Science.gov

Sample records for fuel spray process

  1. Process gases for high velocity oxy-fuel thermal spraying

    SciTech Connect

    Creffield, G.K.; Chapman, I.F.; Cole, M.A.; Page, W.J.; McDonough, T.

    1994-12-31

    The importance of fuel and other process gases for high velocity oxy-fuel (HVOF) thermal spraying and especially the delivery of them to the point of use is well recognized. Problems associated with the supply of liquid fuel gases, at the high flow rates and pressures required by this process, have been addressed. Considerable development work has gone into designing an appropriate liquid withdrawal and vaporizer system for propylene, which overcomes these previous difficulties and enables users to maintain adequate fuel gas flow rates in order to ensure optimum operating conditions for the production of high quality coatings. A feature of the thermal spray process is that the temperature of the workpiece is kept low, typically below 150 C, in order to reduce residual stresses in the coating and to protect heat sensitive substrates. Traditionally this has been by compressed air, however, improved cooling has been achieved using carbon dioxide. Specially designed equipment is now available which provides and directs a cold mixture of carbon dioxide gas and solid particles (snow) via suitable nozzles, on the workpiece. The position of the cooling stream can be varied, depending on the application. These developments emphasize the importance now attached to providing dedicated gas installation packages for HVOF.

  2. Photomicrographic Studies of Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Lee, Dana W; Spencer, Robert C

    1934-01-01

    A large number of photomicrographs of fuel sprays were taken for the purpose of studying the spray structure and the process of spray formation. They were taken at magnifying powers of 2.5, 3.25, and 10, using a spark discharge of very short duration for illumination. Several types and sizes of nozzles were investigated, different liquids were used, and a wide range of injection pressures was employed. The sprays were photographed as they were injected into a glass-walled chamber in which the air density was varied from 14 atmospheres to 0.0013 atmosphere.

  3. Solid oxide fuel cell processing using plasma arc spray deposition techniques

    SciTech Connect

    Ray, E.R.; Spengler, C.J.; Herman, H.

    1991-07-01

    The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect of the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.

  4. Solid oxide fuel cell processing using plasma arc spray deposition techniques. Final report

    SciTech Connect

    Ray, E.R.; Spengler, C.J.; Herman, H.

    1991-07-01

    The Westinghouse Electric Corporation, in conjunction with the Thermal Spray Laboratory of the State University of New York, Stony Brook, investigated the fabrication of a gas-tight interconnect layer on a tubular solid oxide fuel cell with plasma arc spray deposition. The principal objective was to determine the process variables for the plasma spray deposition of an interconnect with adequate electrical conductivity and other desired properties. Plasma arc spray deposition is a process where the coating material in powder form is heated to or above its melting temperature, while being accelerated by a carrier gas stream through a high power electric arc. The molten powder particles are directed at the substrate, and on impact, form a coating consisting of many layers of overlapping, thin, lenticular particles or splats. The variables investigated were gun power, spray distance, powder feed rate, plasma gas flow rates, number of gun passes, powder size distribution, injection angle of powder into the plasma plume, vacuum or atmospheric plasma spraying, and substrate heating. Typically, coatings produced by both systems showed bands of lanthanum rich material and cracking with the coating. Preheating the substrate reduced but did not eliminate internal coating cracking. A uniformly thick, dense, adherent interconnect of the desired chemistry was finally achieved with sufficient gas- tightness to allow fabrication of cells and samples for measurement of physical and electrical properties. A cell was tested successfully at 1000{degree}C for over 1,000 hours demonstrating the mechanical, electrical, and chemical stability of a plasma-arc sprayed interconnect layer.

  5. Detailed fuel spray analysis techniques

    NASA Technical Reports Server (NTRS)

    Mularz, E. J.; Bosque, M. A.; Humenik, F. M.

    1983-01-01

    Detailed fuel spray analyses are a necessary input to the analytical modeling of the complex mixing and combustion processes which occur in advanced combustor systems. It is anticipated that by controlling fuel-air reaction conditions, combustor temperatures can be better controlled, leading to improved combustion system durability. Thus, a research program is underway to demonstrate the capability to measure liquid droplet size, velocity, and number density throughout a fuel spray and to utilize this measurement technique in laboratory benchmark experiments. The research activities from two contracts and one grant are described with results to data. The experiment to characterize fuel sprays is also described. These experiments and data should be useful for application to and validation of turbulent flow modeling to improve the design systems of future advanced technology engines.

  6. Fuel spray diagnostics

    NASA Technical Reports Server (NTRS)

    Bosque, M. A.

    1984-01-01

    Several laser measurement methods are being studied to provide the capability to make droplet size and velocity measurements under a variety of spray conditions. The droplet sizing interferometer (DSI) promises to be a successful technique because of its capability for rapid data acquisition, compilation and analysis. Its main advantage is the ability to obtain size and velocity measurements in air-fuel mixing studies and hot flows. The existing DSI at NASA Lewis is a two-color, two-component system. Two independent orthogonal measurements of size and velocity components can be made simultaneously. It also uses an off-axis large-angle light scatter detection. The fundamental features of the system are optics, signal processing and data management system. The major component includes a transmitter unit, two receiver units, two signal processors, two data management systems, two Bragg cell systems, two printer/plotters, a laser, power supply and color monitor.

  7. Measurements in liquid fuel sprays

    NASA Technical Reports Server (NTRS)

    Chigier, N.

    1984-01-01

    Techniques for studying the events directly preceding combustion in the liquid fuel sprays are being used to provide information as a function of space and time on droplet size, shape, number density, position, angle of flight and velocity. Spray chambers were designed and constructed for: (1) air-assist liquid fuel research sprays; (2) high pressure and temperature chamber for pulsed diesel fuel sprays; and (3) coal-water slurry sprays. Recent results utilizing photography, cinematography, and calibration of the Malvern particle sizer are reported. Systems for simultaneous measurement of velocity and particle size distributions using laser Doppler anemometry interferometry and the application of holography in liquid fuel sprays are being calibrated.

  8. Aerodynamic study on supersonic flows in high-velocity oxy-fuel thermal spray process

    NASA Astrophysics Data System (ADS)

    Katanoda, Hiroshi; Matsuoka, Takeshi; Kuroda, Seiji; Kawakita, Jin; Fukanuma, Hirotaka; Matsuo, Kazuyasu

    2005-06-01

    To clarify the characteristics of gas flow in high velocity oxy-fuel (HVOF) thermal spray gun, aerodynamic research is performed using a special gun. The gun has rectangular cross-sectional area and sidewalls of optical glass to visualize the internal flow. The gun consists of a supersonic nozzle with the design Mach number of 2.0 followed by a straight passage called barrel. Compressed dry air up to 0.78 MPa is used as a process gas instead of combustion gas which is used in a commercial HVOF gun. The high-speed gas flows with shock waves in the gun and jets are visualized by schlieren technique. Complicated internal and external flow-fields containing various types of shock wave as well as expansion wave are visualized.

  9. Impact of alternative fuel rheology on spraying process of small pressure-swirl atomizer

    NASA Astrophysics Data System (ADS)

    Malý, Milan; Janáčková, Lada; Jedelský, Jan; Jícha, Miroslav

    2016-06-01

    A systematic investigation was made to analyse the atomizing performance of a small pressure-swirl atomizer with different crude-oil based fuels and water. The atomizer performance is characterized in terms of discharge coefficient, droplet Sauter mean diameter and nozzle efficiency. Phase-Doppler anemometry was used to measure droplets sizes and velocities and to determine the mean structure of the developed spray. A strong dependence of liquid viscosity on the mass flow rate through the atomizer as well as on the spray quality was found and discussed in comparison with relevant literature.

  10. Modeling of Two-Phase Flow and Heat Transfer in Low-Temperature Oxygen-Fuel Spray Process

    NASA Astrophysics Data System (ADS)

    Shan, Y. G.; Shen, C. H.; Jia, L. B.; Mostaghimi, J.

    2014-01-01

    The low-temperature oxygen-fuel (LTOF) spray is a modification of high velocity oxygen fuel spray. In this process, the high-temperature gas is accelerated to supersonic speed through a Laval nozzle followed by a straight barrel. By injecting room temperature gas into the mixing chamber, the temperature of the gas can be controlled in a range of about 1000-2500 K, so that some oxygen and temperature-sensitive materials, such as titanium and copper, can avoid oxidation or decomposition during the spraying process. The purpose of this paper is to establish a 2-D mathematical model to simulate the supersonic gas dynamics and particles behavior in LTOF process. The temperature and velocity of the flow fields, and the trajectory and heating of in-flight particles are predicted for different operating parameters. The model is validated by experimental data in the literature. Effects of the mixing gas flow rates, particle sizes, and injection conditions on this process were investigated as well.

  11. Tribological Properties of Hard Metal Coatings Sprayed by High-Velocity Air Fuel Process

    NASA Astrophysics Data System (ADS)

    Lyphout, C.; Sato, K.; Houdkova, S.; Smazalova, E.; Lusvarghi, L.; Bolelli, G.; Sassatelli, P.

    2016-01-01

    Lowering the thermal energy and increasing the kinetic energy of hard metal particles sprayed by the newly developed HVAF systems can significantly reduce their decarburization, and increases the sliding wear and corrosion resistance of the resulting coatings, making the HVAF technique attractive, both economically and environmentally, over its HVOF predecessors. Two agglomerated and sintered feedstock powder chemistries, WC-Co (88/12) and WC-CoCr (86/10/4), respectively, with increasing primary carbides grain size from 0.2 to 4.0 microns, have been deposited by the latest HVAF-M3 process onto carbon steel substrates. Their dry sliding wear behaviors and friction coefficients were evaluated at room temperature via Ball-on-disk (ASTM G99-90) wear tests against Al2O3 counterparts, and via Pin-on-disk (ASTM G77-05) wear tests against modified martensitic steel counterparts in both dry and lubricated conditions. Sliding wear mechanisms, with the formation of wavy surface morphology and brittle cracking, are discussed regarding the distribution and size of primary carbides. Corrosion behaviors were evaluated via standard Neutral Salt Spray, Acetic Acid Salt Spray, accelerated corrosion test, and electrochemical polarization test at room temperature. The optimization of the tribological properties of the coatings is discussed, focusing on the suitable selection of primary carbide size for different working load applications.

  12. Modeling of gas turbine fuel nozzle spray

    SciTech Connect

    Rizk, N.K.; Chin, J.S.; Razdan, M.K.

    1997-01-01

    Satisfactory performance of the gas turbine combustor relies on the careful design of various components, particularly the fuel injector. It is, therefore, essential to establish a fundamental basis for fuel injection modeling that involves various atomization processes. A two-dimensional fuel injection model has been formulated to simulate the airflow within and downstream of the atomizer and address the formation and breakup of the liquid sheet formed at the atomizer exit. The sheet breakup under the effects of airblast, fuel pressure, or the combined atomization mode of the air-assist type is considered in the calculation. The model accounts for secondary breakup of drops and the stochastic Lagrangian treatment of spray. The calculation of spray evaporation addresses both droplet heat-up and steady-state mechanisms, and fuel vapor concentration is based on the partial pressure concept. An enhanced evaporation model has been developed that accounts for multicomponent, finite mass diffusivity and conductivity effects, and addresses near-critical evaporation. The present investigation involved predictions of flow and spray characteristics of two distinctively different fuel atomizers under both nonreacting and reacting conditions. The predictions of the continuous phase velocity components and the spray mean drop sizes agree well with the detailed measurements obtained for the two atomizers, which indicates the model accounts for key aspects of atomization. The model also provides insight into ligament formation and breakup at the atomizer exit and the initial drop sizes formed in the atomizer near field region where measurements are difficult to obtain. The calculations of the reacting spray show the fuel-rich region occupied most of the spray volume with two-peak radial gas temperature profiles. The results also provided local concentrations of unburned hydrocarbon and CO in atomizer flowfield.

  13. Thermal spray processing

    SciTech Connect

    Herman, H.; Berndt, C.C.

    1995-03-01

    Thermal spray processing has been used for a number of years to cost-effecticely apply TBC`s for a wide range of heat engine applications. In particular, bond coats are applied by plasma spray and HVOF techniques and partially-stabilized zirconia top coats are applied by plasma spray methods. Thermal spray involves melting and rapid transport of the molten particles to the substrate, where high-rate solidification and coating build-up occur. It is the very nature of this melt processing that leads to the unique layered microstructure, as well as the apparent imperfections, so readily identified with thermal spray. Modeling the process, process-induced residual stresses, and thermal conductivity will be discussed in light of a new understanding of porosity and its anisotropy. Microcracking can be understood using new approaches, allowing a fuller view of the processing-performance connection. Detailed electron microscopic, novel neutron diffraction and fracture analysis of the deposits can lead to a better understanding of how overall microstructure can be controlled to influence critical properties of the deposited TBC system.

  14. Thermal spray processing

    NASA Technical Reports Server (NTRS)

    Herman, H.; Berndt, C. C.

    1995-01-01

    Thermal spray processing has been used for a number of years to cost-effecticely apply TBC's for a wide range of heat engine applications. In particular, bond coats are applied by plasma spray and HVOF techniques and partially-stabilized zirconia top coats are applied by plasma spray methods. Thermal spray involves melting and rapid transport of the molten particles to the substrate, where high-rate solidification and coating build-up occur. It is the very nature of this melt processing that leads to the unique layered microstructure, as well as the apparent imperfections, so readily identified with thermal spray. Modeling the process, process-induced residual stresses, and thermal conductivity will be discussed in light of a new understanding of porosity and its anisotropy. Microcracking can be understood using new approaches, allowing a fuller view of the processing-performance connection. Detailed electron microscopic, novel neutron diffraction and fracture analysis of the deposits can lead to a better understanding of how overall microstructure can be controlled to influence critical properties of the deposited TBC system.

  15. Measurement of spray combustion processes

    NASA Technical Reports Server (NTRS)

    Peters, C. E.; Arman, E. F.; Hornkohl, J. O.; Farmer, W. M.

    1984-01-01

    A free jet configuration was chosen for measuring noncombusting spray fields and hydrocarbon-air spray flames in an effort to develop computational models of the dynamic interaction between droplets and the gas phase and to verify and refine numerical models of the entire spray combustion process. The development of a spray combustion facility is described including techniques for laser measurements in spray combustion environments and methods for data acquisition, processing, displaying, and interpretation.

  16. Pollutant Formation in Monodisperse Fuel Spray Combustion

    NASA Technical Reports Server (NTRS)

    Cernansky, N. P.; Sarv, H.

    1983-01-01

    The combustion of liquid sprays represents an extremely important class of combustion processes. In the transition region, encompassing droplet sizes in the range of 25-80 micron diameter, the mixing and evaporation processes are both incomplete at the flame front and burning occurs in a combined diffusive and premixed fashion. Under these conditions, the relative importance of heterogeneous and homogeneous effects in dominating the combustion process is switched and gives rise to a number of interesting phenomena. NO (sub x) formation in monodisperse spray combustion was investigated with the following specific objectives: (1) to quantitatively determine the effect of droplet size, number density, etc. on NO sub x formation in monodisperse fuel spray combustion; and (2) to isolate the important physical and chemical phenomena in NO sub x formation in these combustion systems.

  17. Experiments on the Distribution of Fuel in Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Lee, Dana W

    1932-01-01

    The distribution of the fuel in sprays for compression-ignition engines was investigated by taking high-speed spark photographs of fuel sprays produced under a wide variety of conditions, and also by injecting them against pieces of Plasticine. A photographic study was made of sprays injected into evacuated chambers, into the atmosphere, into compressed air, and into transparent liquids. Pairs of identical sprays were injected counter to each other and their behavior analyzed. Small high-velocity air jets were directed normally to the axes of fuel sprays, with the result that the envelope of spray which usually obscures the core was blown aside, leaving the core exposed on one side.

  18. Digital Image Processing application to spray and flammability studies

    NASA Technical Reports Server (NTRS)

    Hernan, M. A.; Parikh, P.; Sarohia, V.

    1985-01-01

    Digital Image Processing has been integrated into a new technique for measurements of fuel spray characteristics. The advantages of this technique are: a wide dynamic range of droplet sizes, accounting for nonspherical droplet shapes not possible with other spray assessment techniques. Finally, the technique has been applied to the study of turbojet engine fuel nozzle atomization performance with Jet A and antimisting fuel.

  19. An Experimental Investigation and Numerical Analysis of Multi-Component Fuel Spray

    NASA Astrophysics Data System (ADS)

    Myong, Kwang-Jae; Arai, Motoyuki; Tanaka, Tomoyuki; Senda, Jiro; Fujimoto, Hajime

    In this study, droplet atomization and vaporization characteristics with multi-component fuel were investigated by experimental and numerical simulation methods. Spray characteristics of multi-component fuel including spray cone angle, spray angle and spray tip penetration were analyzed from shadowgraph imaging. Numerical simulation to investigate spatial distribution of fuel-vapor concentration of each component within multi-component fuel was implemented in KIVA code. Vaporization process was calculated by a simple two-phase region which was approximated by modified saturated liquid-vapor line. Experimental results show that spray cone angle and spray angle become larger increasing in mass fraction of low boiling point component. And spray tip penetration becomes shorter with increasing in mass fraction of low boiling point component in vaporizing spray during that is same on every mixed fuel in non-vaporizing spray. From numerical simulation results, temporal and spatial distribution of each fuel vapor concentration was found to be stratification.

  20. Fuel thermal stability effects on spray characteristics

    NASA Technical Reports Server (NTRS)

    Lefebvre, A. H.; Nickolaus, D.

    1987-01-01

    The propensity of a heated hydrocarbon fuel toward solids deposition within a fuel injector is investigated experimentally. Fuel is arranged to flow through the injector at constant temperature, pressure, and flow rate and the pressure drop across the nozzle is monitored to provide an indication of the amount of deposition. After deposits have formed, the nozzle is removed from the test rig and its spray performance is compared with its performance before deposition. The spray characteristics measured include mean drop size, drop-size distribution, and radial and circumferential fuel distribution. It is found that small amounts of deposition can produce severe distortion of the fuel spray pattern. More extensive deposition restores spray uniformity, but the nozzle flow rate is seriously curtailed.

  1. Influence of drop size distribution and fuel vapor fraction on premixed spray combustion

    NASA Astrophysics Data System (ADS)

    Machiroutu, Sridhar Venkatabojji

    Premixed spray combustion is affected by fuel and oxidizer properties, mixture equivalence ratio and spray quality. The spray quality is characterized by a mean droplet diameter (SMD) and a droplet size distribution (DSD). Prior experimental studies have considered only the influence of SMD, in part due to the difficulty in controlling the DSD independently. The present work provides experimental evidence demonstrating the effect of the fuel droplet size distribution and fuel vapor fraction on premixed spray combustion. Combustion experiments were performed in a pilot-ignited, continuous flow, tubular, vertical test rig wherein fuel sprays were injected into an air stream. A novel twin-atomizer technique that allowed control over overall equivalence ratio, SMD, DSD, and fuel vapor fraction of the premixed spray was used to generate test sprays. A line-of-sight, infrared (IR) extinction technique was developed to quantify the fuel vapor fraction in premixed sprays. Radial distributions of fuel vapor were evaluated using an 'onion peeling' deconvolution technique. Combustion of test sprays indicated flame propagation among regions of high fuel vapor fraction to generate a high rate of combustion. In lean premixed sprays, the presence of a low fuel vapor concentration does not impact the combustion process. Experimental evidence demonstrating the enhancement of flame propagation velocity for optimal SMDs of ethanol sprays has been found. It was observed that test sprays with narrower DSDs have faster burning rates and more complete combustion. The DSD of the sprays were characterized with a droplet surface-area-based standard deviation of the DSD.

  2. Preliminary Photomicrographic Studies of Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Lee, Dana W; Spencer, Robert C

    1932-01-01

    Photomicrographs were taken of fuel sprays injected into air at various densities for the purpose of studying the spray structure and the stages in the atomization of the fuel. The photomicrographs were taken at magnifying powers of 2.5, 3.25, and 10, using a spark discharge of very short duration for illumination. The results indicate that the theory advanced by Dr. R. A. Castleman, Jr., on the atomization of fuel in carburetors may also be applied to the atomization of fuel sprays of the solid-injection type. The fuel leaves the nozzle as a solid column, is ruffled and then torn into small, irregular ligaments by the action of the air. These ligaments are then quickly broken up into drops by the surface tension of the fuel. The photomicrographs also show that the dispersion of a fuel spray at a given distance from the nozzle increases with an increase in the jet velocity or an increase in the air density. The first portions of fuel sprays injected from an automatic injection valve into air at atmospheric density have a much greater dispersion than the later portions, but this difference decreases rapidly as the air density is increased.

  3. Process Sprays Uniforms Plasma Coatings

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.; Jacobson, T. P.; Walther, G. C.; Nakamura, H. H.

    1983-01-01

    Composite-powder processing procedure developed along with plasma-spray parameters to achieve homogeneous, well-bonded, low-porosity, self-lubricating coatings. Multicomponent plasma coatings are applied without segretation of components.

  4. Measurements in liquid fuel sprays

    NASA Technical Reports Server (NTRS)

    Chigier, N.; Mao, C. P.

    1985-01-01

    A ground test facility is being established at NASA Lewis Research Center to simulate the environmental and flight conditions needed to study adverse weather effects. One of the most important components is the water spray system which consists of many nozzles fitted on spray bars. Water is injected through air-assisted atomizers to generate uniform size drops to simulate icing in clouds. The primary objective is to provide experimental data on drop size distribution over a wide range of operating conditions. Correlation equations for mean drop size and initial injection parameters are being determined to assist in the design and modification of the Altitude Wind Tunnel. Special emphasis is being placed on the study of the aerodynamic structure of the air-assisted atomizer sprays. Detailed measurements of the variation of drop size distribution and velocity as a function of time and space are being made. Accurate initial and boundary conditions are being provided for computer model evaluation.

  5. Analysis of polydisperse fuel spray flame

    NASA Astrophysics Data System (ADS)

    Nave, Ophir; Lehavi, Yaron; Ajadi, Suraju; Gol'dshtein, Vladimir

    2016-06-01

    In this paper we analyzed the model of polydisperse fuel spray flame by using the sectional approach to describe the droplet-droplet interaction within the spray. The radii of the droplets are described by a probability density function. Our numerical simulations include a comparative analysis between three empirical droplet size distributions: the Rosin-Rammler distribution, the log-normal distribution and the Nakiyama-Tanasawa distribution. The log-normal distribution was found to produce a reasonable approximation to both the number and volume size distribution function. In addition our comparative analysis includes the application of the homotopy analysis method which yields convergent solutions for all values of the relevant parameters. We compared the above results to experimental fuel spray data such as {{Tetralin}} , n-{{Decane}} , and n-{{Heptane}} .

  6. Effect of fuel rate and annealing process of LiFePO{sub 4} cathode material for Li-ion batteries synthesized by flame spray pyrolysis method

    SciTech Connect

    Halim, Abdul; Setyawan, Heru; Machmudah, Siti; Nurtono, Tantular; Winardi, Sugeng

    2014-02-24

    In this study the effect of fuel rate and annealing on particle formation of LiFePO{sub 4} as battery cathode using flame spray pyrolysis method was investigated numerically and experimentally. Numerical study was done using ANSYS FLUENT program. In experimentally, LiFePO{sub 4} was synthesized from inorganic aqueous solution followed by annealing. LPG was used as fuel and air was used as oxidizer and carrier gas. Annealing process attempted in inert atmosphere at 700°C for 240 min. Numerical result showed that the increase of fuel rate caused the increase of flame temperature. Microscopic observation using Scanning Electron Microscopy (SEM) revealed that all particles have sphere and polydisperse. Increasing fuel rate caused decreasing particle size and increasing particles crystallinity. This phenomenon attributed to the flame temperature. However, all produced particles still have more amorphous phase. Therefore, annealing needed to increase particles crystallinity. Fourier Transform Infrared (FTIR) analysis showed that all particles have PO4 function group. Increasing fuel rate led to the increase of infrared spectrum absorption corresponding to the increase of particles crystallinity. This result indicated that phosphate group vibrated easily in crystalline phase. From Electrochemical Impedance Spectroscopy (EIS) analysis, annealing can cause the increase of Li{sup +} diffusivity. The diffusivity coefficient of without and with annealing particles were 6.84399×10{sup −10} and 8.59888×10{sup −10} cm{sup 2} s{sup −1}, respectively.

  7. High-pressure combustion of binary fuel sprays

    NASA Technical Reports Server (NTRS)

    Mikami, Masato; Kono, Michikata; Sato, Jun'ichi; Dietrich, Daniel L.; Williams, Forman A.

