An investigation on erosion behavior of HVOF sprayed WC-CoCr coatings

Present work is an investigation of slurry erosion behavior of WC-CoCr cermet coatings deposited with two different WC grain sizes. HVOF thermal spray process was employed due to its high velocity and low flame temperature characteristics resulting in quality coating. HVOF spraying was assisted with in-flight particle temperature and velocity measurement system to control its heating. Slurry erosion testing was performed using a pot-type slurry erosion tester to evaluate slurry erosion resistance of the coatings. Two parameters were considered for testing viz. erodent particle size and slurry concentration. Surface morphology was examined using SEM images and phase identification was done by XRD. The erosion behavior and mechanism of material removal was studied and discussed based on microstructural examination. It was observed that WC-CoCr cermet coating deposited with fine grain WC exhibits higher slurry erosion resistance under all testing conditions as compared to conventional cermet coating.     

The effects of powder properties on in-flight particle velocity and deposition process during low pressure cold spray process

In cold spray process, impacting velocity and critical velocity of particles dominate the deposition process and coating properties for given materials. The impacting velocity and critical velocity of particles depend on the powder properties and cold spray conditions. In the present study, the in-flight particle velocity of copper powder in low pressure cold spraying was measured using an imaging technique. The effects of particle size and particle morphology on in-flight particle velocity and deposition efficiency were investigated. The critical velocity of copper powder was estimated by combining the in-flight particle velocity and deposition efficiency. The effect of annealing of feedstock powder on deposition and critical velocity was also investigated. The results showed that the irregular shape particle presents higher in-flight velocity than the spherical shape particle under the same condition. For irregular shape particles, the in-flight velocity decreased from 390 to 282 m/s as the particle size increases from 20 to 60 μm. Critical velocities of about 425 m/s and more than 550 m/s were estimated for the feedstock copper powder with spherical and irregular shape morphology, respectively. For the irregular shape particles, the critical velocity decreased from more than 550 to 460 m/s after preheating at 390 °C for 1 h. It was also found that the larger size powder presents a lower critical velocity in this study.     

Numerical simulation on the influence of water spray in thermal plasma treatment of CF4 gas

Nitrogen thermal plasma generated by a non-transferred DC arc plasma torch was used to decompose tetrafluoromethane (CF₄). In the thermal decomposition process, water was used as a chemical reactant source. Two kinds of water spray methods were compared: water spray directly to the arc plasma flame and indirectly to the reactor tube wall. Although the same operating conditions of input power, waste gas, and sprayed water flow rate were employed for each water spray methods, a relatively higher decomposition rate was achieved in the case of water spray to the reactor wall. In order to investigate the effects of water spraying direction on the thermal decomposition process, a numerical simulation on the thermal plasma flow characteristics was carried out considering water injection in the reactor. The simulation was performed using commercial fluid dynamics software of the FLUENT, which is suitable for calculating a complex flow. From the results, it was revealed that water spray to the reactor wall and use of a relatively small quantity of water are more effective methods for decomposition of CF₄, because a sufficiently high temperature area and long reaction time can be maintained over large area.     

Development and properties of nanostructured thermal spray coatings

Nanostructured thermal spray coatings have been intensively studied because of their potential in a wide variety of industrial applications. In the present paper, current development status of nanostructured thermal spray coatings is presented, mainly based on the results of the authors. In the nanostructured WC–Co wear-resistant coatings, the influence of feedstock characteristics on the coating properties was discussed to suggest the desirable morphology of feedstock for thermal spraying. For the nanostructured Cr₂O₃ based solid-lubricant coatings, the advanced feedstock has been developed in order to solve the inhomogeneity problem of the conventional coatings. Various properties of the nanostructured coatings were evaluated and compared with those of the conventional counterparts. These results clearly demonstrate that the significant improvement in coating performance can be achieved by utilizing proper nanostructured coatings.     

