧后, 给料侧苯的浓度明显降低, 其去除率可达到89%. 透过侧的吡啶去除率仅为27%, 得到了较大程度的保留, 剩余的吡啶经收集后可进行单独的深度处理. Co₃O₄/UiO-66@α-Al₂O₃陶瓷膜在对喷涂行业废气中苯成分高效降解的同时, 能够有效解决喷涂行业废气处理过程中氮氧化物的排放问题, 有望成为喷涂行业废气预处理工艺的理想选择.     

Characterization of laser sealed coatings of yttria partially stabilized zirconia

The present paper reports an experimental investigation based on X-ray diffraction (XRD), energy dispersive spectroscopy (EDS), and wavelength dispersive spectroscopy (WDS) analyses of phases formed after laser sealing of plasma sprayed coatings of 8.5 wt% yttria partially stabilized zirconia (YPSZ). X-ray diffraction and X-ray step-scanning analyses showed that the plasma sprayed and sealed coatings consisted mainly of t′ phase with a very small amount of monoclinic phase (m phase) in the plasma sprayed coatings. It was also found that the small amounts of m and cubic phases (c phase) present in the sealed coatings were dependent on laser processing specific energies (specific energy is equal to laser power/traverse speed x beam diameter). It was also found that rhombohedral (r) phase formed after laser sealing of coatings at higher specific energies. A direct relationship between c/a ratio of transformable tetragonal phase (t phase) produced by thermal treatment of sealed coatings and nontransformable tetragonal phase (t′ phase) and the amount of Yttria was obtained. A new equation was derived, which describes the relationship between Yttria concentration and the c/a ratio of tetragonal phases (t or t′).     

Wear resistance of reactive plasma sprayed and laser remelted TiB2-TiC0.3N0.7 based composite coatings against medium carbon steel

Wear resistance of reactive plasma sprayed TiB₂-TiC_0.3N_0.7 based composite coatings and the as-sprayed coating with laser surface treatment was investigated using plate-on-plate tests. Wear tests were performed at different normal loads and sliding speeds under dry sliding conditions in air. The surface morphologies of counterparts against as-sprayed and laser remelted coatings were investigated. The microstructure and chemical composition of wear debris and coatings were studied using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), respectively. The results show that the wear resistance of the laser remelted coating is improved significantly due to their increased microhardness and reduced flaws. The primary wear mechanism of the remelted coating is oxidation wear and its minor wear mechanisms are grain abrasion and fatigue failure during the course of wear test. In contrast, the primary wear mechanism of the as-sprayed coating is grain abrasion at the low sliding speed (370 rpm) and fatigue failure at the high sliding speed (549 rpm). The oxidation wear mechanism is a minor contributor for the as-sprayed coating.