    1995-01-01

    The ultimate objective of this study is to obtain fundamental information relevant to combustion processes that occur in fuel sprays of practical interest at high pressures in internal combustion engines. Since practical fuels are multicomponent and derived from petroleum, the present work involves the model alkane mixture of n-heptane and n-hexadecane. Since burning droplets in sprays can interact with each other, the present work involves investigation of the effects of this interaction on flame shapes and droplet burning times. The small droplets in practical combustion chambers are not significantly influenced by buoyancy. Since such small droplets are difficult to study experimentally, the present work takes advantage of microgravity to lessen buoyancy and enable information about droplet interactions to be obtained by studying larger droplets. The results are intended to provide fundamental understanding that can be used in improving descriptions of practical spray combustion.

  8. Accurate analysis of multicomponent fuel spray evaporation in turbulent flow

    NASA Astrophysics Data System (ADS)

    Rauch, Bastian; Calabria, Raffaela; Chiariello, Fabio; Le Clercq, Patrick; Massoli, Patrizio; Rachner, Michael

    2012-04-01

    The aim of this paper is to perform an accurate analysis of the evaporation of single component and binary mixture fuels sprays in a hot weakly turbulent pipe flow by means of experimental measurement and numerical simulation. This gives a deeper insight into the relationship between fuel composition and spray evaporation. The turbulence intensity in the test section is equal to 10%, and the integral length scale is three orders of magnitude larger than the droplet size while the turbulence microscale (Kolmogorov scales) is of same order as the droplet diameter. The spray produced by means of a calibrated droplet generator was injected in a gas flow electrically preheated. N-nonane, isopropanol, and their mixtures were used in the tests. The generalized scattering imaging technique was applied to simultaneously determine size, velocity, and spatial location of the droplets carried by the turbulent flow in the quartz tube. The spray evaporation was computed using a Lagrangian particle solver coupled to a gas-phase solver. Computations of spray mean diameter and droplet size distributions at different locations along the pipe compare very favorably with the measurement results. This combined research tool enabled further investigation concerning the influencing parameters upon the evaporation process such as the turbulence, droplet internal mixing, and liquid-phase thermophysical properties.

  9. Vacuum plasma spray applications on liquid fuel rocket engines

    NASA Technical Reports Server (NTRS)

    Mckechnie, T. N.; Zimmerman, F. R.; Bryant, M. A.

    1992-01-01

    The vacuum plasma spray process (VPS) has been developed by NASA and Rocketdyne for a variety of applications on liquid fuel rocket engines, including the Space Shuttle Main Engine. These applications encompass thermal barrier coatings which are thermal shock resistant for turbopump blades and nozzles; bond coatings for cryogenic titanium components; wear resistant coatings and materials; high conductivity copper, NaRloy-Z, combustion chamber liners, and structural nickel base material, Inconel 718, for nozzle and combustion chamber support jackets.

  10. Vacuum plasma spray applications on liquid fuel rocket engines

    NASA Astrophysics Data System (ADS)

    McKechnie, T. N.; Zimmerman, F. R.; Bryant, M. A.

    1992-07-01

    The vacuum plasma spray process (VPS) has been developed by NASA and Rocketdyne for a variety of applications on liquid fuel rocket engines, including the Space Shuttle Main Engine. These applications encompass thermal barrier coatings which are thermal shock resistant for turbopump blades and nozzles; bond coatings for cryogenic titanium components; wear resistant coatings and materials; high conductivity copper, NaRloy-Z, combustion chamber liners, and structural nickel base material, Inconel 718, for nozzle and combustion chamber support jackets.

  11. Plasma spray processing of TBC`s

    SciTech Connect

    Herman, H.; Berndt, C.C.

    1995-10-01

    Thermal spray processing has been used for a number of years to cost-effectively apply TBC`s for a wide range of heat engine applications. In particular, bond coats are applied by vacuum plasma spray or HVOF techniques and partially-stabilized zirconia top coats are applied by plasma spray methods. Thermal spray involves melting and rapid transport of the molten particles to the substrate, where high-rate solidification and coating build-up occur. It is the very nature of this melt processing that leads to the unique layered microstructure, as well as the apparent imperfections, so readily identified with thermal spray. Therefore, although the plasma spray of TBCs has been largely successful, it is clear that a major step forward in terms of reliability and performance can be gained by a fundamental understanding of the TBC microstructure with respect to the processing technology and operating environment.

  12. Modeling of Plasma Spray Processes

    NASA Astrophysics Data System (ADS)

    Chang, Chong H.

    1996-10-01

    A comprehensive computational model for thermal plasma processes is being developed with sufficient generality and flexibility to apply to a wide variety of present and proposed plasma processing concepts and devices. In our model for gas-particle flows, the gas is represented as a continuous multicomponent chemically reacting gas with temperature-dependent thermodynamic and transport properties. Ions and electrons are considered as separate components or species of the mixture, while ionization and dissociation reactions are treated as chemical reactions. Entrained particles interacting with the plasma are represented by a stochastic particle model in which the velocities, temperatures, sizes, and other characteristics of typical particles are computed simultaneously with the plasma flow. The model in its present form can simulate particle injection, heating, and melting, but not evaporation and condensation. This model is embodied in the LAVA computer code, which has previously been applied to simulate plasma spraying, mixing and demixing of plasma gases, and departures from chemical (ionization/dissociation), thermal, and excitation equilibrium in plasmas. A transient simulation has been performed of stainless steel particles injected into a swirling high-velocity nitrogen-hydrogen plasma jet in air under typical operating conditions for a newly developed high-velocity high-power (HVHP) torch, which produces plasma jets with peak velocities in excess of 3000 m/s. The calculational results show that strong departures from ionization and dissociation equilibrium develop in the downstream region as the chemical reactions freeze out at lower temperatures. The calculational results also show good agreement with experimental data on particle temperature, velocity, and spray pattern, together with important statistical effects associated with distributions in particle properties and injection conditions. This work was performed under the auspices of the U. S

  13. Spray deposition of Nafion membranes: Electrode-supported fuel cells

    NASA Astrophysics Data System (ADS)

    Bayer, Thomas; Pham, Hung Cuong; Sasaki, Kazunari; Lyth, Stephen Matthew

    2016-09-01

    Fuel cells are a key technology for the successful transition towards a hydrogen society. In order to accelerate fuel cell commercialization, improvements in performance are required. Generally, polymer electrolyte membrane fuel cells (PEFCs) are membrane-supported; the electrocatalyst layer is sprayed onto both sides of the membrane, and sandwiched between carbon-based gas diffusion layers (GDLs). In this work we redesign the membrane electrode assembly (MEA) and fabricate an electrode-supported PEFC. First the electrocatalyst layer is sprayed onto the GDL, and then Nafion dispersion is sprayed over the top of this to form a thin membrane. This method has the advantage of simplifying the fabrication process, allowing the fabrication of extremely thin electrolyte layers (down to ∼10 μm in this case), and reducing the amount of ionomer required in the cell. Electrode-supported PEFCs operate at significantly increased power density compared to conventional membrane-supported PEFCs, with a maximum of 581 mW/cm2 at 80 °C (atmospheric pressure, air at the cathode). Impedance spectroscopy confirmed that the origin of the improved performance was an 80% reduction in the membrane resistance due the thinner Nafion layer. This novel fabrication method is a step towards cheaper, thinner, fully printable PEFCs with high power density and efficiency.

  14. CFD Modeling of Superheated Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Raju, M. S.

    2008-01-01

    An understanding of fuel atomization and vaporization behavior at superheat conditions is identified to be a topic of importance in the design of modern supersonic engines. As a part of the NASA aeronautics initiative, we have undertaken an assessment study to establish baseline accuracy of existing CFD models used in the evaluation of a ashing jet. In a first attempt towards attaining this goal, we have incorporated an existing superheat vaporization model into our spray solution procedure but made some improvements to combine the existing models valid at superheated conditions with the models valid at stable (non-superheat) evaporating conditions. Also, the paper reports some validation results based on the experimental data obtained from the literature for a superheated spray generated by the sudden release of pressurized R134A from a cylindrical nozzle. The predicted profiles for both gas and droplet velocities show a reasonable agreement with the measured data and exhibit a self-similar pattern similar to the correlation reported in the literature. Because of the uncertainty involved in the specification of the initial conditions, we have investigated the effect of initial droplet size distribution on the validation results. The predicted results were found to be sensitive to the initial conditions used for the droplet size specification. However, it was shown that decent droplet size comparisons could be achieved with properly selected initial conditions, For the case considered, it is reasonable to assume that the present vaporization models are capable of providing a reasonable qualitative description for the two-phase jet characteristics generated by a ashing jet. However, there remains some uncertainty with regard to the specification of certain initial spray conditions and there is a need for experimental data on separate gas and liquid temperatures in order to validate the vaporization models based on the Adachi correlation for a liquid involving R134A.

  15. Spark Ignition of Monodisperse Fuel Sprays. Ph.D. Thesis

    NASA Technical Reports Server (NTRS)

    Danis, Allen M.; Cernansky, Nicholas P.; Namer, Izak

    1987-01-01

    A study of spark ignition energy requirements was conducted with a monodisperse spray system allowing independent control of droplet size, equivalent ratio, and fuel type. Minimum ignition energies were measured for n-heptane and methanol sprays characterized at the spark gap in terms of droplet diameter, equivalence ratio (number density) and extent of prevaporization. In addition to sprays, minimum ignition energies were measured for completely prevaporized mixtures of the same fuels over a range of equivalence ratios to provide data at the lower limit of droplet size. Results showed that spray ignition was enhanced with decreasing droplet size and increasing equivalence ratio over the ranges of the parameters studied. By comparing spray and prevaporized ignition results, the existence of an optimum droplet size for ignition was indicated for both fuels. Fuel volatility was seen to be a critical factor in spray ignition. The spray ignition results were analyzed using two different empirical ignition models for quiescent mixtures. Both models accurately predicted the experimental ignition energies for the majority of the spray conditions. Spray ignition was observed to be probabilistic in nature, and ignition was quantified in terms of an ignition frequency for a given spark energy. A model was developed to predict ignition frequencies based on the variation in spark energy and equivalence ratio in the spark gap. The resulting ignition frequency simulations were nearly identical to the experimentally observed values.

  16. Microstructure and properties of tungsten carbide coatings sprayed with various high-velocity oxygen fuel spray systems

    NASA Astrophysics Data System (ADS)

    Schwetzke, R.; Kreye, H.

    1999-09-01

    This article reports on a series of experiments with various high-velocity oxygen fuel spray systems (Jet Kote, Top Gun, Diamond Jet (DJ) Standard, DJ 2600 and 2700, JP-5000, Top Gun-K) using different WC-Co and WC-Co-Cr powders. The microstructure and phase composition of powders and coatings were analyzed by optical and scanning electron microscopy and x-ray diffraction. Carbon and oxygen content of the coatings were determined to study the decarburization and oxidation of the material during the spray process. Coatings were also characterized by their hardness, bond strength, abrasive wear, and corrosion resistance. The results demonstrate that the powders exhibit various degrees of phase transformation during the spray process depending on type of powder, spray system, and spray parameters. Within a relatively wide range, the extent of phase transformation has only little effect on coating properties. Therefore, coatings of high hardness and wear resistance can be produced with all HVOF spray systems when the proper spray powder and process parameters are chosen.

  17. Characterization of coal-water slurry fuel sprays from diesel engine injectors

    SciTech Connect

    Caton, J.A.; Kihm, K.D.

    1993-06-01

    Experiments were conducted to characterize coal-water slurry fuel sprays from diesel engine injectors. Since the combustion event is a strong function of the fuel spray, full characterization of the spray is a necessity for successful engine design and for modeling of the combustion process. Two experimental facilities were used at TAMU to study the injection of coal slurry fuels. The first experimental facility incorporates General Electric locomotive engine components (injection pump, fuel line, and nozzle) and a specially designed diaphragm to separate the abrasive coal slurry fuel from the moving parts of the pump. The second experimental facility is based on an accumulator injector from General Electric. Instrumentation includes instantaneous needle lift and fuel line pressure. A pressurized visualization chamber was used to provide a spray environment which simulated the engine gas density and permitted the use of spray diagnostic techniques. The study was divided into two phases: (1) overall characterization of the spray, and (2) detailed droplet size and size distribution characterization. In addition to this overall characterization of the spray, the second phase of this study characterized the details of the atomization quality.

  18. Preliminary Tests on the Vaporization of Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Rothrock, A M

    1932-01-01

    High-speed motion pictures were taken of fuel sprays injected into the combustion chamber of the N.A.C.A. combustion apparatus. Three fuels, ethyl alcohol, gasoline, and fuel oil, which differed considerably in volatility were tested. By maintaining the engine temperature below that required for ignition the spray could be studied from soon after the start of injection until 130 crank degrees later. The results show that the sprays vaporize appreciably so that it is possible for the ignition in high speed compression-ignition engines to take place from the vapor phase.

  19. A single step solution combustion approach for preparing gadolinia doped ceria solid oxide fuel cell electrolyte material suitable for wet powder and plasma spraying processes

    NASA Astrophysics Data System (ADS)

    Shri Prakash, B.; William Grips, V. K.; Aruna, S. T.

    2012-09-01

    The present study explores the versatility of solution combustion method for preparing powders of varying characteristics suitable for intermediate temperature solid oxide fuel cell (IT-SOFC) fabrication. The promising electrolyte material for IT-SOFC, Gd0.2Ce0.8O2-δ (GDC), is considered for the present investigation. GDC powders consisting of sub-micron sized particles (<250 nm) and micron sized (>20 μm) particles are produced by varying the fuel used in the combustion reaction. Highly sinteractive nano-GDC powders prepared using oxalyl dihydrazide as a fuel results in dense pellets with high conductivity (3 × 10-4 Scm-1 at 400 °C). This powder also results in a stable suspension suitable for wet powder spraying and electrophoretic deposition. Powders with larger particle size (>20 μm) prepared by solution combustion method using mixture of fuels, exhibits necessary flowability for atmospheric plasma spraying (APS). GDC coatings fabricated by APS using flowable powders are dense with superior adhesion between the splats. Good adhesion between the splats in the APS coatings is attributed to the higher level of melting of the combustion synthesized particles in the plasma flame owing to their low specific mass.

  20. Spray drying for processing of nanomaterials

    NASA Astrophysics Data System (ADS)

    Sæderup Lindeløv, Jesper; Wahlberg, Michael

    2009-05-01

    Consolidation of nano-particles into micron-sized granules reduces the potential risks associated with handling nano-powders in dry form. Spray drying is a one step granulation technique which can be designed for safe production of free flowing low dusty granules from suspensions of nano-particles. Spray dried granules are well suited for subsequent processing into final products where the superior properties given by the nano-particles are retained. A spray drier with bag filters inside the drying chamber and recycling of drying gas combined with containment valves are proposed as a safe process for granulation of potential hazardous nano-particles.

  1. Spray Characterization of Gas-to-Liquid Synthetic Jet Fuels

    NASA Astrophysics Data System (ADS)

    Kannaiyan, Kumaran; Sadr, Reza

    2011-11-01

    In the recent years, development of alternative jet fuels is gaining importance owing to the demand for cleaner combustion. In addition to having energy density that matches those of conventional fuels, alternate jet fuels need to possess vital qualities such as rapid atomization and vaporization, quick re-ignition at high altitude, less emission, and poses ease of handling. The fuel preparatory steps (atomization and vaporization) and mixing in a combustion chamber play a crucial role on the subsequent combustion and emission characteristics. Gas-to-Liquid (GTL) synthetic jet fuel obtained from Fischer-Tropsch synthesis has grabbed the global attention due to its cleaner combustion characteristics as a result of the absence of aromatics and sulphur. As a part of an on-going joint effort between Texas A&M at Qatar (TAMUQ), Rolls-Royce (UK), and German Aerospace Laboratory (DLR), a spray characterization experimental facility is set up at TAMUQ to study the spray characteristics of GTL fuel and highlights the influence of change in fuel composition on the spray characteristics. In this work, spray characteristics such as droplet size, velocity, and distribution of different GTL fuel blends is investigated and compared with the spray characteristics of conventional JetA1 fuel. Supported by Qatar Science and Technology Park, QSTP.

  2. Mixing of an Airblast-atomized Fuel Spray Injected into a Crossflow of Air

    NASA Technical Reports Server (NTRS)

    Leong, May Y.; McDonell, Vincent G.; Samuelsen, G. Scott

    2000-01-01

    The injection of a spray of fuel droplets into a crossflow of air provides a means of rapidly mixing liquid fuel and air for combustion applications. Injecting the liquid as a spray reduces the mixing length needed to accommodate liquid breakup, while the transverse injection of the spray into the air stream takes advantage of the dynamic mixing induced by the jet-crossflow interaction. The structure of the spray, formed from a model plain-jet airblast atomizer, is investigated in order to determine and understand the factors leading to its dispersion. To attain this goal, the problem is divided into the following tasks which involve: (1) developing planar imaging techniques that visualize fuel and air distributions in the spray, (2) characterizing the airblast spray without a crossflow, and (3) characterizing the airblast spray upon injection into a crossflow. Geometric and operating conditions are varied in order to affect the atomization, penetration, and dispersion of the spray into the crossflow. The airblast spray is first characterized, using imaging techniques, as it issues into a quiescent environment. The spray breakup modes are classified in a liquid Reynolds number versus airblast Weber number regime chart. This work focuses on sprays formed by the "prompt" atomization mode, which induces a well-atomized and well-dispersed spray, and which also produces a two-lobed liquid distribution corresponding to the atomizing air passageways in the injector. The characterization of the spray jet injected into the crossflow reveals the different processes that control its dispersion. Correlations that describe the inner and outer boundaries of the spray jet are developed, using the definition of a two-phase momentum-flux ratio. Cross-sections of the liquid spray depict elliptically-shaped distributions, with the exception of the finely-atomized sprays which show kidney-shaped distributions reminiscent of those obtained in gaseous jet in crossflow systems. A droplet

  3. Some Characteristics of Fuel Sprays at Low-injection Pressures

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Waldron, C D

    1931-01-01

    This report presents the results of tests conducted at the Langley Memorial Aeronautical Laboratory, Langley Field, Va., to determine some of the characteristics of the fuel sprays obtained from an 0.008-inch and a 0.020-inch open nozzle when injection pressures from 100 to 500 pounds per square inch were used. Fuel oil and gasoline were injected into air at densities of atmospheric land 0.325 pound per cubic foot. It was found that the penetration rate at these low pressures was about the same as the rate obtained with higher pressures. Spray cone-angles were small and individual oil drops were visible in all the sprays. Gasoline and fuel oil sprays had similar characteristics.

  4. Effect of Fuel Additives on Spray Performance of Alternative Jet Fuels

    NASA Astrophysics Data System (ADS)

    Kannaiyan, Kumaran; Sadr, Reza

    2015-11-01

    Role of alternative fuels on reducing the combustion pollutants is gaining momentum in both land and air transport. Recent studies have shown that addition of nanoscale metal particles as fuel additives to liquid fuels have a positive effect not only on their combustion performance but also in reducing the pollutant formation. However, most of those studies are still in the early stages of investigation with the addition of nanoparticles at low weight percentages. Such an addition can affect the hydrodynamic and thermo-physical properties of the fuel. In this study, the near nozzle spray performance of gas-to-liquid jet fuel with and without the addition of alumina nanoparticles are investigated at macro- and microscopic levels using optical diagnostic techniques. At macroscopic level, the addition of nanoparticles is seen to enhance the sheet breakup process when compared to that of the base fuel. Furthermore, the microscopic spray characteristics such as droplet size and velocity are also found to be affected. Although the addition of nanoscale metal particles at low weight percentages does not affect the bulk fluid properties, the atomization process is found to be affected in the near nozzle region. Funded by Qatar National Research Fund.

  5. Image processing system to analyze droplet distributions in sprays

    NASA Technical Reports Server (NTRS)

    Bertollini, Gary P.; Oberdier, Larry M.; Lee, Yong H.

    1987-01-01

    An image processing system was developed which automatically analyzes the size distributions in fuel spray video images. Images are generated by using pulsed laser light to freeze droplet motion in the spray sample volume under study. This coherent illumination source produces images which contain droplet diffraction patterns representing the droplets degree of focus. The analysis is performed by extracting feature data describing droplet diffraction patterns in the images. This allows the system to select droplets from image anomalies and measure only those droplets considered in focus. Unique features of the system are the totally automated analysis and droplet feature measurement from the grayscale image. The feature extraction and image restoration algorithms used in the system are described. Preliminary performance data is also given for two experiments. One experiment gives a comparison between a synthesized distribution measured manually and automatically. The second experiment compares a real spray distribution measured using current methods against the automatic system.

  6. Characteristics of MCrAlY coatings sprayed by high velocity oxygen-fuel spraying system

    SciTech Connect

    Itoh, Y.; Saitoh, M.; Tamura, M.

    2000-01-01

    High velocity oxygen-fuel (HVOF) spraying system in open air has been established for producing the coatings that are extremely clean and dense. It is thought that the HVOF sprayed MCrAlY (M is Fe, Ni and/or Co) coatings can be applied to provide resistance against oxidation and corrosion to the hot parts of gas turbines. Also, it is well known that the thicker coating can be sprayed in comparison with any other thermal spraying systems due to improved residual stresses. However, thermal and mechanical properties of HVOF coatings have not been clarified. Especially, the characteristics of residual stress, that are the most important property from the view point of production technique, have not been made clear. In this paper, the mechanical properties of HVOF sprayed MCrAlY coatings were measured in both the case of as-sprayed and heat-treated coatings in comparison with a vacuum plasma sprayed MCrAlY coatings. It was confirmed that the mechanical properties of HVOF sprayed MCrAlY coatings could be improved by a diffusion heat treatment to equate the vacuum plasma sprayed MCrAlY coatings. Also, the residual stress characteristics were analyzed using a deflection measurement technique and a X-ray technique. The residual stress of HVOF coating was reduced by the shot-peening effect comparable to that of a plasma spray system in open air. This phenomena could be explained by the reason that the HVOF sprayed MCrAlY coating was built up by poorly melted particles.

  7. Dropwise ignition versus external ignition for multicomponent fuel sprays

    NASA Astrophysics Data System (ADS)

    Mawid, M.; Aggarwal, S. K.

    1988-07-01

    An attempt has been made to identify conditions for dropwise ignition and spray ignition. Both pure as well as multicomponent fuels are considered. For dropwise ignition, an existing ignition criterion has been modified to account for the nonlinear dependence of reaction rate on fuel and oxygen concentrations and to account for the multicomponent nature of the fuel. The external or spray ignition is considered through the zero heat flux condition at the ignition source. The effect of chemical kinetics is examined by employing reaction schemes with unity as well as non-unity exponents of fuel and oxygen concentrations. Results indicate that for most of the conditions considered, the individual droplet ignition is favored over the external ignition. Only when the drop diameter is smaller than 30 microns, the spray ignites earlier than droplets. The addition of a small amount of a volatile component significantly enhances the ignitability of both modes. However, the effect is stronger for the dropwise ignition mode.

  8. Some Characteristics of Fuel Sprays from Open Nozzles

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Lee, D W

    1930-01-01

    The penetration and cone-angle of fuel sprays from open nozzles were recorded with the NACA Spray Photography Equipment. The results show that for injection systems in which the rate of pressure rise at the discharge orifice is high, open nozzles give spray-tip velocities and penetrations which compare favorably with those of closed nozzles. The spray cone-angle was the same for all tests, although open nozzles having different orifice diameters were used, and one nozzle was used both as an open and as a closed nozzle. In designing a fuel system using open nozzles, particular care must be taken to avoid air pockets. The check valve should be placed close to the discharge orifice.

  9. Analytical and mechanical testing of high velocity oxy-fuel thermal sprayed and plasma sprayed calcium phosphate coatings.