Simultaneous measurement of particle size, velocity, andtemperature in thermal plasmas

The in-flight measurement of particle parameters (size, velocity, temperature, and local number density) can prove insight into the plasma processing of solid materials. A measurement technique for simultaneously obtaining the size, velocity, and temperature of particles entrained in high-temperature flow fields is described. Particle size and velocity are obtained from a combination laser-particle-sizing system and laser Doppler velocimeter. The particle temperature is determined by a two-color pyrometry technique and the data rate is a measure of relative particle number density. Typical measured temperatures and velocities for the 5-100 μm particles used in plasma spraying are 1600-3500 K and 100-300 m/s, respectively. Since particle size, velocity, and temperature are measured simultaneously, cold particles (<1600 K) are identified and their relative number density can be quantified. Data from two plasma spray systems, a metal one (Ni-Al) and a metal oxide one (Al₂O₃), are presented and their application to understanding the plasma spray-coating process is illustrated     

Very low pressure plasma sprayed alumina and yttria-stabilized zirconia thin dense coatings using a modified transferred arc plasma torch

As a novel thermal spray process, very low pressure plasma spray (VLPPS) process has been significantly used to deposit thin, dense and homogenous ceramic coating materials for special application needs in recent years. In this study, in order to enhance low-energy plasma jet under very low pressure ambience, a home-made transferred arc nozzle was made and mounted on a low-power F100 plasma torch to fully melt or evaporate powder feedstock. As a result, thin and dense alumina (Al₂O₃) and yttria-stabilized zirconia (YSZ) ceramic coatings with an average thickness of 30-40 μm were successfully elaborated by the VLPPS process below 1 mbar. An optical emission spectroscopy (OES) was used to analyze the plasma jet properties. The microstructures of the coatings were observed by means of a scanning electron microscopy (SEM). It was found that the YSZ coatings displayed a bimodal microstructure which was composed of splats formed by melted particles and a little amount of vapor condensation from evaporated particles. However, vapor condensation could not be observed in the Al₂O₃ coatings, and only lamellar splats were found. The mechanical properties of both coatings were also evaluated.     

Uniform nanoparticles by flame-assisted spray pyrolysis (FASP) of low cost precursors

A new flame-assisted spray pyrolysis (FASP) reactor design is presented, which allows the use of inexpensive precursors and solvents (e.g., ethanol) for synthesis of nanoparticles (10–20 nm) with uniform characteristics. In this reactor design, a gas-assisted atomizer generates the precursor solution spray that is mixed and combusted with externally fed inexpensive fuel gases (acetylene or methane) at a defined height above the atomizing nozzle. The gaseous fuel feed can be varied to control the combustion enthalpy content of the flame and onset of particle formation. This way, the enthalpy density of the flame is decoupled from the precursor solution composition. Low enthalpy content precursor solutions are prone to synthesis of non-uniform particles (e.g., bimodal particle size distribution) by standard flame spray pyrolysis (FSP) processes. For example, metal nitrates in ethanol typically produce nanosized particles by gas-to-particle conversion along with larger particles by droplet-to-particle conversion. The present FASP design facilitates the use of such low enthalpy precursor solutions for synthesis of homogeneous nanopowders by increasing the combustion enthalpy density of the flame with low-cost, gaseous fuels. The effect of flame enthalpy density on product properties in the FASP configuration is explored by the example of Bi₂O₃ nanoparticles produced from bismuth nitrate in ethanol. Product powders were characterized by nitrogen adsorption, X-ray diffraction, X-ray disk centrifuge, and transmission electron microscopy. Homogeneous Bi₂O₃ nanopowders were produced both by increasing the gaseous fuel content and, most notably, by cutting the air entrainment prior to ignition of the spray.     