    PubMed

    Haman, J D; Chittur, K K; Crawmer, D E; Lucas, L C

    1999-01-01

    Plasma spraying (PS) is the most frequently used coating technique for implants; however, in other industries a cheaper, more efficient process, high-velocity oxy-fuel thermal spraying (HVOF), is in use. This process provides higher purity, denser, more adherent coatings than plasma spraying. The primary objective of this work was to determine if the use of HVOF could improve the mechanical properties of calcium phosphate coatings. Previous studies have shown that HVOF calcium phosphate coatings are more crystalline than plasma sprayed coatings. In addition, because the coatings are exposed to more complex loading profiles in vivo than standard ASTM tensile tests provide, a secondary objective of this study was to determine the applicability of four-point bend testing for these coatings. Coatings produced by HVOF and PS were analyzed by profilometry, diffuse reflectance Fourier transform infrared spectroscopy, X-ray diffraction, four-point bend, and ASTM C633 tensile testing. HVOF coatings were found to have lower amorphous calcium phosphate content, higher roughness values, and lower ASTM C633 bond strengths than PS coatings; however, both coatings had similar crystal unit cell sizes, phases present (including hydroxyapatite, beta-tricalcium phosphate, and tetracalcium phosphate), and four-point bend bond strengths. Thus, the chemical, structural, and mechanical results of this study, in general, indicate that the use of HVOF to produce calcium phosphate coatings is equivalent to those produced by plasma spraying. PMID:10556851

  10. Dense spray evaporation as a mixing process

    NASA Astrophysics Data System (ADS)

    de Rivas, A.; Villermaux, E.

    2016-05-01

    We explore the processes by which a dense set of small liquid droplets (a spray) evaporates in a dry, stirred gas phase. A dense spray of micron-sized liquid (water or ethanol) droplets is formed in air by a pneumatic atomizer in a closed chamber. The spray is conveyed in ambient air as a plume whose extension depends on the relative humidity of the diluting medium. Standard shear instabilities develop at the plume edge, forming the stretched lamellar structures familiar with passive scalars. Unlike passive scalars however, these lamellae vanish in a finite time, because individual droplets evaporate at their border in contact with the dry environment. Experiments demonstrate that the lifetime of an individual droplet embedded in a lamellae is much larger than expected from the usual d2 law describing the fate of a single drop evaporating in a quiescent environment. By analogy with the way mixing times are understood from the convection-diffusion equation for passive scalars, we show that the lifetime of a spray lamellae stretched at a constant rate γ is tv=1/γ ln(1/+ϕ ϕ ) , where ϕ is a parameter that incorporates the thermodynamic and diffusional properties of the vapor in the diluting phase. The case of time-dependent stretching rates is examined too. A dense spray behaves almost as a (nonconserved) passive scalar.

  11. Characterization of high velocity oxy-fuel combustion sprayed hydroxyapatite.

    PubMed

    Haman, J D; Lucas, L C; Crawmer, D

    1995-02-01

    Bioceramic coatings, created by the high velocity oxy-fuel combustion spraying of hydroxyapatite (HA) powders onto commercially pure titanium, were characterized in order to determine whether this relatively new coating process can be successfully applied to bioceramic coatings of orthopaedic and dental implants. Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy were used to characterize both the HA starting powders and coatings. A 12 wk immersion test was conducted and the resulting changes in the coatings were also characterized. Calcium ion release during dissolution was measured with flame atomic absorption during the first 6 weeks of the immersion study. A comparison of powder and coating X-ray diffraction patterns and lattice parameters revealed an HA-type coating with some loss in crystallinity. Fourier transform infrared results showed a partial loss of the OH- group during spraying, however the phosphate groups were still present. Scanning electron microscopy analysis showed a lamellar structure with very close coating-to-substrate apposition. The coatings experienced a loss of calcium during the immersion study, with the greatest release in calcium occurring during the first 6 days of the study. No significant structural or chemical changes were observed during the 12 wk immersion study. These results indicate that the high velocity oxy-fuel process can produce an HA-type coating; however, the process needs further optimization, specifically in the areas of coating-to-substrate bond strength and minimization of phases present other than HA, before it would be recommended for commercial use. PMID:7749000

  12. Current problems in plasma spray processing

    SciTech Connect

    Berndt, C.C.; Brindley, W.; Goland, A.N.; Herman, H.; Houck, D.L.; Jones, K.; Miller, R.A.; Neiser, R.; Riggs, W.; Sampath, S.; Smith, M.; Spanne, P.

    1991-12-31

    This detailed report summarizes 8 contributions from a thermal spray conference that was held in late 1991 at Brookhaven National Laboratory (Upton, Long Island, NY, USA). The subject of ``Plasma Spray Processing`` is presented under subject headings of Plasma-particle interactions, Deposit formation dynamics, Thermal properties of thermal barrier coatings, Mechanical properties of coatings, Feed stock materials, Porosity: An integrated approach, Manufacture of intermetallic coatings, and Synchrotron x-ray microtomographic methods for thermal spray materials. Each section is intended to present a concise statement of a specific practical and/or scientific problem, then describe current work that is being performed to investigate this area, and finally to suggest areas of research that may be fertile for future activity.

  13. Current problems in plasma spray processing

    SciTech Connect

    Berndt, C.C.; Brindley, W.; Goland, A.N.; Herman, H.; Houck, D.L.; Jones, K.; Miller, R.A.; Neiser, R.; Riggs, W.; Sampath, S.; Smith, M.; Spanne, P. . Thermal Spray Lab.)

    1991-01-01

    This detailed report summarizes 8 contributions from a thermal spray conference that was held in late 1991 at Brookhaven National Laboratory (Upton, Long Island, NY, USA). The subject of Plasma Spray Processing'' is presented under subject headings of Plasma-particle interactions, Deposit formation dynamics, Thermal properties of thermal barrier coatings, Mechanical properties of coatings, Feed stock materials, Porosity: An integrated approach, Manufacture of intermetallic coatings, and Synchrotron x-ray microtomographic methods for thermal spray materials. Each section is intended to present a concise statement of a specific practical and/or scientific problem, then describe current work that is being performed to investigate this area, and finally to suggest areas of research that may be fertile for future activity.

  14. Spray Cooling Processes for Space Applications

    NASA Technical Reports Server (NTRS)

    Kizito, John P.; VanderWal, Randy L.; Berger, Gordon; Tryggvason, Gretar

    2004-01-01

    The present paper reports ongoing work to develop numerical and modeling tools used to design efficient and effective spray cooling processes and to determine characteristic non-dimensional parametric dependence for practical fluids and conditions. In particular, we present data that will delineate conditions towards control of the impingement dynamics of droplets upon a heated substrate germane to practical situations.

  15. Certification of an agricultural spray aircraft on ethanol fuel

    SciTech Connect

    Shauck, M.E.; Zanin, M.G.

    1994-12-31

    A Piper Pawnee, one of the most common agricultural spray aircraft, is currently undergoing Federal Aviation Administration (FAA) certification to allow the use of denatured ethanol as its fuel. This certification is part of a broader effort to introduce ethanol as a replacement for aviation gasoline. Various reasons brought about the choice of an agricultural spray aircraft to be certified on ethanol. One is the minimization of initial fuel distribution problems. Agricultural aviation often requires only single fuel storage since most of the flying is local. Additionally, corn-produced ethanol is the natural fuel of choice for farming operations. The increased power developed on ethanol compared to aviation gasoline (avgas) is very important when operating heavily loaded spray aircraft at very low altitudes. The power-plant, a Lycoming IO-540, is already certified. The aircraft is currently flying on ethanol in order to satisfy the airframe requirements. The effort is being supported by a consortium of organizations of corn-producing states. Upon completion of certification, the aircraft will be demonstrated around the mid-western states. Certification will allow the use of the aircraft in the commercial arena. Many mid-western agricultural spray operations and ag-pilots have already expressed interest in converting their aircraft to ethanol fuel.

  16. Spray Penetration with a Simple Fuel Injection Nozzle

    NASA Technical Reports Server (NTRS)

    Miller, Harold E; Beardsley, Edward G

    1926-01-01

    The purpose of the tests covered by this report was to obtain specific information on the rate of penetration of the spray from a simple injection nozzle, having a single orifice with a diameter of 0.015 inch when injecting into compressed gases. The results have shown that the effects of both chamber and fuel pressures on penetration are so marked that the study of sprays by means of high-speed photography or its equivalent is necessary if the effects are to be appreciated sufficiently to enable rational analysis. It was found for these tests that the negative acceleration of the spray tip is approximately proportional to the 1.5 power of the instantaneous velocity of the spray tip.

  17. The Gas Dynamics of High-Velocity Oxy-Fuel Thermal Sprays

    NASA Astrophysics Data System (ADS)

    Hackett, Charles Marcou

    An experimental study of the gas dynamics of the High-Velocity Oxy-Fuel (HVOF) thermal spray process has been performed. With this process, a hot, combustion-driven, supersonic jet is used to propel particles onto a surface, thus forming metal coatings that provide wear, temperature, and corrosion resistance. The fundamental physics of the spray process were studied and several key areas of interest were identified for in-depth study. Optical diagnostic techniques, including microsecond -exposure schlieren and shadowgraph imaging, were used to visualize the hot supersonic jet produced during the spray process. Energetic turbulent mixing of the jet with the surrounding atmosphere was observed. Measurements of oxide levels in aluminum and mild steel coatings sprayed for a range of conditions indicated that the turbulent mixing influences coating oxidation. However, experiments conducted with a low-speed coaxial shroud of inert gas demonstrated that coating oxide formation can be effectively controlled during the spray process. A simple numerical model was developed to predict the behavior of a spray particle in the HVOF jet. The results of computations indicated that independent control of spray particle velocity and temperature was possible through systematic variations in combustion chamber pressure and particle injection location within the nozzle. This hypothesis was confirmed through a series of experiments in which stainless steel particle velocity and temperature were measured using trace velocimetry and two-color radiative pyrometry, respectively. Combustion chamber pressure had a strong effect on particle velocity. Injection location was used to control the residence time of a particle within the flow, thus allowing manipulation of particle temperature without a measurable effect on velocity. Thus, the results of these experiments revealed that the gas dynamics--the behavior of the compressible gas flow--of the HVOF spray process strongly influenced spray

  18. 9 CFR 590.542 - Spray process drying operations.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 9 Animals and Animal Products 2 2011-01-01 2011-01-01 false Spray process drying operations. 590..., Processing, and Facility Requirements § 590.542 Spray process drying operations. (a) The drying room shall be... interrupted. (1) Spray nozzles, orifices, cores, or whizzers shall be cleaned immediately after cessation...

  19. 9 CFR 590.542 - Spray process drying operations.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 9 Animals and Animal Products 2 2014-01-01 2014-01-01 false Spray process drying operations. 590..., Processing, and Facility Requirements § 590.542 Spray process drying operations. (a) The drying room shall be... interrupted. (1) Spray nozzles, orifices, cores, or whizzers shall be cleaned immediately after cessation...

  20. 9 CFR 590.542 - Spray process drying operations.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 9 Animals and Animal Products 2 2013-01-01 2013-01-01 false Spray process drying operations. 590..., Processing, and Facility Requirements § 590.542 Spray process drying operations. (a) The drying room shall be... interrupted. (1) Spray nozzles, orifices, cores, or whizzers shall be cleaned immediately after cessation...

  1. 9 CFR 590.542 - Spray process drying operations.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 9 Animals and Animal Products 2 2012-01-01 2012-01-01 false Spray process drying operations. 590..., Processing, and Facility Requirements § 590.542 Spray process drying operations. (a) The drying room shall be... interrupted. (1) Spray nozzles, orifices, cores, or whizzers shall be cleaned immediately after cessation...

  2. Automated Plasma Spray (APS) process feasibility study

    NASA Technical Reports Server (NTRS)

    Fetheroff, C. W.; Derkacs, T.; Matay, I. M.

    1981-01-01

    An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing.

  3. Synthesis and Microstructural Evolution of Amorphous/Nanocrystalline Steel Coatings by Different Thermal-Spray Processes

    NASA Astrophysics Data System (ADS)

    Varadaraajan, V.; Guduru, Ramesh K.; Mohanty, P. S.

    2013-04-01

    Amorphous/nanocrystalline coatings are useful in high strength and wear-resistant applications. In the present study, the microstructural evolution of a nanocrystalline high performance steel coatings developed by different spray processes along with a novel "hybrid thermal spray" technique was studied. The hybrid-spray process combines arc and high-velocity oxy-fuel (HVOF) techniques, in which the molten metal at the arcing tip is atomized and rapidly propelled toward the substrate by HVOF jet. This so-called hybrid concept offers the benefits of productivity of electric arc spray combined with improved coating densities of HVOF. The microstructural characterization of the hybrid-spray coatings was performed by x-ray diffraction, electron microscopy, and differential scanning calorimetry, and then compared with coatings of the similar material developed by plasma-, HVOF-, and arc-spray processes individually. The HVOF- and plasma-spray coatings showed amorphous structures with very fine nanocrystals embedded, whereas hybrid- and arc-spray techniques yielded completely crystalline coatings with grain size in the range of several nanometers. The final microstructures in different spray processes could be attributed to the precursor materials employed, process temperatures, and cooling rates during the deposition process.

  4. Modeling of the vacuum plasma spray process

    SciTech Connect

    Varacalle, D.J. Jr. ); Neiser, R.A.; Smith, M.F. )

    1992-01-01

    Experimental and analytical studies have been conducted to investigate gas, particle, and coating dynamics in the vacuum plasma spray (VPS) process for a tungsten powder. VPS coatings were examined metallographically and the results compared with the model's predictions. The plasma was numerically modeled from the cathode tip to the spray distance in the free plume for the experimental conditions of this study. This information was then used as boundary conditions to solve the particle dynamics. The predicted temperature and velocity of the powder particles at standoff were then used as initial conditions for a coating dynamics code. The code predicts the coating morphology for the specific process parameters. The predicted characteristics exhibit good correlation with the observed coating properties.

  5. Modeling of the vacuum plasma spray process

    SciTech Connect

    Varacalle, D.J. Jr.; Neiser, R.A.; Smith, M.F.

    1992-10-01

    Experimental and analytical studies have been conducted to investigate gas, particle, and coating dynamics in the vacuum plasma spray (VPS) process for a tungsten powder. VPS coatings were examined metallographically and the results compared with the model`s predictions. The plasma was numerically modeled from the cathode tip to the spray distance in the free plume for the experimental conditions of this study. This information was then used as boundary conditions to solve the particle dynamics. The predicted temperature and velocity of the powder particles at standoff were then used as initial conditions for a coating dynamics code. The code predicts the coating morphology for the specific process parameters. The predicted characteristics exhibit good correlation with the observed coating properties.

  6. CDS HVOF sprayed coatings: Influence of process variables on coating characteristics

    SciTech Connect

    Knight, R.; Smith, R.W.; Lugscheider, E.

    1994-12-31

    High velocity, oxyfuel (HVOF) coating processes are fast becoming one of today`s dominant thermal spray areas, particularly for the deposition of carbide coatings where HVOF spray can produce results comparable, or even superior, to vacuum and air plasma spray processes. Results and analysis of NiCr, WC/Co, and Cr3C2NiCr coatings sprayed with the continuous detonation system (CDS) HVOF gun are presented. The investigation focused the influence of spray distance, gun/part relative speed, and fuel:oxygen ratio on coating microstructure, microhardness, and phase content. Coatings were sprayed using oxygen and propane (C{sub 3}H{sub 8}) fuel, at typical flow rates of 420 I/min, and 55 I/min, respectively. Coatings were sprayed onto 25 x 75 mm (1 in. x 3in.) 1018-steel substrates, nominally 3 mm (01.25 in.) thick. The coating materials were (-45 {mu}m + 10 {mu}) 80/20 NiCr, (-45 {mu} + 11 {mu}) 88/12 WC/Co, and (-45 {mu} + 11 {mu}m) 75/25 Cr{sub 3}C{sub 2}/NiCr. The CDS HVOF sprayed coatings were analyzed by optical microscopy, microhardness (VHN{sub 300}) and X-ray diffraction techniques to determine the effects of variations in process parameters on the microstructure and characteristics of the coatings and to investigate phase changes in the coating material caused by the HVOF process.

  7. Fuel Spray and Flame Formation in a Compression-Ignition Engine Employing Air Flow

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Waldron, C D

    1937-01-01

    The effects of air flow on fuel spray and flame formation in a high-speed compression-ignition engine have been investigated by means of the NACA combustion apparatus. The process was studied by examining high-speed motion pictures taken at the rate of 2,200 frames a second. The combustion chamber was of the flat-disk type used in previous experiments with this apparatus. The air flow was produced by a rectangular displacer mounted on top of the engine piston. Three fuel-injection nozzles were tested: a 0.020-inch single-orifice nozzle, a 6-orifice nozzle, and a slit nozzle. The air velocity within the combustion chamber was estimated to reach a value of 425 feet a second. The results show that in no case was the form of the fuel spray completely destroyed by the air jet although in some cases the direction of the spray was changed and the spray envelope was carried away by the moving air. The distribution of the fuel in the combustion chamber of a compression-ignition engine can be regulated to some extent by the design of the combustion chamber, by the design of the fuel-injection nozzle, and by the use of air flow.

  8. Evaluation of Convergent Spray Technology(TM) Spray Process for Roof Coating Application

    NASA Technical Reports Server (NTRS)

    Scarpa, J.; Creighton, B.; Hall, T.; Hamlin, K.; Howard, T.

    1998-01-01

    The overall goal of this project was to demonstrate the feasibility of(CST) Convergent Spray Technology (Trademark) for the roofing industry. This was accomplished by producing an environmentally compliant coating utilization recycled materials, a CST(Trademark) spray process portable application cart, and hand-held applicator with a CST(Trademark) spray process nozzle. The project culminated with application of this coating to a nine hundred sixty square foot metal for NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama.

  9. A Comparison of Fuel Sprays from Several Types of Injection Nozzles

    NASA Technical Reports Server (NTRS)

    Lee, Dana W

    1936-01-01

    This report presents the tests results of a series of tests made of the sprays from 14 fuel injection nozzles of 9 different types, the sprays being injected into air at atmospheric density and at 6 and 14 times atmospheric density. High-speed spark photographs of the sprays from each nozzle at each air density were taken at the rate of 2,000 per second, and from them were obtained the dimensions of the sprays and the rates of spray-tip penetration. The sprays were also injected against plasticine targets placed at different distances from the nozzles, and the impressions made in the plasticine were used as an indication of the distribution of the fuel within the spray. Cross-sectional sketches of the different types of sprays are given showing the relative sizes of the spray cores and envelopes. The characteristics of the sprays are compared and discussed with respect to their application to various types of engines.

  10. Thermal Plasma Spraying Applied on Solid Oxide Fuel Cells

    NASA Astrophysics Data System (ADS)

    Soysal, D.; Arnold, J.; Szabo, P.; Henne, R.; Ansar, S. A.

    2013-06-01

    Solid oxide fuel cells (SOFCs), attractive for diverse applications in a broad range from small portable and auxiliary power units, up to central power systems, are conventionally produced by sintering methods. However, plasma spraying promises some advantages particularly for cells with metal support. In the present paper, research activities conducted in recent years at DLR as well as latest developments on plasma sprayed functional layers for SOFC as cathodes, electrolytes, and anodes are reported. Power densities of more than 800 mW/cm2 were achieved for plasma sprayed single cells of 12.56 cm2 size, and 300 mW/cm2, respectively, with a 250 W stack made of 10 cells. These values were attained at 0.7 V and 800 °C, with H2:N2 = 1:1 as fuel gas and air as oxidizing gas. Furthermore, continuous operation of more than 5000 h was attained with a plasma sprayed metal-supported SOFC stack which could also withstand more than 30 redox and thermal cycles.

  11. Combustion characteristics in the transition region of liquid fuel sprays

    NASA Technical Reports Server (NTRS)

    Cernansky, N. P.; Namer, I.; Tidona, R. J.; Sarv, H.

    1984-01-01

    A monodisperse aerosol generator was modified to study ignition requirements, flammability limits, and flame speeds in the transition region. An ignition system was developed and tested. The fabrication of an optical drop sizing system is nearly complete. Preliminary measurements of droplet size effects on the minimum ignition energy for n-heptane sprays performed. Parameteric studies of droplet size effects on minimum ignition energies of various fuels including alcohols are in progress.

  12. Convergent spray process for environmentally friendly coatings

    NASA Technical Reports Server (NTRS)

    Scarpa, Jack

    1995-01-01

    Conventional spray application processes have poor transfer efficiencies, resulting in an exorbitant loss in materials, solvents, and time. Also, with ever tightening Environmental Protection Agency (EPA) regulations and Occupational Safety and Health Administration requirements, the low transfer efficiencies have a significant impact on the quantities of materials and solvents that are released into the environment. High solids spray processes are also limited by material viscosities, thus requiring many passes over the surface to achieve a thickness in the 0.125 -inch range. This results in high application costs and a negative impact on the environment. Until recently, requirements for a 100 percent solid sprayable, environmentally friendly, lightweight thermal protection system that can be applied in a thick (greater than 0.125 inch) single-pass operation exceeded the capability of existing systems. Such coatings must be applied by hand lay-up techniques, especially for thermal and/or fire protection systems. The current formulation of these coatings has presented many problems such as worker safety, environmental hazards, waste, high cost, and application constraints. A system which can apply coatings without using hazardous materials would alleviate many of these problems. Potential applications include the aerospace thermal protective specialty coatings, chemical and petroleum industries that require fire-protection coatings that resist impact, chemicals, and weather. These markets can be penetrated by offering customized coatings applied by automated processes that are environmentally friendly.

  13. EVALUATION OF CONVERGENT SPRAY TECHNOLOGYTM SPRAY PROCESS FOR ROOF COATING APPLICATION

    EPA Science Inventory

    The overall goal of this project was to demonstrate the feasibility of Convergent Spray TechnologyTM for the roofing industry. This was accomplished by producing an environmentally compliant coating utilizing recycled materials, a CSTTM spray process portable application cart, a...

  14. Measurements of Fuel Distribution Within Sprays for Fuel-Injection Engines

    NASA Technical Reports Server (NTRS)

    Lee, Dana W

    1937-01-01

    Two methods were used to measure fuel distribution within sprays from several types of fuel-injection nozzles. A small tube inserted through the wall of an air tight chamber into which the sprays were injected could be moved about inside the chamber. When the pressure was raised to obtain air densities of 6 and 14 atmospheres, some air was forced through the tube and the fuel that was carried with it was separated by absorbent cotton and weighed. Cross sections of sprays from plain, pintle, multiple-orifice, impinging-jets, centrifugal, lip, slit, and annular-orifice nozzles were investigated, at distances of 1, 3, 5, and 7 inches from the nozzles.

  15. High-power diode lasers in spray process diagnostics

    NASA Astrophysics Data System (ADS)

    Larjo, Jussi

    2005-03-01

    Spray processes are commonly employed in many kinds of surface treatment applications, most prominently in medical, material processing and manufacturing industries. While spraying is a well established technology, we still lack complete understanding of all interactions within a given spray process. This is because the physical models of many subprocesses, like turbulent gas flow, particle formation and gas-particle interaction, are limited and often provide only qualitative predictions on the real process. Imaging measurements are essential in gaining better understanding of a spray process. They offer a way to measure properties of both the complete spray plume and individual droplets. A spray analysis system typically requires a high-power stroboscopic light source; Xe flashlamps and Q-switched solid state lasers have been the most common choice until recently. The development of high-power diode lasers has provided a versatile, low-cost and easy to use light source for the analysis of spray processes. We present a real-time diode laser based imaging system to measure droplet density, size and velocity distributions in a spray, together with the spray plume geometry.

  16. The Effects of Fuel and Cylinder Gas Densities on the Characteristics of Fuel Sprays for Oil Engines

    NASA Technical Reports Server (NTRS)

    Joachim, W F; Beardsley, Edward G

    1928-01-01

    This investigation was conducted as a part of a general research on fuel-injection engines for aircraft. The purpose of the investigation was to determine the effects of fuel and cylinder gas densities with several characteristics of fuel sprays for oil engines. The start, growth, and cut-off of single fuel sprays produced by automatic injection valves were recorded on photographic film by means of special high-speed motion-picture apparatus. This equipment, which has been described in previous reports, is capable of taking twenty-five consecutive pictures of the moving spray at the rate of 4,000 per second. The penetrations of the fuel sprays increased and the cone angles and relative distributions decreased with increase in the specific gravity of the fuel. The density of the gas into which the fuel sprays were injected controlled their penetration. This was the only characteristic of the chamber gas that had a measurable effect upon the fuel sprays. Application of fuel-spray penetration data to the case of an engine, in which the pressure is rising during injection, indicated that fuel sprays may penetrate considerably farther than when injected into a gas at a density equal to that of the gas in an engine cylinder at top center.

  17. Two-Phase PIV: Fuel-Spray Interaction with Surrounding Air

    NASA Astrophysics Data System (ADS)

    Dankers, Stefan; Gotthardt, Mark; Stengler, Thomas; Ohmstede, Gerhard; Hentschel, Werner

    The demand for improvement of combustion-engine processes leads to a great need for detailed experimental information about the complicated processes of injection, breakup and propagation of the fuel jet and the vaporization of the fuel. Thus, in the presented work it was the aim to visualize the air flow that is induced by the injected fuel jet and also to explore the air entrainment into the fuel spray. This was done using two-phase PIV (particle image velocimetry). The fuel jet was illuminated with a Nd:YAG PIV-laser and PIV analysis was done by simply measuring the elastically scattered light of the fuel droplets. For the investigation of the surrounding air propylene-carbonate doped with DCM-dye was dispersed and the droplets were added to the continuous gas flow upstream of the chamber. Scattered and fluorescence signals, respectively, were detected perpendicular to the laser sheet with a CCD camera. To detect the gas flow, the scattered light from the liquid fuel was suppressed by an OG 590 longpass filter glass that transmits the fluorescence signal of the DCM-dye. It was possible to measure both the fuel jet and the gas flow in the presence of the fuel spray and a clear separation of the two phases could be achieved. In both (fuel and air) vector pictures corresponding vortices could be identified near the air/fuel boundary layer. Maximum velocities in the jet are depending on the operation conditions up to 150ms-1 and the gas flow has typically a velocity of 1 to 10ms-1. In the region next to the injector the air was pressed away during the injection. After the end of the injection a strong fast air entrainment flow into this region can be observed that compensates the pressure difference.

  18. Carbon nanotube reinforced aluminum nanocomposite via plasma and high velocity oxy-fuel spray forming.

    PubMed

    Laha, T; Liu, Y; Agarwal, A

    2007-02-01

    Free standing structures of hypereutectic aluminum-23 wt% silicon nanocomposite with multiwalled carbon nanotubes (MWCNT) reinforcement have been successfully fabricated by two different thermal spraying technique viz Plasma Spray Forming (PSF) and High Velocity Oxy-Fuel (HVOF) Spray Forming. Comparative microstructural and mechanical property evaluation of the two thermally spray formed nanocomposites has been carried out. Presence of nanosized grains in the Al-Si alloy matrix and physically intact and undamaged carbon nanotubes were observed in both the nanocomposites. Excellent interfacial bonding between Al alloy matrix and MWCNT was observed. The elastic modulus and hardness of HVOF sprayed nanocomposite is found to be higher than PSF sprayed composites. PMID:17450788

  19. Diagnostics and Control in the Thermal Spray Process

    SciTech Connect

    Fincke, James Russell; Swank, William David; Bewley, Randy Lee; Haggard, Delon C; Gevelber, M.; Wroblewski, D.

    2001-12-01

    The plasma-spray process features complex plasma-particle interactions that can result in process variations that limit process repeatability and coating performance. This paper reports our work on the development of real-time diagnostics and control for the plasma spray process. The strategy is to directly monitor and control those degrees of freedom of the process that are observable, controllable and affect resulting coating properties. This includes monitoring of particle velocity and temperature as well as the shape and trajectory of the spray pattern. Diagnostics that have been developed specifically for this purpose are described along with the demonstration of a closed loop process controller based on these measurements.

  20. Improved Orifice Plate for Spray Gun

    NASA Technical Reports Server (NTRS)

    Cunningham, W.

    1986-01-01

    Erratic spray pattern of commercial spray gun changed to repeatable one by simple redesign of two parts. In modified spray gun orifice plate and polytetrafluoroethylene bushing redesigned to assure centering and alignment with nozzle. Such improvement useful in many industrial applications requiring repeatable spray patterns. Might include spraying of foam insulation, paint, other protective coatings, detergents, abrasives, adhesives, process chemicals, or fuels. Unmodified spray gun produces erratic spray because lateral misalignment between orifice plate and nozzle.

  1. Plasma Spraying of Ceramics with Particular Difficulties in Processing

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Schlegel, N.; Guignard, A.; Jarligo, M. O.; Rezanka, S.; Hospach, A.; Vaßen, R.

    2015-01-01

    Emerging new applications and growing demands of plasma-sprayed coatings initiate the development of new materials. Regarding ceramics, often complex compositions are employed to achieve advanced material properties, e.g., high thermal stability, low thermal conductivity, high electronic and ionic conductivity as well as specific thermo-mechanical properties and microstructures. Such materials however, often involve particular difficulties in processing by plasma spraying. The inhomogeneous dissociation and evaporation behavior of individual constituents can lead to changes of the chemical composition and the formation of secondary phases in the deposited coatings. Hence, undesired effects on the coating characteristics are encountered. In this work, examples of such challenging materials are investigated, namely pyrochlores applied for thermal barrier coatings as well as perovskites for gas separation membranes. In particular, new plasma spray processes like suspension plasma spraying and plasma spray-physical vapor deposition are considered. In some cases, plasma diagnostics are applied to analyze the processing conditions.

  2. Plasma Spraying of Ceramics with Particular Difficulties in Processing

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Schlegel, N.; Guignard, A.; Jarligo, M. O.; Rezanka, S.; Hospach, A.; Vaßen, R.

    2014-09-01

    Emerging new applications and growing demands of plasma-sprayed coatings initiate the development of new materials. Regarding ceramics, often complex compositions are employed to achieve advanced material properties, e.g., high thermal stability, low thermal conductivity, high electronic and ionic conductivity as well as specific thermo-mechanical properties and microstructures. Such materials however, often involve particular difficulties in processing by plasma spraying. The inhomogeneous dissociation and evaporation behavior of individual constituents can lead to changes of the chemical composition and the formation of secondary phases in the deposited coatings. Hence, undesired effects on the coating characteristics are encountered. In this work, examples of such challenging materials are investigated, namely pyrochlores applied for thermal barrier coatings as well as perovskites for gas separation membranes. In particular, new plasma spray processes like suspension plasma spraying and plasma spray-physical vapor deposition are considered. In some cases, plasma diagnostics are applied to analyze the processing conditions.

  3. Solid oxide fuel cell electrolytes produced by a combination of suspension plasma spray and very low pressure plasma spray.

    SciTech Connect

    Slamovich, Elliot; Fleetwood, James; McCloskey, James F.; Hall, Aaron Christopher; Trice, Rodney Wayne

    2010-07-01

    Plasma spray coating techniques allow unique control of electrolyte microstructures and properties as well as facilitating deposition on complex surfaces. This can enable significantly improved solid oxide fuel cells (SOFCs), including non-planar designs. SOFCs are promising because they directly convert the oxidization of fuel into electrical energy. However, electrolytes deposited using conventional plasma spray are porous and often greater than 50 microns thick. One solution to form dense, thin electrolytes of ideal composition for SOFCs is to combine suspension plasma spray (SPS) with very low pressure plasma spray (VLPPS). Increased compositional control is achieved due to dissolved dopant compounds in the suspension that are incorporated into the coating during plasma spraying. Thus, it is possible to change the chemistry of the feed stock during deposition. In the work reported, suspensions of sub-micron diameter 8 mol.% Y2O3-ZrO2 (YSZ) powders were sprayed on NiO-YSZ anodes at Sandia National Laboratories (SNL) Thermal Spray Research Laboratory (TSRL). These coatings were compared to the same suspensions doped with scandium nitrate at 3 to 8 mol%. The pressure in the chamber was 2.4 torr and the plasma was formed from a combination of argon and hydrogen gases. The resultant electrolytes were well adhered to the anode substrates and were approximately 10 microns thick. The microstructure of the resultant electrolytes will be reported as well as the electrolyte performance as part of a SOFC system via potentiodynamic testing and impedance spectroscopy.

  4. Analysis of a High Velocity Oxygen-Fuel (HVOF) thermal spray torch. Part 1, Numerical formulation

    SciTech Connect

    Oberkampf, W.L.; Talpallikar, M.

    1994-01-01

    The fluid and particle dynamics of a High Velocity Oxygen-Fuel (HVOF) torch are analyzed using computational fluid dynamic (CFD) techniques. The thermal spray device analyzed is similar to a Metco Diamond Jet torch with powder injection. The spray nozzle is axisymmetric with powder injection on the centerline, premixed fuel and oxygen fed from an annulus, and air cooling injected along the interior surface of the aircap. Choked flow conditions occur at the exit of the aircap and a supersonic, under-expanded jet develops externally. The CFD simulation assumes three injection streams (solid metal particles with argon as a carrier gas, premixed oxygen/fuel, and air) inside the aircap and solves the combusting two-phase flow until the external spray stream decays to sonic conditions. The numerical formulation solves the mass, momentum, and energy transfer for both the gas and particle phase and strongly couples each phase. The combustion process is modeled using approximate equilibrium chemistry with dissociation of the gas with a total of nine species. Melting and re-solidification of the metal panicles is modeled as a lumped-mass system. Turbulent flow is modeled by a two equation k-{epsilon} turbulence model, including compressibility effects on turbulent dissipation. A time iterative, implicit, finite volume numerical method is used to solve the partial differential equations. A companion paper [10] presents the results of the numerical simulation and gives a detailed discussion of the gas and panicle dynamics.

  5. Fuel gas conditioning process

    DOEpatents

    Lokhandwala, Kaaeid A.

    2000-01-01

    A process for conditioning natural gas containing C.sub.3+ hydrocarbons and/or acid gas, so that it can be used as combustion fuel to run gas-powered equipment, including compressors, in the gas field or the gas processing plant. Compared with prior art processes, the invention creates lesser quantities of low-pressure gas per unit volume of fuel gas produced. Optionally, the process can also produce an NGL product.

  6. Some Effects of Air and Fuel Oil Temperatures on Spray Penetration and Dispersion

    NASA Technical Reports Server (NTRS)

    Gelalles, A G

    1930-01-01

    Presented here are experimental results obtained from a brief investigation of the appearance, penetration, and dispersion of oil sprays injected into a chamber of highly heated air at atmospheric pressure. The development of single sprays injected into a chamber containing air at room temperature and at high temperature was recorded by spray photography equipment. A comparison of spray records showed that with the air at the higher temperature, the spray assumed the appearance of thin, transparent cloud, the greatest part of which rapidly disappeared from view. With the chamber air at room temperature, a compact spray with an opaque core was obtained. Measurements of the records showed a decrease in penetration and an increase in the dispersion of the spray injected into the heated air. No ignition of the fuel injected was observed or recorded until the spray particles came in contact with the much hotter walls of the chamber about 0.3 second after the start of injection.

  7. Effects of fuel cetane number on the structure of diesel spray combustion: An accelerated Eulerian stochastic fields method

    NASA Astrophysics Data System (ADS)

    Jangi, Mehdi; Lucchini, Tommaso; Gong, Cheng; Bai, Xue-Song

    2015-09-01

    An Eulerian stochastic fields (ESF) method accelerated with the chemistry coordinate mapping (CCM) approach for modelling spray combustion is formulated, and applied to model diesel combustion in a constant volume vessel. In ESF-CCM, the thermodynamic states of the discretised stochastic fields are mapped into a low-dimensional phase space. Integration of the chemical stiff ODEs is performed in the phase space and the results are mapped back to the physical domain. After validating the ESF-CCM, the method is used to investigate the effects of fuel cetane number on the structure of diesel spray combustion. It is shown that, depending of the fuel cetane number, liftoff length is varied, which can lead to a change in combustion mode from classical diesel spray combustion to fuel-lean premixed burned combustion. Spray combustion with a shorter liftoff length exhibits the characteristics of the classical conceptual diesel combustion model proposed by Dec in 1997 (http://dx.doi.org/10.4271/970873), whereas in a case with a lower cetane number the liftoff length is much larger and the spray combustion probably occurs in a fuel-lean-premixed mode of combustion. Nevertheless, the transport budget at the liftoff location shows that stabilisation at all cetane numbers is governed primarily by the auto-ignition process.

  8. HVOF thermal spray process for internal diameter applications

    SciTech Connect

    Poe, M.W.

    1994-12-31

    Thermal spray has been selected as the coating process of choice for many OEM and repair/restoration applications. Although the thermal spray process has historically been limited to coating `line-of-sight` surfaces, advances in thermal spray equipment design now allow protective and/or restorative coatings to be applied to deep internal diameters utilizing state-of-the-art HVOF processing. The advanced designs include both `standard` and `mini` torches to coat rotating components, plus a rotating extension for coating stationary ID`s. In addition, a wide range of coating materials has been developed and engineered to combat the deleterious effects of wear found in severe service environments. The resultant coatings have exceptionally high bond strength with no interconnected porosity and low residual stress. This unique process provides an important adjunct to the field of thermal spray process capabilities.

  9. Thermomechanical processing of plasma sprayed intermetallic sheets

    DOEpatents

    Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleischhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

    2001-01-01

    A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

  10. Ultrafast high-repetition imaging of fuel sprays using picosecond fiber laser.

    PubMed

    Purwar, Harsh; Wang, Hongjie; Tang, Mincheng; Idlahcen, Saïd; Rozé, Claude; Blaisot, Jean-Bernard; Godin, Thomas; Hideur, Ammar

    2015-12-28

    Modern diesel injectors operate at very high injection pressures of about 2000 bar resulting in injection velocities as high as 700 m/s near the nozzle outlet. In order to better predict the behavior of the atomization process at such high pressures, high-resolution spray images at high repetition rates must be recorded. However, due to extremely high velocity in the near-nozzle region, high-speed cameras fail to avoid blurring of the structures in the spray images due to their exposure time. Ultrafast imaging featuring ultra-short laser pulses to freeze the motion of the spray appears as an well suited solution to overcome this limitation. However, most commercial high-energy ultrafast sources are limited to a few kHz repetition rates. In the present work, we report the development of a custom-designed picosecond fiber laser generating ∼ 20 ps pulses with an average power of 2.5 W at a repetition rate of 8.2 MHz, suitable for high-speed imaging of high-pressure fuel jets. This fiber source has been proof tested by obtaining backlight images of diesel sprays issued from a single-orifice injector at an injection pressure of 300 bar. We observed a consequent improvement in terms of image resolution compared to standard white-light illumination. In addition, the compactness and stability against perturbations of our fiber laser system makes it particularly suitable for harsh experimental conditions. PMID:26832004

  11. Numerical Simulation and Experimental Characterization of a Binary Aluminum Alloy Spray - Application to the Spray Rolling Process

    SciTech Connect

    S. B. Johnson; J.-P. Delplanque; Y. Lin; Y. Zhou; E. J. Lavernia; K. M. McHugh

    2005-02-01

    A stochastic, droplet-resolved model has been developed to describe the behavior of a binary aluminum alloy spray during the spray-rolling process. In this process, a molten aluminum alloy is atomized and the resulting spray is depostied on the rolls of a twin-roll caster to produce aluminum strip. The one-way coupled spray model allows the prediction of spray characteristics such as enthalph and solid fraction, and their distribution between the nozzle and the depostion surface. This paper outlines the model development and compares the predicted spray dynamics to PDI measurements performed in a controlled configuration. Predicted and measured droplet velocity and size distributions are presented for two points along the spray centerline along with predicted spray averaged specific enthalph and solid fraction curves.

  12. The Selection of the Spray Deposition Rate during the Spray Rolling Process

    SciTech Connect

    Yaojun Lin; Kevin M. McHugh; Yizhang Zhou; Enrique J. Lavernia

    2004-11-01

    This article presents a detailed theoretical analysis of the selection of the maximum and minimum spray deposition rates under steady-state conditions during the spray-rolling process. The following predictions are made on the basis of the preceding theoretical analysis. First, the key factor that may control the minimum spray deposition rate is either the removal of porosity or the removal of prior droplet boundaries. With an increase in initial liquid fraction at the deposit/roll interfaces, the mechanism changes from the former to the latter. Second, the mechanism that controls the maximum spray deposition rate is related to either the drag-in angle or the distance between the nozzle and the deposited material’s surface. With an increase in roll diameter or a decrease in distance between the nozzle and the roll-axis plane, the controlling mechanism is changed from the former to the latter. Third, both the calculated maximum and minimum spray deposition rates markedly increase with an increase in roll diameter and roll rotational frequency. In addition, the present theoretical analysis suggests that spray rolling can be optimized to manufacture strips with a high production rate.

  13. Gas density effect on dropsize of simulated fuel sprays

    NASA Technical Reports Server (NTRS)

    Ingebo, Robert D.

    1989-01-01

    Two-phase flow in pneumatic two-fluid fuel nozzles was investigated experimentally to determine the effect of atomizing-gas density and gas mass-flux on liquid-jet breakup in sonic-velocity gas-flow. Dropsize data were obtained for the following atomizing-gases: nitrogen; argon; carbon dioxide; and helium. They were selected to cover a gas molecular-weight range of 4 to 44. Atomizing-gas mass-flux ranged from 6 to 50 g/sq cm-sec and four differently sized two-fluid fuel nozzles were used having orifice diameters that varied from 0.32 to 0.56 cm. The ratio of liquid-jet diameter to SMD, D sub o/D sub 32, was correlated with aerodynamic and liquid-surface forces based on the product of the Weber and Reynolds number, and gas-to-liquid density ratio, rho sub g/rho sub 1. To correlate spray dropsize with breakup forces produced by using different atomizing-gases, a new molecular-scale dimensionless group was derived. The derived dimensionless group was used to obtain an expression for the ratio of liquid-jet diameter to SMD, D sub o/D sub 32. The mathematical expression of this phenomenon incorporates the product of the Weber and Reynolds number, liquid viscosity, surface tension, acoustic gas velocity, the RMS velocity of gas molecules, the acceleration of gas molecules due to gravity, and gas viscosity. The mathematical expression encompassing these parameters agrees well with the atomization theory for liquid-jet breakup in high velocity gas flow. Also, it was found that at the same gas mass-flux, helium was considerably more effective than nitrogen in producing small droplet sprays with SMD's in the order of 5 micrometers.

  14. Gas density effect on dropsize of simulated fuel sprays

    NASA Technical Reports Server (NTRS)

    Ingebo, Robert D.

    1989-01-01

    Two-phase flow in pneumatic two-fluid fuel nozzles was investigated experimentally to determine the effect of atomizing-gas density and gas mass-flux on liquid-jet breakup in sonic-velocity gas-flow. Dropsize data were obtained for the following atomizing-gases: nitrogen; argon; carbon dioxide; and helium. They were selected to cover a gas molecular-weight range of 4 to 44. Atomizing-gas mass-flux ranged from 6 to 50 g/sq cm-sec and four differently sized two-fluid fuel nozzles were used having orifice diameters that varied from 0.32 to 0.56 cm. The ratio of liquid-jet diameter to SMD, D sub o/D sub 32, was correlated with aerodynamic and liquid-surface forces based on the product of the Weber and Reynolds number, We*Re, and gas-to-liquid density ratio, rho sub g/rho sub l. To correlate spray dropsize with breakup forces produced by using different atomizing-gases, a new molecular-scale dimensionless group was derived. The derived dimensionless group was used to obtain an expression for the ratio of liquid-jet diameter to SMD, D sub o/D sub 32. The mathematical expression of this phenomenon incorporates the product of the Weber and Reynolds number, liquid viscosity, surface tension, acoustic gas velocity, the RMS velocity of gas molecules, the acceleration of gas molecules due to gravity, and gas viscosity. The mathematical expression encompassing these parameters agrees well with the atomization theory for liquid-jet breakup in high velocity gas flow. Also, it was found that at the same gas mass-flux, helium was considerably more effective than nitrogen in producing small droplet sprays with SMD's in the order of 5 micrometers.

  15. A Numerical Study on Gas Phase Dynamics of High-Velocity Oxygen Fuel Thermal Spray

    NASA Astrophysics Data System (ADS)

    Baik, Jae-Sang; Park, Sun-Kyu; Kim, Youn-Jea

    2008-08-01

    The high-velocity oxygen fuel (HVOF) thermal spray is used for a particulate deposition process in which micro-sized particles are propelled and heated in a supersonic combusting gas stream. It is characterized by high gas velocity and high density and is being used in an increasing variety of coating applications, such as ceramic and composite coatings, to improve wear and abrasion resistance. The particle temperature and velocity are two of the most important parameters in HVOF thermal spraying, which affect the quality of the coatings. To understand the particle dynamics, it is necessary to study, first, the thermal flow characteristics in the HVOF system. In this study, a numerical analysis is performed to predict the gas dynamic behaviors, and the effect of the geometrical parameter is studied to optimize the nozzle design.

  16. Plasma Spray-PVD: A New Thermal Spray Process to Deposit Out of the Vapor Phase

    NASA Astrophysics Data System (ADS)

    von Niessen, Konstantin; Gindrat, Malko

    2011-06-01

    Plasma spray-physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland). Even though it is a thermal spray process, it can deposit coatings out of the vapor phase. The basis of PS-PVD is the low pressure plasma spraying (LPPS) technology that has been well established in industry for several years. In comparison to conventional vacuum plasma spraying (VPS) or low pressure plasma spraying (LPPS), the new proposed process uses a high energy plasma gun operated at a reduced work pressure of 0.1 kPa (1 mbar). Owing to the high energy plasma and further reduced work pressure, PS-PVD is able to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam-physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Owing to the forced gas stream of the plasma jet, complex shaped parts such as multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight of the coating source can be coated homogeneously. This article reports on the progress made by Sulzer Metco in developing a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria-stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This process includes not only preferable coating properties such as strain tolerance and erosion

  17. Process optimization of ultrasonic spray coating of polymer films.

    PubMed

    Bose, Sanjukta; Keller, Stephan S; Alstrøm, Tommy S; Boisen, Anja; Almdal, Kristoffer

    2013-06-11

    In this work we have performed a detailed study of the influence of various parameters on spray coating of polymer films. Our aim is to produce polymer films of uniform thickness (500 nm to 1 μm) and low roughness compared to the film thickness. The coatings are characterized with respect to thickness, roughness (profilometer), and morphology (optical microscopy). Polyvinylpyrrolidone (PVP) is used to do a full factorial design of experiments with selected process parameters such as temperature, distance between spray nozzle and substrate, and speed of the spray nozzle. A mathematical model is developed for statistical analysis which identifies the distance between nozzle and substrate as the most significant parameter. Depending on the drying of the sprayed droplets on the substrate, we define two broad regimes, "dry" and "wet". The optimum condition of spraying lies in a narrow window between these two regimes, where we obtain a film of desired quality. Both with increasing nozzle-substrate distance and temperature, the deposition moves from a wet state to a dry regime. Similar results are also achieved for solvents with low boiling points. Finally, we study film formation during spray coating with poly (D,L-lactide) (PDLLA). The results confirm the processing knowledge obtained with PVP and indicate that the observed trends are identical for spraying of other polymer films. PMID:23631433

  18. A laser tomographic investigation of liquid fuel sprays

    NASA Technical Reports Server (NTRS)

    Yule, A. J.; Ahseng, C.; Felton, P.; Ungut, A.; Chigier, N. A.

    1980-01-01

    A light scattering technique is combined with a tomographic transformation to convert line of sight integrated data, measured in sprays, to measurements of droplet size and concentration in volume elements within the spray. The technique is developed and assessed by systematic experiments in axisymmetric sprays generated by twin-fluid atomisers. The good agreement found shows that, provided certain conditions are satisfied by the local spray structure, the technique provides information on spray structure, similar in detail and extent to that derived by photography, but with reduced experimental time. The technique is applied to an investigation of a kerosene spray vaporizing in a hot gas stream.

  19. A Nonlinear Model for Fuel Atomization in Spray Combustion

    NASA Technical Reports Server (NTRS)

    Liu, Nan-Suey (Technical Monitor); Ibrahim, Essam A.; Sree, Dave

    2003-01-01

    Most gas turbine combustion codes rely on ad-hoc statistical assumptions regarding the outcome of fuel atomization processes. The modeling effort proposed in this project is aimed at developing a realistic model to produce accurate predictions of fuel atomization parameters. The model involves application of the nonlinear stability theory to analyze the instability and subsequent disintegration of the liquid fuel sheet that is produced by fuel injection nozzles in gas turbine combustors. The fuel sheet is atomized into a multiplicity of small drops of large surface area to volume ratio to enhance the evaporation rate and combustion performance. The proposed model will effect predictions of fuel sheet atomization parameters such as drop size, velocity, and orientation as well as sheet penetration depth, breakup time and thickness. These parameters are essential for combustion simulation codes to perform a controlled and optimized design of gas turbine fuel injectors. Optimizing fuel injection processes is crucial to improving combustion efficiency and hence reducing fuel consumption and pollutants emissions.