Surface Modification of Al2O3 Fiber with Binary Nanoparticles using a Dry-Mechanical Coating Technique

Integrating materials with different functionalities into a composite material to obtain synergetic properties has generated considerable interest in various scientific and technical fields. In this study, a dry-mechanical coating process was used to fix nanosized Al₂O₃ and CuO particles directly onto the surface of Al₂O₃ fiber substrates by employing high shear and compression forces. The resulting composite materials showed good dispersion and homogeneous distribution of Al₂O₃ and CuO nanoparticles. Important coating parameters, including initial particle loadings and processing times were investigated for their effects on coating characteristics and product properties. The experimental results showed that the product surface area increased with higher nanoparticle loadings. The degree of dispersion and homogenous distribution of Al₂O₃ nanoparticles with CuO nanoparticles increased with the processing time. Additionally, the crystalline phase of raw materials was preserved during the coating process under the conditions studied in this work.     

Green synthesis of Au nanoparticles using potato extract: stability and growth mechanism

Airborne particle release during the spray application of coatings was analyzed in the nanometre and micrometre size range. In order to represent realistic conditions of domestic and handcraft use, the spray application was performed using two types of commercial propellant spray cans and a manual gravity spray gun. Four different types of coatings doped with three kinds of metal-oxide tracer nanoparticle additives (TNPA) were analyzed. Depending on the used coating and the kind of spray unit, particulate release numbers between 5 × 10⁸ and 3 × 10¹⁰ particles per gram ejection mass were determined in the dried spray aerosols. The nanoparticulate fraction amounted values between 10 and 60 no%. The comparison between nanoparticle-doped coatings with non-doped ones showed no TNPA-attributed differences in both the macroscopic spray process characteristics and the particle release numbers. SEM, TEM and EDX-analyzes showed that the spray aerosols were composed of particles made up solely from matrix material and sheathed pigments, fillers and TNPAs. Isolated ZnO- or Fe₂O₃-TNPAs could not be observed.     

Numerical study of semi-molten droplet impingement

Due to the low thermal conductivity of ceramics large temperature gradients are present through the powder particles during plasma spray deposition. As a result the particles often impinge at the substrate in a semi-molten form; which in turn substantially affects the final characteristics of the coating being formed. This study is dedicated to the novel modelling development and simulation of a semi-molten droplet impingement. The study examines the impingement process during impact, spreading and solidification of semi-molten zirconia. The simulation provides an insight to the heat transfer process during impact and solidification of a semi-molten powder particle and illustrates the freezing-induced break-up mechanism at the splat periphery.     

Influence of metal powder shape on drag coefficient in a spray jet

In plasma spraying, particle shape, size, distribution and density are the important factors to be considered in order to ensure high spray efficiency and better coating properties. In the present work, nickel, iron and aluminium irregular powders in the size range from 50 to 63 μm were spheroidized using thermal plasma processing. The spheroidization experiments have been carried out at different gas flow rates and plasma torch power levels. The sphericity was analyzed using shape factor. Drag coefficients of the powders were estimated using Reynolds number and sphericity of the powders in plasma. For irregular particles, the drag coefficient is higher than that of the spherical because of its large area of contact with plasma. The temperature dependent on drag coefficient is also discussed. Increasing temperature increases the drag coefficient of the powder particles injected in to the plasma jet. Increasing plasma jet temperature changes the density and viscosity of the plasma which affects the particle’s drag coefficient in the plasma. The results are reported and discussed.     

A Review of Advanced Composite and Nanostructured Coatings by Solid-State Cold Spraying Process

Cold spraying (CS) has been widely explored over the last decade due to its low process temperature and limited thermal effect on spray materials. As a solid-state process, the inherent deficiencies of traditional thermal spraying such as oxidation, decomposition, and grain growth are avoided. This article summarizes the research work on the fabrication of composites and nanostructured coatings by the promising CS process. After a brief introduction to CS and its deposition mechanisms, the preparation methods of spray powders are classified. Different methods are appropriate for particles of various properties, and the tendency is to design composite powders by combined methods in order to create coatings with specified properties. Then, the co-deposition mechanism of composite particles as well as research findings on metal–metal, metal–ceramic, and metal–intermetallic composite coatings are reviewed concerning the deposition characteristics, microstructure and its relation to properties. Moreover, CS has been used to deposit a variety of nanostructured materials, including metals, metal–ceramic composites, and even ceramics, retaining their nanocrystalline nature in the coating without grain growth or phase transformation. Finally, the potential applications of CS and issues to be addressed in coating deposition are discussed.     