  20. Characterization of Liquid Fuel Evaporation of a Lifted Methanol Spray Flame in a Vitiated Coflow Burner

    NASA Technical Reports Server (NTRS)

    Cabra, Ricardo; Dibble, Robert W.; Chen, Jyh-Yuan

    2002-01-01

    An experimental investigation of lifted spray flames in a coflow of hot, vitiated gases is presented. The vitiated coflow burner is a spray flame that issues into a coaxial flow of hot combustion products from a lean, premixed H2/Air flame. The spray flame in a vitiated coflow emulates the combustion that occurs in many advanced combustors without the detailed fluid mechanics. Two commercially available laser diagnostic systems are used to characterize the spray flame and to demonstrate the vitiated coflow burner's amenability to optical investigation. The Ensemble Particle Concentration and Size (EPCS) system is used to measure the path-average droplet size distribution and liquid volume fraction at several axial locations while an extractive probe instrument named the Real-time Fuel-air Analyzer (RFA) is used to measure the air to fuel ratio downstream of the spray nozzle with high temporal and spatial resolution. The effect of coflow conditions (stoichiometry) and dilution of the fuel with water was studied with the EPCS optical system. As expected, results show that water retards the evaporation and combustion of fuels. Measurements obtained by the RFA extractive probe show that while the Delavan manufactured nozzle does distribute the fuel over the manufacturer specified spray angle, it unfortunately does not distribute the fuel uniformly, providing conditions that may result in the production of unwanted NOx. Despite some limitations due to the inherent nature of the experimental techniques, the two diagnostics can be readily applied to spray flames in the vitiated coflow environment.

  1. Experimental design and performance analysis of alumina coatings deposited by a detonation spray process

    NASA Astrophysics Data System (ADS)

    Saravanan, P.; Selvarajan, V.; Joshi, S. V.; Sundararajan, G.

    2001-01-01

    The increasing demands for high-quality coatings has made it inevitable that the surface coating industry would put more effort into precisely controlling the coating process. Statistical design of experiments is an effective method for finding the optimum spray parameters to enhance thermal spray coating properties. In the present investigation, an attempt is made to produce high-quality alumina (Al2O3) coatings by optimizing the detonation spray process parameters following a (L16-24) factorial design approach. The process parameters that were varied include the fuel ratio, carrier gas flow rate, frequency of detonations and spray distance. The coating characteristics were quantified with respect to roughness, hardness and porosity. The performance of the coatings was quantitively evaluated using erosion, abrasion and sliding wear testing. Through statistical analysis of the experimental results, performed by the ANOVA method, the significance of each process parameter together with an optimal variable combination was obtained for the desired coating attributes. Confirmation experiments were conducted to verify the optimal spray parameter combination, which clearly showed the possibility of producing high-quality Al2O3 coatings.

  2. Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

    NASA Technical Reports Server (NTRS)

    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.

  3. Computational fluid dynamic analysis of a High-Velocity Oxygen-Fuel (HVOF) thermal spray torch

    SciTech Connect

    Hassan, B.; Oberkampf, W.L.; Neiser, R.A.; Roemer, T.J.

    1995-09-01

    The gas dynamics of a High-Velocity Oxygen-Fuel (HVOF) torch are analyzed using computational fluid dynamics (CFD) techniques. The thermal spray device analyzed is similar to a Metco Diamond Jet torch with powder feed. The injection nozzle is assumed to be axisymmetric with premixed fuel and oxygen fed from an annulus, and air cooling injected along the interior surface of the aircap. The aircap, a cronically converging nozzle, achieves choked flow conditions at the exit and a supersonic, under-expanded jet develops externally. Finite difference equations for mass, momentum, and energy conservation are solved for the gas dynamics. The combustion process is modeled using a single-step and a 12-step quasi-global finite-rate chemistry model with dissociation of the gas and a total of nine species. Turbulent flow inside the aircap and in the free-jet decay is modeled using a two-equation k-{epsilon} model. An iterative, implicit, finite volume numerical method is used to solve the gas dynamic equations inside and outside the torch . The CFD results are compared with recent experimental measurements of pressure inside the HVOF aircap. Comparisons are made for two flow rates of premixed fuel and oxygen and air cooling. This paper presents the first published comparisons of CFD predictions and experimental measurements for HVOF tbermal spraying.

  4. Microstructure and Sliding Wear Behavior of Fe-Based Coatings Manufactured with HVOF and HVAF Thermal Spray Processes

    NASA Astrophysics Data System (ADS)

    Milanti, A.; Matikainen, V.; Bolelli, G.; Koivuluoto, H.; Lusvarghi, L.; Vuoristo, P.

    2016-04-01

    The microstructure and micromechanical behavior of thermally sprayed Fe-based coatings manufactured with high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) processes were investigated. Fe-Cr-Ni-Si-B-C and Fe-Cr-Ni-Mo-Si-B-C powders were used as the feedstock materials. The coatings showed a highly dense microstructure with near-zero oxidation. The microstructure of the feedstock powders was better retained when sprayed with HVAF process. Differential scanning calorimetry revealed two small exothermic peaks at about 600 °C for the HVOF-sprayed coatings, without any increase in weight in thermogravimetric analysis. It suggested the re-precipitation of carbides that were dissolved during spraying due to the higher particle temperature reported by spray diagnostics system during the HVOF process (≈1800 °C) compared to the HVAF one (≈1400 °C). Micro- and nano-indentations helped to show the difference in inter-lamellar cohesive strength and, in turn, in the particle deposition mechanism. Coatings sprayed with Fe-Cr-Ni-Mo-Si-B-C composition possessed higher sliding wear resistance than that of Fe-Cr-Ni-Si-B-C due to higher nano-hardness. More specifically, HVOF-sprayed Fe-Cr-Ni-Mo-Si-B-C coating showed the largest intra-lamellar hardness, the largest elasticity, and high quality of particle interfaces which resulted in lower sliding wear rate.

  5. Microstructure and Sliding Wear Behavior of Fe-Based Coatings Manufactured with HVOF and HVAF Thermal Spray Processes

    NASA Astrophysics Data System (ADS)

    Milanti, A.; Matikainen, V.; Bolelli, G.; Koivuluoto, H.; Lusvarghi, L.; Vuoristo, P.

    2016-06-01

    The microstructure and micromechanical behavior of thermally sprayed Fe-based coatings manufactured with high-velocity oxygen fuel (HVOF) and high-velocity air fuel (HVAF) processes were investigated. Fe-Cr-Ni-Si-B-C and Fe-Cr-Ni-Mo-Si-B-C powders were used as the feedstock materials. The coatings showed a highly dense microstructure with near-zero oxidation. The microstructure of the feedstock powders was better retained when sprayed with HVAF process. Differential scanning calorimetry revealed two small exothermic peaks at about 600 °C for the HVOF-sprayed coatings, without any increase in weight in thermogravimetric analysis. It suggested the re-precipitation of carbides that were dissolved during spraying due to the higher particle temperature reported by spray diagnostics system during the HVOF process (≈1800 °C) compared to the HVAF one (≈1400 °C). Micro- and nano-indentations helped to show the difference in inter-lamellar cohesive strength and, in turn, in the particle deposition mechanism. Coatings sprayed with Fe-Cr-Ni-Mo-Si-B-C composition possessed higher sliding wear resistance than that of Fe-Cr-Ni-Si-B-C due to higher nano-hardness. More specifically, HVOF-sprayed Fe-Cr-Ni-Mo-Si-B-C coating showed the largest intra-lamellar hardness, the largest elasticity, and high quality of particle interfaces which resulted in lower sliding wear rate.

  6. Investigation of spray characteristics for flashing injection of fuels containing dissolved air and superheated fuels

    NASA Technical Reports Server (NTRS)

    Solomon, A. S. P.; Chen, L. D.; Faeth, G. M.

    1982-01-01

    The flow, atomization and spreading of flashing injector flowing liquids containing dissolved gases (jet/air) as well as superheated liquids (Freon II) were considered. The use of a two stage expansion process separated by an expansion chamber, ws found to be beneficial for flashing injection particularly for dissolved gas systems. Both locally homogeneous and separated flow models provided good predictions of injector flow properties. Conventional correlations for drop sizes from pressure atomized and airblast injectors were successfully modified, using the separated flow model to prescribe injector exit conditions, to correlate drop size measurements. Additional experimental results are provided for spray angle and combustion properties of sprays from flashing injectors.

  7. Modeling of formation of deposited layer by plasma spray process

    NASA Astrophysics Data System (ADS)

    Lee, Joo-Dong; Ra, Hyung-Yong; Hong, Kyung-Tae; Hur, Sung-Kang

    1992-03-01

    An analytical model is developed to describe the plasma deposition process in which average solidified thickness and coating and substrate temperatures are obtained. During the deposition process, the solidification rate is periodically varied, due to the impingement of liquid splats, and the amount of liquid in the coating layer increases. Periodical variation of the solidification rate causes temperature fluctuation in coating and substrate. The nature of interfacial structure of plasma-sprayed NiCrBSi MA powder is compared with the result predicted using the model, which indicates that the liquid deposited at the coating surface during deposition causes discontinuous boundaries within the coating. The spraying rate and the solidification rate reverse periodically with spraying process.

  8. Cold spray deposition of Ti2AlC coatings for improved nuclear fuel cladding

    NASA Astrophysics Data System (ADS)

    Maier, Benjamin R.; Garcia-Diaz, Brenda L.; Hauch, Benjamin; Olson, Luke C.; Sindelar, Robert L.; Sridharan, Kumar

    2015-11-01

    Coatings of Ti2AlC MAX phase compound have been successfully deposited on Zircaloy-4 (Zry-4) test flats, with the goal of enhancing the accident tolerance of LWR fuel cladding. Low temperature powder spray process, also known as cold spray, has been used to deposit coatings ∼90 μm in thickness using powder particles of <20 μm. X-ray diffraction analysis showed the phase-content of the deposited coatings to be identical to the powders indicating that no phase transformation or oxidation had occurred during the coating deposition process. The coating exhibited a high hardness of about 800 HK and pin-on-disk wear tests using abrasive ruby ball counter-surface showed the wear resistance of the coating to be significantly superior to the Zry-4 substrate. Scratch tests revealed the coatings to be well-adhered to the Zry-4 substrate. Such mechanical integrity is required for claddings from the standpoint of fretting wear resistance and resisting wear handling and insertion. Air oxidation tests at 700 °C and simulated LOCA tests at 1005 °C in steam environment showed the coatings to be significantly more oxidation resistant compared to Zry-4 suggesting that such coatings can potentially provide accident tolerance to nuclear fuel cladding.

  9. Cold spray deposition of Ti2AlC coatings for improved nuclear fuel cladding

    NASA Astrophysics Data System (ADS)

    Maier, Benjamin R.; Garcia-Diaz, Brenda L.; Hauch, Benjamin; Olson, Luke C.; Sindelar, Robert L.; Sridharan, Kumar

    2015-11-01

    Coatings of Ti2AlC MAX phase compound have been successfully deposited on Zircaloy-4 (Zry-4) test flats, with the goal of enhancing the accident tolerance of LWR fuel cladding. Low temperature powder spray process, also known as cold spray, has been used to deposit coatings ˜90 μm in thickness using powder particles of <20 μm. X-ray diffraction analysis showed the phase-content of the deposited coatings to be identical to the powders indicating that no phase transformation or oxidation had occurred during the coating deposition process. The coating exhibited a high hardness of about 800 HK and pin-on-disk wear tests using abrasive ruby ball counter-surface showed the wear resistance of the coating to be significantly superior to the Zry-4 substrate. Scratch tests revealed the coatings to be well-adhered to the Zry-4 substrate. Such mechanical integrity is required for claddings from the standpoint of fretting wear resistance and resisting wear handling and insertion. Air oxidation tests at 700 °C and simulated LOCA tests at 1005 °C in steam environment showed the coatings to be significantly more oxidation resistant compared to Zry-4 suggesting that such coatings can potentially provide accident tolerance to nuclear fuel cladding.

  10. 9 CFR 590.542 - Spray process drying operations.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 9 Animals and Animal Products 2 2010-01-01 2010-01-01 false Spray process drying operations. 590.542 Section 590.542 Animals and Animal Products FOOD SAFETY AND INSPECTION SERVICE, DEPARTMENT OF AGRICULTURE EGG PRODUCTS INSPECTION INSPECTION OF EGGS AND EGG PRODUCTS (EGG PRODUCTS INSPECTION ACT) Sanitary, Processing, and Facility Requirements...

  11. Development of WC-Co Coatings Deposited by Warm Spray Process

    NASA Astrophysics Data System (ADS)

    Chivavibul, Pornthep; Watanabe, Makoto; Kuroda, Seiji; Kawakita, Jin; Komatsu, Masayuki; Sato, Kazuto; Kitamura, Junya

    2008-12-01

    The high-velocity oxy-fuel (HVOF) process is commonly used to deposit WC-Co coatings. There are some problems with this process; especially the decomposition and decarburization of WC during spraying make a coating brittle. To suppress such degradation, the warm spray (WS) process was applied to deposit WC-Co coatings, which is capable of controlling the flame temperature in the range of 500-2000 °C. The microstructure and phases of the deposited coatings were characterized by using SEM and XRD, and the mechanical properties such as hardness, fracture toughness, and wear properties were also investigated. WS process successfully suppressed the formation of the detrimental phases such as W2C and W, which are usually observed in HVOF coatings. The WS coatings showed the similar trend of the hardness variation for Co content with a sintered bulk material. Improvement of toughness and wear behavior was also observed in WS coatings.

  12. Ultrafine Particulate Dispersed High-Temperature Coatings by Hybrid Spray Process

    NASA Astrophysics Data System (ADS)

    Mohanty, P. S.; Roche, A. D.; Guduru, R. K.; Varadaraajan, V.

    2010-01-01

    Oxide dispersion strengthened alloys (ODS), although not commonly used in coating applications, have long been used for high-temperature structural applications due to their superior creep properties. In this paper, we present the design, synthesis, and characterization of a new class of functionally engineered high-temperature coatings in which ultrafine oxide particulates are dispersed in the matrix alloy to achieve superior creep resistance along with improved high-temperature corrosion and erosion resistance. These coatings were fabricated using a novel technique called “hybrid spray process”. Hybrid spray technique combines arc spray and high-velocity oxy fuel (HVOF) spray processes; the metallic matrix alloys are fused by the wire arcing component of the process, whereas the ultrafine particles are synthesized in-flight by the HVOF component from liquid precursors. These particulate dispersed high-temperature composite coatings were fabricated using liquid precursors for SiO2, Cr2O3, Al2O3, and wire feed stock of 55/45 NiCr, in one step. The coatings were then characterized using electron microscopy (SEM/TEM) and thermogravimetric analysis (TGA). High-temperature erosion, oxidation, and corrosion performance of these coatings were also evaluated and compared with 304 stainless steel, arc sprayed NiCr coatings as well as Alloy 625 overlay cladding. The hybrid spray process produced dense coatings with uniform dispersion of the ultrafine oxide particles. Further, these coatings also demonstrated superior corrosion, erosion, and oxidation resistance; SiO2 particulate dispersion being most effective in terms of high-temperature corrosion resistance.

  13. Adapting of the Background-Oriented Schlieren (BOS) Technique in the Characterization of the Flow Regimes in Thermal Spraying Processes

    NASA Astrophysics Data System (ADS)

    Tillmann, W.; Abdulgader, M.; Rademacher, H. G.; Anjami, N.; Hagen, L.

    2014-01-01

    In thermal spraying technique, the changes in the in-flight particle velocities are considered to be only a function of the drag forces caused by the dominating flow regimes in the spray jet. Therefore, the correct understanding of the aerodynamic phenomena occurred at nozzle out let and at the substrate interface is an important task in the targeted improvement in the nozzle and air-cap design as well as in the spraying process in total. The presented work deals with the adapting of an innovative technique for the flow characterization called background-oriented Schlieren. The flow regimes in twin wire arc spraying (TWAS) and high velocity oxygen fuel (HVOF) were analyzed with this technique. The interfering of the atomization gas flow with the intersected wires causes in case of TWAS process a deformation of the jet shape. It leads also to areas with different aero dynamic forces. The configurations of the outlet air-caps in TWAS effect predominantly the outlet flow characteristics. The ratio between fuel and oxygen determine the dominating flow regimes in the HVOF spraying jet. Enhanced understanding of the aerodynamics at outlet and at the substrate interface could lead to a targeted improvement in thermal spraying processes.

  14. The Effect of Nozzle Design and Operating Conditions on the Atomization and Distribution of Fuel Sprays

    NASA Technical Reports Server (NTRS)

    Lee, Dana W

    1933-01-01

    The atomization and distribution characteristics of fuel sprays from automatic injection valves for compression-ignition engines were determined by catching the fuel drops on smoked-glass plates, and then measuring and counting the impressions made in the lampblack. The experiments were made in an air-tight chamber in which the air density was raised to values corresponding to engine conditions.

  15. Multilayer refractory nozzles produced by plasma-spray process

    NASA Technical Reports Server (NTRS)

    Bliton, J. L.; Rausch, J. L.

    1966-01-01

    Multilayer rocket nozzles formed by plasma spraying have good thermal shock resistance and can be reheated in an oxidizing environment without loss of coating adherence. Suggested application of this process are for the production of refractory components, which can be formed as surfaces of revolution.

  16. A Study on Reactive Spray Deposition Technology Processing Parameters in the Context of Pt Nanoparticle Formation

    NASA Astrophysics Data System (ADS)

    Roller, Justin M.; Maric, Radenka

    2015-12-01

    Catalytic materials are complex systems in which achieving the desired properties (i.e., activity, selectivity and stability) depends on exploiting the many degrees of freedom in surface and bulk composition, geometry, and defects. Flame aerosol synthesis is a process for producing nanoparticles with ample processing parameter space to tune the desired properties. Flame dynamics inside the reactor are determined by the input process variables such as solubility of precursor in the fuel; solvent boiling point; reactant flow rate and concentration; flow rates of air, fuel and the carrier gas; and the burner geometry. In this study, the processing parameters for reactive spray deposition technology, a flame-based synthesis method, are systematically evaluated to understand the residence times, reactant mixing, and temperature profiles of flames used in the synthesis of Pt nanoparticles. This provides a framework for further study and modeling. The flame temperature and length are also studied as a function of O2 and fuel flow rates.

  17. Coal-water slurry spray characteristics of an electronically-controlled accumulator fuel injection system

    SciTech Connect

    Caton, J.A.; Payne, S.E.; Terracina, D.P.; Kihm, K.D.

    1993-12-31

    Experiments have been complete to characterize coal-water slurry sprays from a electronically-controlled accumulator fuel injection system of diesel engine. The sprays were injected into a pressurized chamber equipped with windows. High speed movies, fuel pressures and needle lifts were obtained as a function of time, orifice diameter, coal loading, gas density in the chamber, and accumulator fuel pressure. For the base conditions 50% (by mass) coal loading, 0.4 mm diameter nozzle hole, coal-water slurry pressure of 82 MPa (12,000 psi), and a chamber density of 25 kg/m{sup 3}, the break-up time was 0. 30 ms. An empirical correlation for both spray tip penetration and initial jet velocity was developed. For the conditions of this study, the spray tip penetration and initial jet velocity were 15% greater for coal-water slurry than for diesel fuel or water. Cone angles of the sprays were dependent on the operating conditions and fluid, as well as the time and locations of the measurement. The time-averaged cone angle for the base case conditions was 13.6{degree}. Results of this study and the correlation are specific to the tested coal-water slurry and are not general for other coal-water slurry fuels.

  18. Penetration and Duration of Fuel Sprays from a Pump Injection System

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Marsh, E T

    1934-01-01

    High-speed motion pictures were taken of individual fuel sprays from a pump injection system. The changes in the spray-tip penetration with changes in the pump speed, injection-valve opening and closing pressures, discharge-orifice area, injection-tube length and diameter, and pump throttle setting were measured. The pump was used with and without a check valve. The results show that the penetration of the spray tip can be controlled by the dimensions of the injection tube, the area of the discharge orifice, and the injection-valve opening and closing pressures.

  19. Detailed investigation of a vaporising fuel spray. Part 1: Experimental investigation of time averaged spray

    NASA Technical Reports Server (NTRS)

    Yule, A. J.; Seng, C. A.; Boulderstone, R.; Ungut, A.; Felton, P. G.; Chigier, N. A.

    1980-01-01

    A laser tomographic light scattering technique provides rapid and accurate high resolution measurements of droplet sizes, concentrations, and vaporization. Measurements using a computer interfaced thermocouple are presented and it is found that the potential exists for separating gas and liquid temperature measurements and diagnosing local spray density by in situ analysis of the response characteristics of the thermocouple. The thermocouple technique provides a convenient means for measuring mean gas velocity in both hot and cold two phase flows. The experimental spray is axisymmetric and has carefully controlled initial and boundary conditions. The flow is designed to give relatively insignificant transfer of momentum and mass from spray to air flow. The effects of (1) size-dependent droplet dispersion by the turbulence, (2) the initial spatial segregation of droplet sizes during atomization, and (3) the interaction between droplets and coherent large eddies are diagnosed.

  20. Solid oxide fuel cell electrolytes produced via very low pressure suspension plasma spray and electrophoretic deposition

    NASA Astrophysics Data System (ADS)

    Fleetwood, James D.

    Solid oxide fuel cells (SOFCs) are a promising element of comprehensive energy policies due to their direct mechanism for converting the oxidization of fuel, such as hydrogen, into electrical energy. Both very low pressure plasma spray and electrophoretic deposition allow working with high melting temperature SOFC suspension based feedstock on complex surfaces, such as in non-planar SOFC designs. Dense, thin electrolytes of ideal composition for SOFCs can be fabricated with each of these processes, while compositional control is achieved with dissolved dopant compounds that are incorporated into the coating during deposition. In the work reported, sub-micron 8 mole % Y2O3-ZrO2 (YSZ) and gadolinia-doped ceria (GDC), powders, including those in suspension with scandium-nitrate dopants, were deposited on NiO-YSZ anodes, via very low pressure suspension plasma spray (VLPSPS) at Sandia National Laboratories' Thermal Spray Research Laboratory and electrophoretic deposition (EPD) at Purdue University. Plasma spray was carried out in a chamber held at 320 - 1300 Pa, with the plasma composed of argon, hydrogen, and helium. EPD was characterized utilizing constant current deposition at 10 mm electrode separation, with deposits sintered from 1300 -- 1500 °C for 2 hours. The role of suspension constituents in EPD was analyzed based on a parametric study of powder loading, powder specific surface area, polyvinyl butyral (PVB) content, polyethyleneimine (PEI) content, and acetic acid content. Increasing PVB content and reduction of particle specific surface area were found to eliminate the formation of cracks when drying. PEI and acetic acid content were used to control suspension stability and the adhesion of deposits. Additionally, EPD was used to fabricate YSZ/GDC bilayer electrolyte systems. The resultant YSZ electrolytes were 2-27 microns thick and up to 97% dense. Electrolyte performance as part of a SOFC system with screen printed LSCF cathodes was evaluated with peak

  1. Effect of aviation fuel type and fuel injection conditions on the spray characteristics of pressure swirl and hybrid air blast fuel injectors

    NASA Astrophysics Data System (ADS)

    Feddema, Rick

    Feddema, Rick T. M.S.M.E., Purdue University, December 2013. Effect of Aviation Fuel Type and Fuel Injection Conditions on the Spray Characteristics of Pressure Swirl and Hybrid Air Blast Fuel Injectors. Major Professor: Dr. Paul E. Sojka, School of Mechanical Engineering Spray performance of pressure swirl and hybrid air blast fuel injectors are central to combustion stability, combustor heat management, and pollutant formation in aviation gas turbine engines. Next generation aviation gas turbine engines will optimize spray atomization characteristics of the fuel injector in order to achieve engine efficiency and emissions requirements. Fuel injector spray atomization performance is affected by the type of fuel injector, fuel liquid properties, fuel injection pressure, fuel injection temperature, and ambient pressure. Performance of pressure swirl atomizer and hybrid air blast nozzle type fuel injectors are compared in this study. Aviation jet fuels, JP-8, Jet A, JP-5, and JP-10 and their effect on fuel injector performance is investigated. Fuel injector set conditions involving fuel injector pressure, fuel temperature and ambient pressure are varied in order to compare each fuel type. One objective of this thesis is to contribute spray patternation measurements to the body of existing drop size data in the literature. Fuel droplet size tends to increase with decreasing fuel injection pressure, decreasing fuel injection temperature and increasing ambient injection pressure. The differences between fuel types at particular set conditions occur due to differences in liquid properties between fuels. Liquid viscosity and surface tension are identified to be fuel-specific properties that affect the drop size of the fuel. An open aspect of current research that this paper addresses is how much the type of aviation jet fuel affects spray atomization characteristics. Conventional aviation fuel specifications are becoming more important with new interest in alternative

  2. Characterization of Spray Lubricants for the Die Casting Process

    SciTech Connect

    Sabau, Adrian S

    2008-01-01

    During the die casting process, lubricants are sprayed in order to cool the dies and facilitate the ejection of the casting. The cooling effects of the die lubricant were investigated using Thermogravimetric analysis (TGA), heat flux sensors (HFS), and infrared imaging. The evolution of the heat flux and pictures taken using a high speed infrared camera revealed that lubricant application was a transient process. The short time response of the HFS allows the monitoring and data acquisition of the surface temperature and heat flux without additional data processing. A similar set of experiments was performed with deionized water in order to assess the lubricant effect. The high heat flux obtained at 300 C was attributed to the wetting and absorbant properties of the lubricant. Pictures of the spray cone and lubricant flow on the die were also used to explain the heat flux evolution.

  3. Formation of oxides of nitrogen in monodisperse spray combustion of hydrocarbon fuels

    NASA Technical Reports Server (NTRS)

    Nizami, A. A.; Singh, S.; Cernansky, N. P.

    1982-01-01

    Experimental results of exit plane NO/NO(x) emissions from atmospheric monodisperse fuel spray combustion are presented. Six different hydrocarbon fuels were studied: isopropanol, n-propanol, n-octane, iso-octane, n-heptane and methanol. The results indicate an optimum droplet size for minimizing NO/NO(x) production for all of the test fuels. At the optimum droplet diameter, reductions in NO/NO(x) relative to the NO(x) occurred at droplet diameters of 55 and 48 microns respectively, as compared to a 50-micron droplet size for isopropanol. The occurrence of the minimum NO(x) point at different droplet diameters for the different fuels appears to be governed by the extent of prevaporization of the fuel in the spray, and is consistent with theoretical calculations based on each fuel's physical properties. Estimates are also given for the behavior of heavy fuels and of polydisperse fuel sprays in shifting the minimum NO(x) point compared to a monodisperse situation.

  4. Iron-Based Amorphous Coatings Produced by HVOF Thermal Spray Processing-Coating Structure and Properties

    SciTech Connect

    Beardsley, M B

    2008-03-26

    The feasibility to coat large SNF/HLW containers with a structurally amorphous material (SAM) was demonstrated on sub-scale models fabricated from Type 316L stainless steel. The sub-scale model were coated with SAM 1651 material using kerosene high velocity oxygen fuel (HVOF) torch to thicknesses ranging from 1 mm to 2 mm. The process parameters such as standoff distance, oxygen flow, and kerosene flow, were optimized in order to improve the corrosion properties of the coatings. Testing in an electrochemical cell and long-term exposure to a salt spray environment were used to guide the selection of process parameters.

  5. Simultaneous two-phase flow measurement of spray mixing process by means of high-speed two-color PIV

    NASA Astrophysics Data System (ADS)

    Zhang, Ming; Xu, Min; Hung, David L. S.

    2014-09-01

    In this article, a novel high-speed two-color PIV optical diagnostic technique has been developed and applied to simultaneously measure the velocity flow-fields of a multi-hole spark-ignition direct injection (SIDI) fuel injector spray and its ambient gas in a high-pressure constant volume chamber. To allow for the phase discrimination between the fuel droplets and ambient gas, a special tracer-filter system was designed. Fluorescent seeding particles with Sauter mean diameter (SMD) of 4.8 µm were used to trace the gas inside the chamber. With a single high-speed Nd:YLF laser sheet (527 nm) as the incident light source, the Mie-scattering signal marked the phase of the fuel spray, while the fluorescent signal generated from the seeding particles tracked the phase of ambient gas. A high-speed camera, with an image-doubler (mounted in front of the camera lens) that divided the camera pixels into two parts focusing on the same field of view, was used to collect the Mie-scattering signal and LIF (laser induced fluorescence) signal simultaneously with two carefully selected optical filters. To accommodate the large dynamic range of velocities in the two phases (1-2 orders of magnitude difference), two separation times (dt) were introduced. This technique was successfully applied to the liquid spray and ambient gas two-phase flow measurement. The measurement accuracy was compared with those from LDV (laser Doppler velocimetry) measurement and good agreement was obtained. Ambient gas motion surrounding the fuel spray was investigated and characterized into three zones. The momentum transfer process between the fuel spray and ambient gas in each zone was analyzed. The two-phase flow interaction under various superheated conditions was investigated. A strengthened momentum transfer from the liquid spray to the ambient was observed with increased superheat degree.

  6. Diesel engine emissions and combustion predictions using advanced mixing models applicable to fuel sprays

    NASA Astrophysics Data System (ADS)

    Abani, Neerav; Reitz, Rolf D.

    2010-09-01

    An advanced mixing model was applied to study engine emissions and combustion with different injection strategies ranging from multiple injections, early injection and grouped-hole nozzle injection in light and heavy duty diesel engines. The model was implemented in the KIVA-CHEMKIN engine combustion code and simulations were conducted at different mesh resolutions. The model was compared with the standard KIVA spray model that uses the Lagrangian-Drop and Eulerian-Fluid (LDEF) approach, and a Gas Jet spray model that improves predictions of liquid sprays. A Vapor Particle Method (VPM) is introduced that accounts for sub-grid scale mixing of fuel vapor and more accurately and predicts the mixing of fuel-vapor over a range of mesh resolutions. The fuel vapor is transported as particles until a certain distance from nozzle is reached where the local jet half-width is adequately resolved by the local mesh scale. Within this distance the vapor particle is transported while releasing fuel vapor locally, as determined by a weighting factor. The VPM model more accurately predicts fuel-vapor penetrations for early cycle injections and flame lift-off lengths for late cycle injections. Engine combustion computations show that as compared to the standard KIVA and Gas Jet spray models, the VPM spray model improves predictions of in-cylinder pressure, heat released rate and engine emissions of NOx, CO and soot with coarse mesh resolutions. The VPM spray model is thus a good tool for efficiently investigating diesel engine combustion with practical mesh resolutions, thereby saving computer time.

  7. Ceramic plasma-sprayed coating of melting crucibles for casting metal fuel slugs

    SciTech Connect

    K.H. Kim; C.T. Lee; C.B. Lee; R.S. Fielding; J.R. Kennedy

    2013-10-01

    Thermal cycling and melt reaction studies of ceramic coatings plasma-sprayed on Nb substrates were carried out to evaluate the performance of barrier coatings for metallic fuel casting applications. Thermal cycling tests of the ceramic plasma-sprayed coatings to 1450 degrees C showed that HfN, TiC, ZrC, and Y2O3 coating had good cycling characteristics with few interconnected cracks even after 20 cycles. Interaction studies by 1550 degrees C melt dipping tests of the plasma-sprayed coatings also indicated that HfN and Y2O3 do not form significant reaction layer between U–20 wt.% Zr melt and the coating layer. Plasma-sprayed Y2O3 coating exhibited the most promising characteristics among HfN, TiC, ZrC, and Y2O3 coating.

  8. Numerical investigation of spray ignition of a multi-component fuel surrogate

    NASA Astrophysics Data System (ADS)

    Backer, Lara; Narayanaswamy, Krithika; Pepiot, Perrine

    2014-11-01

    Simulating turbulent spray ignition, an important process in engine combustion, is challenging, since it combines the complexity of multi-scale, multiphase turbulent flow modeling with the need for an accurate description of chemical kinetics. In this work, we use direct numerical simulation to investigate the role of the evaporation model on the ignition characteristics of a multi-component fuel surrogate, injected as droplets in a turbulent environment. The fuel is represented as a mixture of several components, each one being representative of a different chemical class. A reduced kinetic scheme for the mixture is extracted from a well-validated detailed chemical mechanism, and integrated into the multiphase turbulent reactive flow solver NGA. Comparisons are made between a single-component evaporation model, in which the evaporating gas has the same composition as the liquid droplet, and a multi-component model, where component segregation does occur. In particular, the corresponding production of radical species, which are characteristic of the ignition of individual fuel components, is thoroughly analyzed.

  9. Spent graphite fuel element processing

    SciTech Connect

    Holder, N.D.; Olsen, C.W.

    1981-07-01

    The Department of Energy currently sponsors two programs to demonstrate the processing of spent graphite fuel elements. General Atomic in San Diego operates a cold pilot plant to demonstrate the processing of both US and German high-temperature reactor fuel. Exxon Nuclear Idaho Company is demonstrating the processing of spent graphite fuel elements from Rover reactors operated for the Nuclear Rocket Propulsion Program. This work is done at Idaho National Engineering Laboratory, where a hot facility is being constructed to complete processing of the Rover fuel. This paper focuses on the graphite combustion process common to both programs.

  10. Spray formation processes of impinging jet injectors

    NASA Technical Reports Server (NTRS)

    Anderson, W. E.; Ryan, H. M.; Pal, S.; Santoro, R. J.

    1993-01-01

    A study examining impinging liquid jets has been underway to determine physical mechanisms responsible for combustion instabilities in liquid bi-propellant rocket engines. Primary atomization has been identified as an important process. Measurements of atomization length, wave structure, and drop size and velocity distribution were made under various ambient conditions. Test parameters included geometric effects and flow effects. It was observed that pre-impingement jet conditions, specifically whether they were laminar or turbulent, had the major effect on primary atomization. Comparison of the measurements with results from a two dimensional linear aerodynamic stability model of a thinning, viscous sheet were made. Measured turbulent impinging jet characteristics were contrary to model predictions; the structure of waves generated near the point of jet impingement were dependent primarily on jet diameter and independent of jet velocity. It has been postulated that these impact waves are related to pressure and momentum fluctuations near the impingement region and control the eventual disintegration of the liquid sheet into ligaments. Examination of the temporal characteristics of primary atomization (ligament shedding frequency) strongly suggests that the periodic nature of primary atomization is a key process in combustion instability.

  11. MONOLITHIC FUEL FABRICATION PROCESS DEVELOPMENT AT THE IDAHO NATIONAL LABORATORY

    SciTech Connect

    Glenn A. Moore; Francine J. Rice; Nicolas E. Woolstenhulme; W. David SwanK; DeLon C. Haggard; Jan-Fong Jue; Blair H. Park; Steven E. Steffler; N. Pat Hallinan; Michael D. Chapple; Douglas E. Burkes

    2008-10-01

    Within the Reduced Enrichment for Research and Test Reactors (RERTR) program directed by the US Department of Energy (DOE), UMo fuel-foils are being developed in an effort to realize high density monolithic fuel plates for use in high-flux research and test reactors. Namely, targeted are reactors that are not amenable to Low Enriched Uranium (LEU) fuel conversion via utilization of high density dispersion-based fuels, i.e. 8-9 gU/cc. LEU conversion of reactors having a need for >8-9 gU/cc fuel density will only be possible by way of monolithic fuel forms. The UMo fuel foils under development afford fuel meat density of ~16 gU/cc and thus have the potential to facilitate LEU conversions without any significant reactor-performance penalty. Two primary challenges have been established with respect to UMo monolithic fuel development; namely, fuel element fabrication and in-reactor fuel element performance. Both issues are being addressed concurrently at the Idaho National Laboratory. An overview is provided of the ongoing monolithic UMo fuel development effort at the Idaho National Laboratory (INL); including development of complex/graded fuel foils. Fabrication processes to be discussed include: UMo alloying and casting, foil fabrication via hot rolling, fuel-clad interlayer application via co-rolling and thermal spray processes, clad bonding via Hot Isostatic Pressing (HIP) and Friction Bonding (FB), and fuel plate finishing.

  12. Measurement of vapor/liquid distributions in a binary-component fuel spray using laser imaging of droplet scattering and vapor absorption

    NASA Astrophysics Data System (ADS)

    Li, Shiyan; Zhang, Yuyin; Wu, Shenqi; Xu, Bin

    2014-08-01

    Fuel volatility has a great effect on its evaporation processes and the mixture formation and thus combustion and emissions formation processes in internal combustion engines. To date, however, instead of the actual gasoline or diesel fuel, many researchers have been using single-component fuel in their studies, because the composition of the former is too complicated to understand the real physics behind the evaporation and combustion characteristics. Several research groups have reported their results on droplets evaporation in a spray of multi-component fuel, carried out both numerically and experimentally. However, there are plenty of difficulties in quantitative determination of vapor concentration and droplet distributions of each component in a multicomponent fuel spray. In this study, to determine the vapor phase concentration and droplet distributions in an evaporating binary component fuel spray, a laser diagnostics based on laser extinction by droplet scattering and vapor absorption was developed. In practice, measurements of the vapor concentration distributions of the lower (n-tridencane) and higher (n-octane) volatility components in the binary component fuel sprays have been carried out at ambient temperatures of 473K and 573K, by substituting p-xylene for noctane or α-methylnaphthalene for n-tridecane. p-Xylene and α-methylnaphthalene were selected as the substitutes is because they have strong absorption band near 266nm and transparent near 532nm and, their thermo-physical properties are similar to those of the original component. As a demonstration experiment, vapor/liquid distribution of the lower boiling point (LBP) and higher boiling point (HBP) components in the binary component fuel spray have been obtained.

  13. Numerical Investigation of Combustion and Flow Dynamics in a High Velocity Oxygen-Fuel Thermal Spray Gun

    NASA Astrophysics Data System (ADS)

    Wang, Xiaoguang; Song, Qiuzhi; Yu, Zhiyi

    2016-02-01

    The combustion and flow behavior within a high velocity oxygen-fuel (HVOF) thermal spray gun is very complex and involves multiphase flow, heat transfer, chemical reactions, and supersonic/subsonic transitions. Additionally, this behavior has a significant effect on the formation of a coating. Non-premixed combustion models have been developed and are able to provide insight into the underlying physics of the process. Therefore, this investigation employs a non-premixed combustion model and the SST k - ω turbulence model to simulate the flow field of the JP5000 (Praxair-TAFA, US) HVOF thermal spray gun. The predicted temperature and velocity have a high level of agreement with experimental data when using the non-premixed combustion model. The results are focused on the fuel combustion, the subsequent gas dynamics within the HVOF gun, and the development of a supersonic free jet outside the gun. Furthermore, the oxygen/fuel inlet turbulence intensity, the fuel droplet size, and the oxygen/fuel ratio are investigated to determine their effect on the supersonic flow characteristics of the combustion gas.

  14. Furnace endoscope—measuring fuel spray properties in hot and corrosive environments

    NASA Astrophysics Data System (ADS)

    Miikkulainen, P.; Kankkunen, A.; Järvinen, M. P.

    2004-12-01

    A furnace endoscope was developed to carry out in-furnace measurements of black liquor sprays in order to discover the initial velocity, opening angle and trajectory of the spray, and compare spray disintegration mechanisms and spray appearance with the ones measured in a spray chamber. An error analysis of the velocity measurement method was carried out, and the meaning of the optimum measurement distance from the optics to the observed object is discussed. Some details of the development process of the probe are also presented, especially the definition of the scale of the image and the cooling system of the protection tubes. The furnace endoscope can be used in difficult conditions, such as those found inside a chemical recovery boiler (~1,200°C and corrosive chemicals) with promising and accurate measurement results. The equipment has been tested in several furnaces.

  15. Investigation of spray dispersion and particulate formation in diesel fuel flames

    NASA Technical Reports Server (NTRS)

    Back, L. H.; Bankston, C. P.; Kwack, E. Y.; Bellan, J.; Harstad, K.

    1988-01-01

    An experimental study of electrostatical atomized and dispersed diesel fuel jets was conducted at various back pressures to 40 atm. A new electrostatic injection technique was utilized to generate continuous, stable fuel sprays at charge densities of 1.5 to 2.0 C/m3 of fluid at one atm, and about 1.0 C/m3 at 40 atm. Flowrates were varied from 0.5 to 2.5 ml/s and electric potentials to -18 kV. Visual observations showed that significant enhanced dispersion of charged fuel jets occurred at high back pressures compared to aerodynamic breakup and dispersion. The average drop size was about the same as the spray triode orifice diameter, and was between the Kelly theory and the Rayleigh limit. The ignition tests, done only at one atm, indicated stable combustion of the electrostatically dispersed fuel jets.

  16. Combustion characteristics in the transition region of liquid fuel sprays

    NASA Technical Reports Server (NTRS)

    Cernansky, N. P.; Namer, I.; Tidona, R. J.

    1984-01-01

    A number of important effects were observed in the droplet size transition region in spray combustion systems. In this region, where the mechanism of flame propagation is transformed from diffusive to premixed dominated combustion, the following effects have been observed: (1) maxima in burning velocity; (2) extension of flammability limits; (3) minima in ignition energy; and (4) minima in NO(x) formation. Unfortunately, because of differences in experimental facilities and limitations in the ranges of experimental data, a unified description of these transition region effects is not available at this time. Consequently, a fundamental experimental investigation was initiated to study the effect of droplet size, size distribution, and operating parameters on these transition region phenomena in a single well controlled spray combustion facility.

  17. Fuel processing device

    DOEpatents

    Ahluwalia, Rajesh K.; Ahmed, Shabbir; Lee, Sheldon H. D.

    2011-08-02

    An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

  18. Properties of Aluminum Deposited by a High-Velocity Oxygen-Fueled Process

    SciTech Connect

    Chow, R; Decker, T A; Gansert, R V; Gansert, D; Lee, D

    2001-06-12

    Aluminum coatings deposited by a HVOF process have been demonstrated and relevant coating properties evaluated according to two deposition parameters, the spray distance and the oxygen-to-fuel flow ratio. The coating porosity, surface roughness, and microhardness are measured. The coating properties are fairly insensitive to spray distance, the distance between the nozzle and the workpiece, and fuel ratios, the oxygen-to-fuel flow. Increasing the fuel content does appear to improve the process productivity in terms of surface roughness. Minimization of nozzle loading is discussed.

  19. Statistical representation of a spray as a point process

    SciTech Connect

    Subramaniam, S.

    2000-10-01

    The statistical representation of a spray as a finite point process is investigated. One objective is to develop a better understanding of how single-point statistical information contained in descriptions such as the droplet distribution function (ddf), relates to the probability density functions (pdfs) associated with the droplets themselves. Single-point statistical information contained in the droplet distribution function (ddf) is shown to be related to a sequence of single surrogate-droplet pdfs, which are in general different from the physical single-droplet pdfs. It is shown that the ddf contains less information than the fundamental single-point statistical representation of the spray, which is also described. The analysis shows which events associated with the ensemble of spray droplets can be characterized by the ddf, and which cannot. The implications of these findings for the ddf approach to spray modeling are discussed. The results of this study also have important consequences for the initialization and evolution of direct numerical simulations (DNS) of multiphase flows, which are usually initialized on the basis of single-point statistics such as the droplet number density in physical space. If multiphase DNS are initialized in this way, this implies that even the initial representation contains certain implicit assumptions concerning the complete ensemble of realizations, which are invalid for general multiphase flows. Also the evolution of a DNS initialized in this manner is shown to be valid only if an as yet unproven commutation hypothesis holds true. Therefore, it is questionable to what extent DNS that are initialized in this manner constitute a direct simulation of the physical droplets. Implications of these findings for large eddy simulations of multiphase flows are also discussed. (c) 2000 American Institute of Physics.

  20. Monolithic Fuel Fabrication Process Development

    SciTech Connect

    C. R. Clark; N. P. Hallinan; J. F. Jue; D. D. Keiser; J. M. Wight

    2006-05-01

    The pursuit of a high uranium density research reactor fuel plate has led to monolithic fuel, which possesses the greatest possible uranium density in the fuel region. Process developments in fabrication development include friction stir welding tool geometry and cooling improvements and a reduction in the length of time required to complete the transient liquid phase bonding process. Annealing effects on the microstructures of the U-10Mo foil and friction stir welded aluminum 6061 cladding are also examined.

  1. Penetration and Duration of Fuel Sprays from a Pump Injection System

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Marsh, E T

    1931-01-01

    High-speed motion pictures were taken of individual fuel sprays from a pump injection system. The changes in the spray-tip penetration with changes in the pump speed, injection-valve opening and closing pressures, discharge-orifice area, injection-tube length and diameter, and pump throttle setting were measured. In addition, the effects of the variables on the time lag and duration of injection can be controlled by the dimensions of the injection tube, the area of the discharge orifice, and the injection-valve opening and closing pressures.

  2. Direct numerical simulation of ignition in turbulent n-heptane liquid-fuel spray jets

    SciTech Connect

    Wang, Y.; Rutland, C.J.

    2007-06-15

    Direct numerical simulation was used for fundamental studies of the ignition of turbulent n-heptane liquid-fuel spray jets. A chemistry mechanism with 33 species and 64 reactions was adopted to describe the chemical reactions. The Eulerian method is employed to solve the carrier-gas flow field and the Lagrangian method is used to track the liquid-fuel droplets. Two-way coupling interaction is considered through the exchange of mass, momentum, and energy between the carrier-gas fluid and the liquid-fuel spray. The initial carrier-gas temperature was 1500 K. Six cases were simulated with different droplet radii (from 10 to 30 {mu}m) and two initial velocities (100 and 150 m/s). From the simulations, it was found that evaporative cooling and turbulence mixing play important roles in the ignition of liquid-fuel spray jets. Ignition first occurs at the edges of the jets where the fuel mixture is lean, and the scalar dissipation rate and the vorticity magnitude are very low. For smaller droplets, ignition occurs later than for larger droplets due to increased evaporative cooling. Higher initial droplet velocity enhances turbulence mixing and evaporative cooling. For smaller droplets, higher initial droplet velocity causes the ignition to occur earlier, whereas for larger droplets, higher initial droplet velocity delays the ignition time. (author)

  3. Novel method for the measurement of liquid film thickness during fuel spray impingement on surfaces.

    PubMed

    Henkel, S; Beyrau, F; Hardalupas, Y; Taylor, A M K P

    2016-02-01

    This paper describes the development and application of a novel optical technique for the measurement of liquid film thickness formed on surfaces during the impingement of automotive fuel sprays. The technique makes use of the change of the light scattering characteristics of a metal surface with known roughness, when liquid is deposited. Important advantages of the technique over previously established methods are the ability to measure the time-dependent spatial distribution of the liquid film without a need to add a fluorescent tracer to the liquid, while the measurement principle is not influenced by changes of the pressure and temperature of the liquid or the surrounding gas phase. Also, there is no need for non-fluorescing surrogate fuels. However, an in situ calibration of the dependence of signal intensity on liquid film thickness is required. The developed method can be applied to measure the time-dependent and two-dimensional distribution of the liquid fuel film thickness on the piston or the liner of gasoline direct injection (GDI) engines. The applicability of this technique was evaluated with impinging sprays of several linear alkanes and alcohols with different thermo-physical properties. The surface temperature of the impingement plate was controlled to simulate the range of piston surface temperatures inside a GDI engine. Two sets of liquid film thickness measurements were obtained. During the first set, the surface temperature of the plate was kept constant, while the spray of different fuels interacted with the surface. In the second set, the plate temperature was adjusted to match the boiling temperature of each fuel. In this way, the influence of the surface temperature on the liquid film created by the spray of different fuels and their evaporation characteristics could be demonstrated. PMID:26906828

  4. Resistive substrate heater for film processing by spray pyrolysis

    NASA Astrophysics Data System (ADS)

    Rousseau, B.; De Barros, D.; La Manna, J.; Weiss, F.; Duneau, G.; Odier, P.; De Sousa Meneses, D.; Auger, Y.; Melin, P.; Echegut, P.

    2004-09-01

    We describe a simple and inexpensive resistive heater usable in the spray pyrolysis process. It is based on a resistively heated ceramic plate. By using such a heater substrate temperatures exceeding 900 °C are easily achieved on the substrate. The heater consists of a ceramic plate enclosed in a stainless steel box. A refractory wire woven in a regular frame inside the ceramic provides an excellent heating uniformity over the entire surface. Performances and parameters of the system are given. We apply this device to the preparation of thick films of HTc oxides such as (Hg,Re)Ba2Ca2Cu3O8+δ.

  5. Modeling the effects of drop drag and breakup on fuel sprays

    NASA Astrophysics Data System (ADS)

    Liu, Alex B.; Mather, Daniel; Reitz, Rolf D.