Plasma spraying-an innovative coating technique: process variantsand applications

The use of plasma processing for spraying is reviewed, with emphasis on the material used, their sprayed structure, and successfully applied coatings. It is noted that new and further developments in plasma spray processes, spray devices, and spray materials have led to advantages in the realization of functional coatings and applications ranging from conventional to highly specialized industries. Different functions of the sprayed coatings can be achieved by choosing various plasma-process variations and any of a high number of useful coating materials. The plasma-spray process can be regarded as almost universal because of its inherently high process temperature, which allows almost unlimited combinations of coating and base material to be used     

Electrophoreted Zn-TiO2-ZnO nanocomposite coating films for photocatalytic degradation of 2-chlorophenol

TiO₂-ZnO nano-powders with different TiO₂/ZnO ratios have been synthesized by hydrothermal method. Nanocomposite coating films consisting of TiO₂-ZnO and Zn with thickness of 20 μm have been electrophoreted on steel plates by rapid plating from a ZnO-based alkaline bath. X-ray diffraction, scanning electron microscopy and energy dispersive X-ray analysis were used to investigate the structure, the size distribution, and the composition of prepared nano-powders and plated materials. The effect of the operating parameters such as powder contents, pH and current density on the electrophoresis process has been investigated and optimum conditions of coating process were determined. Corrosion properties of plated samples have been studied by salt spray test. The catalytic activity of the prepared nanocomposite Zn-TiO₂-ZnO films for the photocatalytic degradation of 2-chlorophenol (2-CP) was measured.     

Ignition and volatile combustion behaviors of a single lignite particle in a fluidized bed under O2/H2O condition

O₂/H₂O combustion, as a new evolution of oxy-fuel combustion, has gradually gained more attention recently for carbon capture in a coal-fired power plant. The physical and chemical properties of steam e.g. reactivity, thermal capacity, diffusivity, can affect the coal combustion process. In this work, the ignition and volatile combustion characteristics of a single lignite particle were first investigated in a fluidized bed combustor under O₂/H₂O atmosphere. The flame and particle temperatures were measured by a calibrated two-color pyrometry and pre-buried thermocouple, respectively. Results indicated that the volatile flame became smaller and brighter as the oxygen concentration increased. The ignition delay time of particle in dense phase was shorter than that in dilute phase due to its higher heat transfer coefficient. Also, the volatile flame was completely separated from particles (defined as off-flame) in dense phase while the flame lay on the particle surface (defined as on-flame) in dilute phase. The self-heating of fuel particles by on-flame in dilute phase was more obvious than that in dense phase, leading to earlier char combustion. At low oxygen concentration, the flame in the H₂O atmosphere was darker than that in the N₂ atmosphere because the heat capacity of H₂O is higher than that of N₂. With the increase of oxygen concentration, the flame temperature in the O₂/H₂O atmosphere was dramatically enhanced rather than that in the O₂/N₂ atmosphere, where the diffusion rate of oxygen in O₂/N₂ atmosphere became the dominant factor.     

Influence of pores on the surface microcompression mechanical response of thermal barrier coatings fabricated by atmospheric plasma spray—Finite element simulation

Surface microcompression is a very important technique to characterize the mechanical properties of film and coating systems. In this paper, surface microcompression simulation for La₂Zr₂O₇ (LZ) thermal barrier coatings (TBCs) was implemented by finite element method, especially, the influence of pores on the surface microcompression mechanical response of the thermal barrier coatings fabricated by atmospheric plasma spray (APS) was focused on. The simulation results indicate that the pores not only affect the stress distribution beneath the contact area between the indenter and coating surface, but also affect the shape of the force-displacement curve and the plastic deformation behavior of TBCs. The micromechanism was discussed in detail in this study. At the same time, by using the surface microcompression technique, a new direction or method was proposed to characterize the pore content of the coating quantitatively.     

The influence of process parameters on deposition characteristics of a soft/hard composite coating in kinetic spray process

In kinetic spray processes, the non-uniformity of resultant composite coatings is generally caused by the difference in critical velocity and deposition efficiency between the components of a mixed feedstock. In the present paper, the effects of process parameters, such as feed rate, spray distance, and particle velocity, on the compositional variation between the mixed feedstock and resultant composite coating have been investigated. The results showed that the high diamond fraction in the coating can be achieved using a low feed rate, intermediate spray distance, and high impact particle velocity. The possibility of impact between hard brittle diamond particles is the main factor affecting the diamond fraction in the coating. Although the deposition efficiency, diamond fraction, and bond strength of the coating increase with particle velocity, a slight decrease of cohesive strength between diamond particle and bronze base was also observed.     

Measurement of particle velocity and characterization of deposition in aluminum alloy kinetic spraying process

Particle velocity is a very important parameter in kinetic spraying (or cold gas dynamic spraying). It is difficult to measure the velocity of a particle with supersonic speed at low temperature (lower than 500 °C). Thus, in many investigations only estimated values are used for evaluating coating processes. In this paper, the modeling of particle acceleration was reviewed, and the measurement of in-flight particle velocity in a kinetic spraying process was performed. Particle velocity and flux distributions from different process gas temperatures and pressures were investigated. The influences of process gas temperature and pressure on particle velocity were discussed. Characteristic of Al-Si feedstock deposition onto a mild steel substrate was described by comparing coatings structures with the in-flight particle conditions. The deposition behavior showed two critical particle velocities for Al-Si powder deposition onto a substrate and for particle-particle bonding.     

Adhesive and cohesive properties by indentation method of plasma-sprayed hydroxyapatite coatings

Adhesive and cohesive properties of the plasma-sprayed hydroxyapatite (HA) coatings, deposited on Ti-6Al-4V substrates by varying the plasma power level and spray distance (SD), were evaluated by an indentation method. The crystallinity and the porosity decreased with increasing both of these two parameters. The microhardness value, Young's modulus (E) and coating fracture toughness (K_C) were found to increase with a combinational increase in spray power and SD. The Knoop and Vickers indentation methods were used to estimate E and K_C, respectively. The critical point at which no crack appears at the interface was determined by the interface indentation test. This was used to define the apparent interfacial toughness (K_Ca) which is representative of the crack initiation resistance of the interface. It was found that K_Ca reaches to a maximum at a medium increase in both spray power and SD, while other mechanical properties of the coatings reaches to the highest value with further increase in these two plasma parameters. The tensile adhesion strength of the coatings, measure by the standard adhesion test, ISO 13779-4, was shown to alter in the same manner with K_Ca results. It was deduced that a combinational increase in spray power and SD which leads to a higher mechanical properties in the coatings, does not necessarily tends to a better mechanical properties at the interface.     

Preparation and ablation properties of ZrC-SiC coating for carbon/carbon composites by solid phase infiltration

A novel ZrC-SiC coating was prepared on carbon/carbon (C/C) composites surface by solid phase infiltration and the ablation properties of the ZrC-SiC coated C/C composites under oxyacetylene flame were studied. The results show that the coating prepared on the condition of optimum process parameters exhibits dense surface and outstanding anti-ablation ability. After ablation for 20 s, the mass ablation rates of the coated C/C composites can be lowered to 2.36 × 10⁻³ g/s, 37.1% reduction compared with uncoated C/C composites. The oxide layer composed of ZrO₂ and SiO₂ acts as oxygen diffusion barrier and the evaporation of ZrO₂ and SiO₂ absorbs a great amount of heat from the flame and reduces the erosive attack on the coating.