    1993-03-01

    Spray models were evaluated using experimentally measured trajectories and drop sizes of single drops injected into a high relative velocity gas flow. The computations were made using a modified version of the KIVA-2 code. It was found that the drop drag coefficient and the drop breakup time model constant had to be adjusted in order to match the measurements. Based on these findings, a new drop drag submodel is proposed in which the drop drag coefficient changes dynamically with the flow conditions. The model accounts for the effects of drop distortion and oscillation due to the relative motion between the drop and the gas. The value of the drag coefficient varies between the two limits of that of a rigid sphere (no distortion) and that of a disk (maximum distortion). The modified model was also applied to diesel sprays. The results show that the spray tip penetration is relatively insensitive to the value used for the drop drag coefficient. However, the distribution of drop sizes within sprays is influenced by drop drag. This is due to the fact that changes in drop drag produce changes in the drop-gas relative velocity. This, in turn, causes changes in the spray drop size through the drop breakup and coalescence processes. The changes occur in such a way that the net effect on the spray penetration is small over the tested ranges of conditions. These results emphasize that measurements of spray penetration are not sufficient to test and produce improved spray models. Instead, local measurements of drop size and velocity are needed to develop accurate spray models.

  6. Development of a Convergent Spray Technologies(tm) Spray Process for a Solventless Sprayable Coating, MCC-1

    NASA Technical Reports Server (NTRS)

    Patel, Anil K.; Meeks, C.

    1998-01-01

    This paper discusses the application of Convergent Spray Technologies (TM) Spray Process to the development and successful implementation of Marshall Convergent Coating (MCC-1) as a primary Thermal Protection System (TPS) for the Space Shuttle Solid Rocket Boosters (SRBs). This paper discusses the environmental and process benefits of the MCC-1 technology, shows the systematic steps taken in developing the technology, including statistical sensitivity studies of about 35 variables. Based on the process and post-flight successes on the SRB, it will be seen that the technology is "field-proven". Application of this technology to other aerospace and commercial programs is summarized to illustrate the wide range of possibilities.

  7. Effect of Operating Parameters on a Dual-Stage High Velocity Oxygen Fuel Thermal Spray System

    NASA Astrophysics Data System (ADS)

    Khan, Mohammed N.; Shamim, Tariq

    2014-08-01

    High velocity oxygen fuel (HVOF) thermal spray systems are being used to apply coatings to prevent surface degradation. The coatings of temperature sensitive materials such as titanium and copper, which have very low melting points, cannot be applied using a single-stage HVOF system. Therefore, a dual-stage HVOF system has been introduced and modeled computationally. The dual-spray system provides an easy control of particle oxidation by introducing a mixing chamber. In addition to the materials being sprayed, the thermal spray coating quality depends to a large extent on flow behavior of reacting gases and the particle dynamics. The present study investigates the influence of various operating parameters on the performance of a dual-stage thermal spray gun. The objective is to develop a predictive understanding of various parameters. The gas flow field and the free jet are modeled by considering the conservation of mass, momentum, and energy with the turbulence and the equilibrium combustion sub models. The particle phase is decoupled from the gas phase due to very low particle volume fractions. The results demonstrate the advantage of a dual-stage system over a single-stage system especially for the deposition of temperature sensitive materials.

  8. Numerical simulation of emulsified fuel spray combustion with puffing and micro-explosion

    SciTech Connect

    Watanabe, Hirotatsu; Matsushita, Yohsuke; Aoki, Hideyuki; Miura, Takatoshi

    2010-05-15

    The purpose of this study was to develop numerical simulation of spray combustion of emulsified fuel with considering puffing and micro-explosion. First, a mathematical model for puffing was proposed. In the proposed puffing model, the rate of mass change of a droplet during puffing was expressed by the evaporation rate of dispersed water and the mass change rate due to fine droplets spouted from the droplet surface. The mass change rate due to fine droplets was related to the evaporation rate of the dispersed water and each liquid content. This model had only one experimental parameter. The essential feature of this model was that it was simple to apply to numerical simulation of spray combustion. First, the validity of the proposed puffing model was investigated with the experimental results for a single droplet. The calculated results for a single droplet with the experimental parameter varying from 5.0 to 10 were in good agreement with the experimental results. Moreover, numerical simulation of spray combustion of emulsified fuel was carried out. The occurrence of puffing and micro-explosion was determined by the inner droplet temperature. When micro-explosion occurred, a droplet changed to vapor rapidly. When the proposed puffing model was used in numerical simulation of spray combustion, the experimental parameter in the puffing model was determined for each droplet by random numbers within the range 5.0-10. The calculated results of spray combustion of emulsified fuel without considering puffing or micro-explosions were different from the experimental results even where combustion reactions were almost terminated. Meanwhile, the calculated results when considering puffing and micro-explosions were in good agreement with experimental results at the same location. (author)

  9. Fabrication of low cost cutting wheel via thermal spray process

    NASA Astrophysics Data System (ADS)

    Anasyida, A. S.; Nurulakmal, M. S.

    2012-09-01

    The present study is mainly focused on development of metal cutting wheel. The process involved hard particles (abrasives) being bonded on the wheel to enhance the cutting capability by thermal spraying process and followed by polymer bonding. The purpose of this work is to produce low cost cutting wheel and study the performance of cutting behavior. Two different types of powders; silicon carbide (SiC) as bonding agent and chromium carbide (Cr3C2) as abrasives were used. Wear loss and depth of cut as function of load, cutting time and cutting speed were evaluated. The results showed that the speed and load were the main factors that affected the cutting efficiency and the optimum cutting process can be performed at low cutting speed and high load or at high cutting speed and low load.

  10. Analysis of a High Velocity Oxygen-Fuel (HVOF) thermal spray torch. Part 2, Computational results

    SciTech Connect

    Oberkampf, W.L.; Talpallikar, M.

    1993-12-31

    The fluid dynamics inside and outside a High Velocity Oxygen-Fuel (HVOF) torch are analyzed using computational fluid dynamic (CFD) techniques. The thermal spray device analyzed is similar to a Metco Diamond Jet torch with powder injection. The spray nozzle is axisymmetric with powder injected on the centerline, premixed fuel and oxygen fed from an annulus, and air cooling injected along the interior surface of the aircap choked flow conditions occur at the exit of the aircap and a supersonic, under-expanded jet develops externally. The details of the CFD simulation are given in a companion paper. This paper describes the general gas dynamic features of HVOF spraying and then gives a detailed discussion of the computational predictions of the present analysis. The gas velocity, temperature, pressure and Mach number distributions are presented for various locations inside and outside the torch. Characteristics of the metal spray particle velocity, temperature, Mach number, trajectory, and phase state (solid or liquid) are also presented and discussed. Extensive numerical flow visualization is provided to show flow features such as mixing layers, shock waves, and expansion waves.

  11. Application of high velocity oxygen fuel flame (HVOF) spraying to fabrication of La0.8Sr0.2Ga0.8Mg0.2O3 electrolyte for solid oxide fuel cells

    NASA Astrophysics Data System (ADS)

    Zhang, Shan-Lin; Li, Cheng-Xin; Li, Chang-Jiu; Yang, Guan-Jun; Liu, Meilin

    2016-01-01

    La0.8Sr0.2Ga0.8Mg0.2O3 (LSGM) is considered a promising electrolyte for intermediate-temperature solid oxide fuel cells (IT-SOFCs) due to its high ionic conductivity and stability under fuel cell operating conditions. Here we report our findings in investigating the feasibility of using a high velocity oxygen fuel flame (HVOF) spraying process for cost-effective fabrication of dense LSGM electrolyte membranes. The flame and in-flight particle behavior were simulated numerically to optimize the microstructure and phase compositions of the LSGM deposits. The measured gas leakage rate of an LSGM deposit is ∼7 × 10-7 cm4gf-1 s-1. The single cell assembled with 50-55 μm HVOF-sprayed LSGM electrolyte shows open circuit voltage (OCV) of 1.08 V at 800 °C, suggesting that the as-sprayed LSGM deposit is dense enough for direct application as SOFC electrolyte. At 800 °C, the ionic conductivity of the sprayed LSGM deposit is ∼0.04 S cm-1, indicating that the HVOF spraying is a promising process for low-temperature fabrication of dense LSGM electrolyte membranes for IT-SOFCs.

  12. Plasma sprayed manganese-cobalt spinel coatings: Process sensitivity on phase, electrical and protective performance

    NASA Astrophysics Data System (ADS)

    Han, Su Jung; Pala, Zdenek; Sampath, Sanjay

    2016-02-01

    Manganese cobalt spinel (Mn1.5Co1.5O4, MCO) coatings are prepared by the air plasma spray (APS) process to examine their efficacy in serving as protective coatings from Cr-poisoning of the cathode side in intermediate temperature-solid oxide fuel cells (IT-SOFCs). These complex oxides are susceptible to process induced stoichiometric and phase changes which affect their functional performance. To critically examine these effects, MCO coatings are produced with deliberate modifications to the spray process parameters to explore relationship among process conditions, microstructure and functional properties. The resultant interplay among particle thermal and kinetic energies are captured through process maps, which serve to characterize the parametric effects on properties. The results show significant changes to the chemistry and phase composition of the deposited material resulting from preferential evaporation of oxygen. Post deposition annealing recovers oxygen in the coatings and allows partial recovery of the spinel phase, which is confirmed through thermo-gravimetric analysis (TGA)/differential scanning calorimetry (DSC), X-ray Diffraction (XRD), and magnetic hysteresis measurements. In addition, coatings with high density after sintering show excellent electrical conductivity of 40 S cm-1 at 800 °C while simultaneously providing requisite protection characteristics against Cr-poisoning. This study provides a framework for optimal evaluation of MCO coatings in intermediate temperature SOFCs.

  13. Heat Transfer to Fuel Sprays Injected into Heated Gases

    NASA Technical Reports Server (NTRS)

    Selden, Robert F; Spencer, Robert C

    1938-01-01

    This report presents the results of a study made of the influence of several variables on the pressure decrease accompanying injection of a relatively cool liquid into a heated compressed gas. Indirectly, this pressure decrease and the time rate of change of it are indicative of the total heat transferred as well as the rate of heat transfer between the gas and the injected liquid. Air, nitrogen, and carbon dioxide were used as ambient gases; diesel fuel and benzene were the injected liquids. The gas densities and gas-fuel ratios covered approximately the range used in compression-ignition engines. The gas temperatures ranged from 150 degrees c. to 350 degrees c.

  14. 9 CFR 590.544 - Spray process powder; definitions and requirements.

    Code of Federal Regulations, 2014 CFR

    2014-01-01

    ... 9 Animals and Animal Products 2 2014-01-01 2014-01-01 false Spray process powder; definitions and requirements. 590.544 Section 590.544 Animals and Animal Products FOOD SAFETY AND INSPECTION SERVICE... INSPECTION ACT) Sanitary, Processing, and Facility Requirements § 590.544 Spray process powder;...

  15. 9 CFR 590.544 - Spray process powder; definitions and requirements.

    Code of Federal Regulations, 2012 CFR

    2012-01-01

    ... 9 Animals and Animal Products 2 2012-01-01 2012-01-01 false Spray process powder; definitions and requirements. 590.544 Section 590.544 Animals and Animal Products FOOD SAFETY AND INSPECTION SERVICE... INSPECTION ACT) Sanitary, Processing, and Facility Requirements § 590.544 Spray process powder;...

  16. 9 CFR 590.544 - Spray process powder; definitions and requirements.

    Code of Federal Regulations, 2013 CFR

    2013-01-01

    ... 9 Animals and Animal Products 2 2013-01-01 2013-01-01 false Spray process powder; definitions and requirements. 590.544 Section 590.544 Animals and Animal Products FOOD SAFETY AND INSPECTION SERVICE... INSPECTION ACT) Sanitary, Processing, and Facility Requirements § 590.544 Spray process powder;...

  17. 9 CFR 590.544 - Spray process powder; definitions and requirements.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 9 Animals and Animal Products 2 2010-01-01 2010-01-01 false Spray process powder; definitions and... INSPECTION ACT) Sanitary, Processing, and Facility Requirements § 590.544 Spray process powder; definitions and requirements. (a) Definition of product: (1) Primary powder is that powder which is...

  18. 9 CFR 590.544 - Spray process powder; definitions and requirements.

    Code of Federal Regulations, 2011 CFR

    2011-01-01

    ... 9 Animals and Animal Products 2 2011-01-01 2011-01-01 false Spray process powder; definitions and... INSPECTION ACT) Sanitary, Processing, and Facility Requirements § 590.544 Spray process powder; definitions and requirements. (a) Definition of product: (1) Primary powder is that powder which is...

  19. In-flight particle pyrometer for thermal spray processes. Final report, October 1, 1992--December 31, 1994

    SciTech Connect

    1995-02-20

    The objective of the project was to produce an industrial hardened particle temperature sensor. In general the thermal spray community believes that the particle temperature and velocity prior to impact on the substrate are two of the predominant parameters which effect coating quality. Prior to the full scale prototyping of such an instrument it was necessary to firmly establish the relationship between operating parameters, particle temperature and coating characteristics. It was shown in the first year of this project that the characteristics and consistency of the coatings formed are directly determined by particle velocity and temperature at impact. For the HVOF spray process the authors have also shown that the particle velocity is determined primarily by chamber pressure, while stoichiometry (the ratio of oxygen to fuel) has a minor influence. Hence, particle velocity can be controlled by maintaining the chamber pressure at a set point. Particle temperature, on the other hand is primarily a function of stoichiometry. Therefore particle velocity and temperature can be independently controlled. In the second year (FY-94), an industrial hardened prototype particle temperature sensor (In-flight Particle Pyrometer) was produced. The IPP is a two-color radiation pyrometer incorporating improvements which make the device applicable to the measurement of in-flight temperature of particles over a wide range of operating conditions in thermal spray processes. The device is insensitive to particulate loading (particle feed rate), particle composition, particle size distribution, and provides an ensemble average particle temperature. The sensor head is compact and coupled to the electronics via a fiber optic cable. Fiber optic coupling allows maximum flexibility of deployment while providing isolation of the electronics from electromagnetic interference and the hot, particulate laden environment of a typical spray booth. The device is applicable to all thermal spray

  20. The effect of process parameters on Twin Wire Arc spray pattern shape

    DOE PAGESBeta

    Hall, Aaron Christopher; McCloskey, James Francis; Horner, Allison Lynne

    2015-04-20

    A design of experiments approach was used to describe process parameter—spray pattern relationships in the Twin Wire Arc process using zinc feed stock in a TAFA 8835 (Praxair, Concord, NH, USA) spray torch. Specifically, the effects of arc current, primary atomizing gas pressure, and secondary atomizing gas pressure on spray pattern size, spray pattern flatness, spray pattern eccentricity, and coating deposition rate were investigated. Process relationships were investigated with the intent of maximizing or minimizing each coating property. It was determined that spray pattern area was most affected by primary gas pressure and secondary gas pressure. Pattern eccentricity was mostmore » affected by secondary gas pressure. Pattern flatness was most affected by primary gas pressure. Lastly, coating deposition rate was most affected by arc current.« less

  1. The effect of process parameters on Twin Wire Arc spray pattern shape

    SciTech Connect

    Hall, Aaron Christopher; McCloskey, James Francis; Horner, Allison Lynne

    2015-04-20

    A design of experiments approach was used to describe process parameter—spray pattern relationships in the Twin Wire Arc process using zinc feed stock in a TAFA 8835 (Praxair, Concord, NH, USA) spray torch. Specifically, the effects of arc current, primary atomizing gas pressure, and secondary atomizing gas pressure on spray pattern size, spray pattern flatness, spray pattern eccentricity, and coating deposition rate were investigated. Process relationships were investigated with the intent of maximizing or minimizing each coating property. It was determined that spray pattern area was most affected by primary gas pressure and secondary gas pressure. Pattern eccentricity was most affected by secondary gas pressure. Pattern flatness was most affected by primary gas pressure. Lastly, coating deposition rate was most affected by arc current.

  2. Effect of Moderate Air Flow on the Distribution of Fuel Sprays After Injection Cut-0ff

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Spencer, R C

    1935-01-01

    High-speed motion pictures were taken of fuel sprays with the NACA spray-photographic apparatus to study the distribution of the liquid fuel from the instant of injection cut-off until about 0.05 second later. The fuel was injected into a glass-walled chamber in which the air density was varied from 1 to 13 times atmospheric air density (0.0765 to 0.99 pound per cubic foot) and in which the air was at room temperature. The air in the chamber was set in motion by means of a fan, and was directed counter to the spray at velocities up to 27 feet per second. The injection pressure was varied from 2,000 to 6,000 pounds per square inch. A 0.20-inch single-orifice nozzle, an 0.008-inch single-orifice nozzle, a multiorifice nozzle, and an impinging-jets nozzle were used. The best distribution was obtained by the use of air and a high-dispersion nozzle.

  3. Preparation of polyaniline/sodium alanate hybrid using a spray-drying process

    SciTech Connect

    Moreira, B. R. E-mail: fabiopassador@gmail.com Passador, F. R. E-mail: fabiopassador@gmail.com Pessan, L. A. E-mail: fabiopassador@gmail.com

    2014-05-15

    Nowadays, hydrogen is highly interesting as an energy source, in particular in the automotive field. In fact, hydrogen is attractive as a fuel because it prevents air pollution and greenhouse emissions. One of the main problems with the utilization of hydrogen as a fuel is its on-board storage. The purpouse of this work was to develop a new hybrid material consisting of a polyaniline matrix with sodium alanate (NaAlH{sub 4}) using a spray-drying process. The polyaniline used for this experiment was synthesized by following a well-established method for the synthesis of the emeraldine base form of polyaniline using dodecylbenzenesulfonic acid as dopant. Micro particles of polyaniline/sodium alanate hybrids with 30 and 50 wt% of sodium alanate were prepared by using a spray-drying technique. Dilute solutions of polyaniline/sodium alanate were first prepared, 10g of the solid materials were mixed with 350 ml of toluene under stirring at room temperature for 24h and the solutions were dried using spray-dryer (Büchi, Switzerland) with 115°C of an inlet temperature. The hybrids were analyzed by differential scanning calorimetry, FT-IR and scanning electron microscopy (SEM). The addition of sodium alanate decreased the glass transition temperature of the hybrids when compared to neat polyaniline. FT-IR spectrum analysis was performed to identify the bonding environment of the synthesized material and was observed that simply physically mixture occurred between polyaniline and sodium alanate. The SEM images of the hybrids showed the formation of microspheres with sodium alanate dispersed in the polymer matrix.

  4. Preparation of polyaniline/sodium alanate hybrid using a spray-drying process

    NASA Astrophysics Data System (ADS)

    Moreira, B. R.; Passador, F. R.; Pessan, L. A.

    2014-05-01

    Nowadays, hydrogen is highly interesting as an energy source, in particular in the automotive field. In fact, hydrogen is attractive as a fuel because it prevents air pollution and greenhouse emissions. One of the main problems with the utilization of hydrogen as a fuel is its on-board storage. The purpouse of this work was to develop a new hybrid material consisting of a polyaniline matrix with sodium alanate (NaAlH4) using a spray-drying process. The polyaniline used for this experiment was synthesized by following a well-established method for the synthesis of the emeraldine base form of polyaniline using dodecylbenzenesulfonic acid as dopant. Micro particles of polyaniline/sodium alanate hybrids with 30 and 50 wt% of sodium alanate were prepared by using a spray-drying technique. Dilute solutions of polyaniline/sodium alanate were first prepared, 10g of the solid materials were mixed with 350 ml of toluene under stirring at room temperature for 24h and the solutions were dried using spray-dryer (Büchi, Switzerland) with 115°C of an inlet temperature. The hybrids were analyzed by differential scanning calorimetry, FT-IR and scanning electron microscopy (SEM). The addition of sodium alanate decreased the glass transition temperature of the hybrids when compared to neat polyaniline. FT-IR spectrum analysis was performed to identify the bonding environment of the synthesized material and was observed that simply physically mixture occurred between polyaniline and sodium alanate. The SEM images of the hybrids showed the formation of microspheres with sodium alanate dispersed in the polymer matrix.

  5. Improvement of wear resistance of sprayed layer on 52100 steel by friction stir processing

    NASA Astrophysics Data System (ADS)

    Rahbar-kelishami, A.; Abdollah-zadeh, A.; Hadavi, M. M.; Seraj, R. A.; Gerlich, A. P.

    2014-10-01

    The influence of friction stir processing (FSP) on wear resistance is studied on a thermally sprayed coating in terms of microstructure and mechanical properties. A high-chromium steel coating sprayed on AISI 52100 steel has been processed, and it is shown that FSP can improve the sprayed layer wear resistance compared to the as-sprayed and quenched and tempered condition. It is suggested that improved toughness is the main contribution to wear performance rather than hardness. It is observed that FSP provides increased hardness and toughness simultaneously, while tempering of the quenched AISI 52100 steel increases toughness while hardness decreases.

  6. Processing-microstructure-property relations in HVOF sprayed calcium phosphate based bioceramic coatings.

    PubMed

    Khor, K A; Li, H; Cheang, P

    2003-06-01

    Hydroxyapatite (HA) based bioceramic coatings were deposited onto titanium alloy substrates using the high velocity oxy-fuel (HVOF) spray technique. This study aimed to reveal the relations among processing parameters, microstructure, and properties of the bioceramic coatings. The processing conditions were altered through changing the starting HA powder size, content of bioinert ceramic additives or composite powder preparation techniques. Coating structure was characterized through scanning electron microscopy (SEM) and transmission electron microscopy (TEM); and the mechanical properties, Young's modulus and fracture toughness, of the coatings were evaluated through indentation techniques. Results demonstrated dominant influence of the melt state of HA powders on the phase composition of resultant coatings, and it was found that the HVOF HA coatings possess competitive mechanical properties. Furthermore, addition of titania or zirconia, as secondary phase in HA, showed promising effect on improving the mechanical properties of the HVOF HA-based coatings. Chemical reactions between HA and titania; and, HA and zirconia during coating deposition were revealed and characterized. Incorporation modes of the additives into HA and their reinforcing mechanisms were elucidated. The relationship among the processing, microstructure, and mechanical properties of the HVOF sprayed bioceramic coatings was summarily examined. PMID:12699659

  7. Shaping process makes fuels

    SciTech Connect

    Tabak, S.A.; Krambeck, F.J.

    1985-09-01

    The Mobil Olefin to Gasoline and Distillate (MOGD) process is described in which light olefinic compunds can be converted to high quality gasoline and distillate. This process, now ready for commercialization is based on a unique synthetic zeolite catalyst, the shape of which selectively oligomerizes light olefins to higher molecular weight iso-olefins. The highly flexible process can be designed to produce distillate/gasoline ratios of 0/100 to 90/10 for a commercial plant, depending on market requirements. MOGD is applicable to a wide range of feed streams ranging from ethylene to 400 degrees F end point olefinic naphtha. The process has been tested using commercially produced catalyst in refinery-scale equipment.

  8. Simultaneous imaging of fuel vapor mass fraction and gas-phase temperature inside gasoline sprays using two-line excitation tracer planar laser-induced fluorescence.

    PubMed

    Zigan, Lars; Trost, Johannes; Leipertz, Alfred

    2016-02-20

    This paper reports for the first time, to the best of our knowledge, on the simultaneous imaging of the gas-phase temperature and fuel vapor mass fraction distribution in a direct-injection spark-ignition (DISI) spray under engine-relevant conditions using tracer planar laser-induced fluorescence (TPLIF). For measurements in the spray, the fluorescence tracer 3-pentanone is added to the nonfluorescent surrogate fuel iso-octane, which is excited quasi-simultaneously by two different excimer lasers for two-line excitation LIF. The gas-phase temperature of the mixture of fuel vapor and surrounding gas and the fuel vapor mass fraction can be calculated from the two LIF signals. The measurements are conducted in a high-temperature, high-pressure injection chamber. The fluorescence calibration of the tracer was executed in a flow cell and extended significantly compared to the existing database. A detailed error analysis for both calibration and measurement is provided. Simultaneous single-shot gas-phase temperature and fuel vapor mass fraction fields are processed for the assessment of cyclic spray fluctuations. PMID:26906600

  9. Fuel spray simulation with two-fluid nozzles

    NASA Astrophysics Data System (ADS)

    Ingebo, Robert D.

    1989-01-01

    Two-phase interacting flow inside a two-fluid fuel atomizer was investigated and a correction of aerodynamic and liquid-surface forces with characteristic drop diameter was obtained for liquid-jet breakup in Mach 1 gas flow. Nitrogen gas mass-flux was varied from 6 to 50 g/sq cm sec by using four differently sized two-fluid atomizers with nozzle diameters varying from 0.32 to 0.56 cm. The correlation was derived by using the acoustic gas velocity, V sub c, as a basic parameter in defining and evaluating the dimensionless product of the Weber (We) and Reynolds (Re) numbers. By using the definition of WeRe, it was found that the ratio of orifice diameter to Sauter mean drop diameter could be correlated with the dimensionless ratio WeRe and the gas to liquid density ratio.

  10. Investigations of some aspects of the spray process in a single wire arc plasma spray system using high speed camera.

    PubMed

    Tiwari, N; Sahasrabudhe, S N; Tak, A K; Barve, D N; Das, A K

    2012-02-01

    A high speed camera has been used to record and analyze the evolution as well as particle behavior in a single wire arc plasma spray torch. Commercially available systems (spray watch, DPV 2000, etc.) focus onto a small area in the spray jet. They are not designed for tracking a single particle from the torch to the substrate. Using high speed camera, individual particles were tracked and their velocities were measured at various distances from the spray torch. Particle velocity information at different distances from the nozzle of the torch is very important to decide correct substrate position for the good quality of coating. The analysis of the images has revealed the details of the process of arc attachment to wire, melting of the wire, and detachment of the molten mass from the tip. Images of the wire and the arc have been recorded for different wire feed rates, gas flow rates, and torch powers, to determine compatible wire feed rates. High speed imaging of particle trajectories has been used for particle velocity determination using time of flight method. It was observed that the ripple in the power supply of the torch leads to large variation of instantaneous power fed to the torch. This affects the velocity of the spray particles generated at different times within one cycle of the ripple. It is shown that the velocity of a spray particle depends on the instantaneous torch power at the time of its generation. This correlation was established by experimental evidence in this paper. Once the particles leave the plasma jet, their forward speeds were found to be more or less invariant beyond 40 mm up to 500 mm from the nozzle exit. PMID:22380128

  11. Erosion Resistance of High Velocity Oxy-Fuel WC-Co-Cr Thermal Spray Coatings

    NASA Astrophysics Data System (ADS)

    Imeson, Chris

    Thermal spray coatings have been incorporated in oil and gas extraction efforts for many years. Recently, High Velocity Oxy-Fuel (HVOF) has become increasingly incorporated where erosive environments are present. This study investigates the microstructural and mechanical properties of HVOF WC-Co-Cr coatings deposited at SharkSkin Coatings ltd. The deposited coatings exhibited a low porosity with high adhesion strength, hardness, and superior erosion resistance. In this study, a recirculating solid particle erosion testing machine was designed and fabricated to simulate an erosive environment on a laboratory scale. This study was also aimed at improving microstructures and mechanical properties of the coatings by modifying the two coating deposition parameters e.g. standoff and pre-cycle heating. It was determined that pre-spray substrate heating negatively affected the coatings microstructures e.g. porosity, while reducing the stand-off distance positively influenced the coating microstructures and mechanical properties, e.g. erosion resistance.

  12. Numerical simulation of the flow field and fuel sprays in an IC engine

    NASA Technical Reports Server (NTRS)

    Nguyen, H. L.; Schock, H. J.; Ramos, J. I.; Carpenter, M. H.; Stegeman, J. D.

    1987-01-01

    A two-dimensional model for axisymmetric piston-cylinder configurations is developed to study the flow field in two-stroke direct-injection Diesel engines under motored conditions. The model accounts for turbulence by a two-equation model for the turbulence kinetic energy and its rate of dissipation. A discrete droplet model is used to simulate the fuel spray, and the effects of the gas phase turbulence on the droplets is considered. It is shown that a fluctuating velocity can be added to the mean droplet velocity every time step if the step is small enough. Good agreement with experimental data is found for a range of ambient pressures in Diesel engine-type microenvironments. The effects of the intake swirl angle in the spray penetration, vaporization, and mixing in a uniflow-scavenged two-stroke Diesel engine are analyzed. It is found that the swirl increases the gas phase turbulence levels and the rates of vaporization.

  13. Flame structure of wall-impinging diesel fuel sprays injected by group-hole nozzles

    SciTech Connect

    Gao, Jian; Moon, Seoksu; Nishida, Keiya; Matsumoto, Yuhei; Zhang, Yuyin

    2009-06-15

    This paper describes an investigation of the flame structure of wall-impinging diesel sprays injected by group-hole nozzles in a constant-volume combustion vessel at experimental conditions typical of a diesel engine. The particular emphasis was on the effect of the included angle between two orifices (0-15 deg. in current study) on the flame structure and combustion characteristics under various simulated engine load conditions. The laser absorption scattering (LAS) technique was applied to analyze the spray and mixture properties. Direct flame imaging and OH chemiluminescence imaging were utilized to quantify the ignition delay, flame geometrical parameters, and OH chemiluminescence intensity. The images show that the asymmetric flame structure emerges in wall-impinging group-hole nozzle sprays as larger included angle and higher engine load conditions are applied, which is consistent with the spray shape observed by LAS. Compared to the base nozzle, group-hole nozzles with large included angles yield higher overall OH chemiluminescence intensity, wider flame area, and greater proportion of high OH intensity, implying the better fuel/air mixing and improved combustion characteristics. The advantages of group-hole nozzle are more pronounced under high load conditions. Based on the results, the feasibility of group-hole nozzle for practical direct injection diesel engines is also discussed. It is concluded that the asymmetric flame structure of a group-hole nozzle spray is favorable to reduce soot formation over wide engine loads. However, the hole configuration of the group-hole nozzle should be carefully considered so as to achieve proper air utilization in the combustion chamber. Stoichiometric diesel combustion is another promising application of group-hole nozzle. (author)

  14. Titanium dioxide reinforced hydroxyapatite coatings deposited by high velocity oxy-fuel (HVOF) spray.

    PubMed

    Li, H; Khor, K A; Cheang, P

    2002-01-01

    Hydroxyapatite (HA) coatings with titania addition were produced by the high velocity oxy-fuel (HVOF) spray process. Mechanical properties of the as-sprayed coatings in terms of adhesive strength, shear strength and fracture toughness were investigated to reveal the effect of the titania reinforcement on HA. Qualitative phase analysis with X-ray diffraction (XRD) showed that mutual chemical reaction between TiO2 and HA, that formed CaTiO3 occurred during coating formation. Differential scanning calorimetry (DSC) analysis of the starting powders showed that the mutual chemical reaction temperature was approximately 1410 degrees C and the existence of TiO2 can effectively inhibit the decomposition of HA at elevated temperatures. The positive influence of TiO2 addition on the shear strength was revealed. The incorporation of 10 vol% TiO2 significantly improved the Young's modulus of HA coatings from 24.82 (+/- 2.44) GPa to 43.23 (+/- 3.20) GPa. It decreased to 38.51 (+/- 3.65) GPa as the amount of TiO2 increased to 20 vol%. However, the addition of TiO2 has a negative bias on the adhesive strength of HA coatings especially when the content of TiO2 reached 20 vol%. This is attributed to the weak chemical bonding and brittle phases existing at the splats' interface that resulted from mutual chemical reactions. The fracture toughness exhibited values of 0.48 (+/- 0.08) MPa m0.5, 0.60 (+/- 0.07) MPa m0.5 and 0.67 (+/- 0.06) MPa m0.5 for the HA coating, 10 vol% TiO2 blended HA coating and 20 vol% TiO2 blended HA coating respectively. The addition of TiO2 in HA coating with the amount of less than 20 vol% is suggested for satisfactory toughening effect in HVOF HA coating. PMID:11762858

  15. Monitoring of fuel consumption and aromatics formation in a kerosene spray flame as characterized by fluorescence spectroscopy.

    PubMed

    Allouis, C; Apicella, B; Barbella, R; Beretta, F; Ciajolo, A; Tregrossi, A

    2003-06-01

    The large presence of aromatic compounds in distillate fossil fuels should allow, in line of principle, to follow the fuel consumption and/or the presence of unburned fuel in a high temperature environment like a burner or the exhaust of combustion systems by exploiting the high fluorescence emission of aromatic fuel components. To this aim an UV-excited fluorescence source has to be used since the aromatic fuel components are strongly fluorescing in the UV region of the emission spectrum. In this work UV-excited laser induced fluorescence (LIF) diagnostics was applied to spray flames of kerosene in order to follow the fuel consumption and the formation of aromatic species. A strong UV signal was detected in the spray region of the flame that presented a shape similar to that found in the LIF spectra preliminary measured on the cold spray and in the room-temperature fluorescence of fuel solutions. The decrease of UV signal along the spray flame region was associated to the consumption of the fuel, but more difficult seems to be the attribution of a broad visible emission, that is present downstream of the flame. The visible emission feature could be assigned to flame-formed PAH species contained in the high molecular weight species, hypothesizing that their fluorescence spectra are shifted toward the visible for effect of the high temperature flame environment. PMID:12718975

  16. Effects of Air-Fuel Spray and Flame Formation in a Compression-Ignition Engine

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Waldron, C D

    1937-01-01

    High-speed motion pictures were taken at the rate of 2,500 frames per second of the fuel spray and flame formation in the combustion chamber of the NACA combustion apparatus. The compression ratio was 13.2 and the speed 1,500 revolutions per minute. An optical indicator was used to record the time-pressure relationship in the combustion chamber. The air-fuel ratio was varied from 10.4 to 365. The results showed that as the air-fuel ratio was increased definite stratification of the charge occurred in the combustion chamber even though moderate air flow existed. The results also showed the rate of vapor diffusion to be relatively slow.

  17. High-Velocity Oxygen Fuel Thermal Spray of Fe-Based Amorphous Alloy: a Numerical and Experimental Study

    NASA Astrophysics Data System (ADS)

    Ajdelsztajn, L.; Dannenberg, J.; Lopez, J.; Yang, N.; Farmer, J.; Lavernia, E. J.

    2009-09-01

    The fabrication of dense coatings with appropriate properties using a high velocity oxygen fuel (HVOF) spray process requires an in-depth understanding of the complete gas flow field and particle behavior during the process. A computational fluid dynamics (CFD) model is implemented to investigate the gas flow behavior that occurs during the HVOF process and a simplified one-dimensional decoupled model of the in-flight thermal behavior of the amorphous Fe-based powder particles was developed and applied for three different spray conditions. The numerical results were used to rationalize the different coating microstructures described in the experimental results. Low porosity and amorphous coatings were produced using two different particle size distributions (16 to 25 μm and 25 to 53 μm). The amorphous characteristics of the powder were retained in the coating due to melting and rapid solidification in the case of very fine powder or ligaments (<16 μm) and to the fact that the crystallization temperature was not reached in the case of the large particles (16 to 53 μm).

  18. The functional TiO2-biodegradable plastic composite material produced by HVOF spraying process.

    PubMed

    Bang, Hee-Seon; Bang, Han-Sur; Lee, Yoon-Ki

    2007-11-01

    Photocatalytic TiO2 coatings on bio-degradable plastic(polybutylene succinate: PBS) were prepared by HVOF spraying using three kinds of agglomerated powders (P200: 200 nm, P30: 30 nm, P7: 7 nm). The microstructures of the coatings were characterized with SEM and XRD analysis, and the photocatalytic efficiency of the coatings was evaluated by photo degradation of gaseous acetaldehyde. For both the HVOF sprayed P200 and P30 coatings, high anatase ratio of 100% was achieved, regardless of the fuel gas pressure. On the other hand, for the HVOF sprayed P7 coating, the anatase ratio decreased from 100% to 49.1% with increasing fuel gas pressure. This decrease may be attributed to the much higher susceptibility to heat of the 7 nm agglomerated powders than the 30 nm and 200 nm agglomerated powders. In terms of the photocatalytic efficiency, HVOF sprayed P200 and P30 coatings seemed to outperform the P7 coatings because of their higher anatase ratios. However, the HVOF sprayed P7 coatings did not show photocatalytic activity possibly because of the extremely small reaction surface area to the photo-catalytic activity and low anatase ratio. Therefore, the present study found that functional PBS plastic with photocatalytic performance could be produced by spraying of ceramics such as TiO2. PMID:18047069

  19. Photocatalytic Iron Oxide Coatings Produced by Thermal Spraying Process

    NASA Astrophysics Data System (ADS)

    Navidpour, A. H.; Salehi, M.; Amirnasr, M.; Salimijazi, H. R.; Azarpour Siahkali, M.; Kalantari, Y.; Mohammadnezhad, M.

    2015-12-01

    Recently, hematite coatings with semiconductor properties have received attention for photocatalytic applications. In this study, plasma and flame spraying techniques were used for hematite deposition on 316 stainless steel plates. X-ray diffraction was used for phase composition analysis, and methylene blue was used as an organic pollutant to evaluate the photocatalytic activity of thermally sprayed coatings. The results showed that all these coatings could act under visible-light irradiation but the one deposited by flame spraying at 20 cm stand-off distance showed the highest photocatalytic activity. The results showed that wavelength of the light source and pH of the solution affected the photocatalytic activity significantly. It was also shown that thermally sprayed iron oxide coatings could have a high photo-absorption ability, which could positively affect the photocatalytic activity.

  20. Literature on fabrication of tungsten for application in pyrochemical processing of spent nuclear fuels

    SciTech Connect

    Edstrom, C.M.; Phillips, A.G.; Johnson, L.D.; Corle, R.R.

    1980-10-11

    The pyrochemical processing of nuclear fuels requires crucibles, stirrers, and transfer tubing that will withstand the temperature and the chemical attack from molten salts and metals used in the process. This report summarizes the literature that pertains to fabrication (joining, chemical vapor deposition, plasma spraying, forming, and spinning) is the main theme. This report also summarizes a sampling of literature on molbdenum and the work previously performed at Argonne National Laboratory on other container materials used for pyrochemical processing of spent nuclear fuels.

  1. Effects of 2-Ethylhexyl Nitrate on Diesel-Spray Processes

    SciTech Connect

    Higgins, B.; Mueller, C.; Siebers, D.

    1998-08-01

    Diesel fuel ignition-enhancing additives, such as 2-ethylhexyl nitrate, are known to reduce emissions from diesel engines; however, the mechanisms by which the emissions reduction occur are not understood. This report covers the first phase of a research project supported by Ethyl Corporation that is aimed at developing a detailed understanding of how 2-ethylhexyl nitrate alters in-cylinder injection, ignition, and combustion processes to reduce diesel engine emissions.

  2. Some Factors Affecting the Reproducibility of Penetration and the Cut-Off of Oil Sprays for Fuel-injection Engines

    NASA Technical Reports Server (NTRS)

    Beardsley, E G

    1928-01-01

    This investigation was undertaken at the Langley Memorial Aeronautical Laboratory in connection with a general research on fuel-injection for aircraft. The purpose of the investigation was to determine the factors controlling the reproducibility of spray penetration and secondary discharges after cut-off. The development of single sprays from automatic injection valves was recorded by means of special high-speed photographic apparatus capable of taking 25 consecutive pictures of the moving spray at a rate of 4,000 per second. The effect of two types of injection valves, injection-valve tube length, initial pressure in the injection-valve tube, speed of the injection control mechanism, and time of spray cut-off, on the reproducibility of spray penetration, and on secondary discharges were investigated. It was found that neither type of injection valve materially affected spray reproducibility. The initial pressure in the injection-valve tube controlled the reproducibility of spray penetrations. An increase in the initial pressure or in the length of the injection-valve tube slightly increased the spray penetration within the limits of this investigation. The speed of the injection-control mechanism did not affect the penetration. Analysis of the results indicates that secondary discharges were caused in this apparatus by pressure waves initiated by the rapid opening of the cut-off valve. The secondary discharges were eliminated in this investigation by increasing the length of the injection-valve tube. (author)

  3. Synchronized droplet size measurements for coal-water-slurry (CWS) diesel sprays of an electronically-controlled fuel injection system

    SciTech Connect

    Kihm, K.D.; Terracina, D.P.; Payne, S.E.; Caton, J.A.

    1993-12-31

    Experiments were completed to study intermittent coal-water slurry (CWS) fuel sprays injected from an electronically-controlled accumulator injector system. A laser diffraction particle analyzing (LDPA) technique was used to measure the spray diameters (Sauter mean diameter, SMD) assuming the Rosin-Rammler two parameter model. In order to ensure an accurate synchronization of the measurement with the intermittent sprays, a new synchronization technique was developed using the light extinction signal as a triggering source for the data taking initiation. This technique allowed measurement of SMDs near the spray tip where the light extinction was low and the data were free from the multiscattering bias. Coal-water slurry fuel with 50% coal loading in mass containing 5 {mu}m mass median diameter coal particulates was considered. Injection pressures ranging from 28 to 110 MPa, two different nozzle orifice diameters, 0.2 ad 0.4 mm, and four axial measurement locations from 60 to 120 mm from the nozzle orifice were studied. Measurements were made for pressurized (2.0 MPa in gauge) and for ambient chamber conditions. The spray SMD showed an increase with the distance of the axial measurement location and with the ambient gas density, and showed a decrease with increasing injection pressure. A correlation of the Sauter mean diameter with the injection conditions was determined. The results were also compared with previous SMD correlations that were available only for diesel fuel sprays.

  4. Computer-Controlled Detonation Spraying: From Process Fundamentals Toward Advanced Applications

    NASA Astrophysics Data System (ADS)

    Ulianitsky, V.; Shtertser, A.; Zlobin, S.; Smurov, I.

    2011-06-01

    Detonation spraying is a well-known technology which is applied for deposition of diverse powders, in particular cermets, to form various protective coatings. Actual progress is related to a recently developed technique of computer-controlled detonation spraying and its application in non-traditional domains as development of composite and graded coatings or metallization of plastics. The gas detonation parameters are analyzed to estimate the efficiency of different fuels to vary particle-in-flight velocity and temperature over a broad range thus providing conditions to spray diverse powders. A particle of a given nature and fixed size could be sprayed in a solid state or being strongly overheated above the melting point by variation of the quantity of the explosive gas mixture which is computer-controlled. Particle-in-flight velocity and temperature are calculated and compared with jet monitoring by a CCD-camera-based diagnostic tool and experimental data on splats formation.

  5. Effect of orifice length-diameter ratio on fuel sprays for compression-ignition engines

    NASA Technical Reports Server (NTRS)

    Gelalles, A G

    1933-01-01

    Experimental results on the effect of the length-diameter ratio of the orifice on the spray characteristics, together with a brief analysis of the factors affecting these characteristics, are presented in this report. The length-diameter ratios tested ranged from 0.5 to 10; the orifice diameters from 0.008 to 0.040 inch; and the injection pressures from 2,000 to 8,000 pounds per square inch. The density of the air into which the fuel was discharged was varied from 0.38 to 1.35 pounds per cubic foot.

  6. In vitro performance of ceramic coatings obtained by high velocity oxy-fuel spray.

    PubMed

    Melero, H; Garcia-Giralt, N; Fernández, J; Díez-Pérez, A; Guilemany, J M

    2014-01-01

    Hydroxyapatite coatings obtained by plasma-spraying have been used for many years to improve biological performance of bone implants, but several studies have drawn attention to the problems arising from high temperatures and the lack of mechanical properties. In this study, plasma-spraying is substituted by high velocity oxy-fuel (HVOF) spray, with lower temperatures reached, and TiO2 is added in low amounts to hydroxyapatite in order to improve the mechanical properties. Four conditions have been tested to evaluate which are those with better biological properties. Viability and proliferation tests, as well as differentiation assays and morphology observation, are performed with human osteoblast cultures onto the studied coatings. The hydroxyapatite-TiO2 coatings maintain good cell viability and proliferation, especially the cases with higher amorphous phase amount and specific surface, and promote excellent differentiation, with a higher ALP amount for these cases than for polystyrene controls. Observation by SEM corroborates this excellent behaviour. In conclusion, these coatings are a good alternative to those used industrially, and an interesting issue would be improving biological behaviour of the worst cases, which in turn show the better mechanical properties. PMID:25201392

  7. Particle melting behavior during high-velocity oxygen fuel thermal spraying

    NASA Astrophysics Data System (ADS)

    He, J.; Ice, M.; Lavernia, E.

    2001-03-01

    Particle melting behavior during high-velocity oxygen fuel (HVOF) thermal spraying was investigated using Inconel 625 powders. The powder characteristics and coating properties were investigated using scanning electron microscopy (SEM), x-ray, and microhardness studies. Results indicated that the volume fraction of unmelted particles in the coatings was dependent on the proportion of powder within a specified size range, in these experiments, 30 to 50 µm. This particle size range was primarily determined by the particle temperature, which was measured during spraying. Particle temperature significantly decreased as particle size increased. The microhardness values for the coatings containing unmelted particles were predicted by a simple rule-of-mixtures equation for the case of a low volume fraction of unmelted particles. However, for the condition of high volume fraction of unmelted particles, the measured microhardness values did not compare favorably with the calculated values, probably due to the presence of porosity, which occurred in the form of voids found among unmelted particles. The microstructure and characteristics of the feedstock powder were retained in the corresponding coating under certain spray conditions.

  8. Prediction of the structure of fuel sprays in gas turbine combustors

    NASA Technical Reports Server (NTRS)

    Shuen, J. S.

    1985-01-01

    The structure of fuel sprays in a combustion chamber is theoretically investigated using computer models of current interest. Three representative spray models are considered: (1) a locally homogeneous flow (LHF) model, which assumes infinitely fast interphase transport rates; (2) a deterministic separated flow (DSF) model, which considers finite rates of interphase transport but ignores effects of droplet/turbulence interactions; and (3) a stochastic separated flow (SSF) model, which considers droplet/turbulence interactions using random sampling for turbulence properties in conjunction with random-walk computations for droplet motion and transport. Two flow conditions are studied to investigate the influence of swirl on droplet life histories and the effects of droplet/turbulence interactions on flow properties. Comparison of computed results with the experimental data show that general features of the flow structure can be predicted with reasonable accuracy using the two separated flow models. In contrast, the LHF model overpredicts the rate of development of the flow. While the SSF model provides better agreement with measurements than the DSF model, definitive evaluation of the significance of droplet/turbulence interaction is not achieved due to uncertainties in the spray initial conditions.

  9. On the gas dynamics of HVOF thermal sprays. [HVOF (High-Velocity Oxy-Fuel)

    SciTech Connect

    Hackett, C.M.; Settles, G.S.; Miller, J.D.

    1993-01-01

    An experimental study has been performed on the gas dynamic aspects of the HVOF thermal spray process. A commercially-available HVOF gun (Hobart Tafa JP-5000) is used in this study. Optical diagnostic techniques including microsecond-exposure schlieren and shadowgraph imaging are applied to visualize the hot supersonic jet produced by this equipment without any particle injection. Rapid turbulent mixing of the jet with the surrounding atmosphere is observed, which is an issue of concern in coating quality because of the possibility of oxidation of the sprayed particles. This mixing appears principally to be a function of the density ratio between the hot jet and the cold atmosphere, rather than depending upon the combustion-chamber pressure or barrel length. The supersonic core of the HVOF jet dissipates rapidly due to the, mixing, so that the jet is no longer supersonic when it impinges upon the target surface being sprayed. Secondary issues also observed in this study include strong jet-noise radiation from the HVOF plume and the entrainment and induced bulk motion of the surrounding air. All these issues have a background in the field of gas dynamics which has not been previously applied to thermal spray technology.

  10. A moments-based algorithm for optimizing the information mined in post-processing spray images

    NASA Astrophysics Data System (ADS)

    Tan, Z. P.; Zinn, B. T.; Lubarsky, E.; Bibik, O.; Shcherbik, D.; Shen, L.

    2016-02-01

    The Moments-algorithm was developed to post-process images of sprays with the aim of characterizing the sprays' complex features (e.g., trajectory, dispersions and dynamics) in terms of simple curves, which can be used for developing correlation models and design tools. To achieve this objective, the algorithm calculates the first moments of pixel intensity values in instantaneous images of the spray to determine its center-of-gravity ( CG) trajectory (i.e., the spray density-weighted centerline trajectory). Thereafter, the second moments (i.e., standard-deviations, σ) of intensities are calculated to describe the dispersion of spray materials around the CG. After the instantaneous CG's and σ's for the instantaneous images have been obtained, they are arithmetically averaged to produce the average spray trajectories and dispersions. Additionally, the second moments of instantaneous CG's are used to characterize the spray's fluctuation magnitude. The Moments-algorithm has three main advantages over threshold-based edge-tracking and other conventional post-processing approaches: (1) It simultaneously describes the spray's instantaneous and average trajectories, dispersions and fluctuations, instead of just the outer/inner-edges, (2) the use of moments to define these spray characteristics is more physically meaningful because they reflect the statistical distribution of droplets within the spray plume instead of relying on an artificially interpreted "edge", and (3) the use of moments decreases the uncertainties of the post-processed results because moments are mathematically defined and do not depend upon user-adjustments/interpretations.

  11. Electrostatic application of antimicrobial sprays to sanitize food handling and processing surfaces for enhanced food safety

    NASA Astrophysics Data System (ADS)

    Lyons, Shawn M.; Harrison, Mark A.; Law, S. Edward

    2011-06-01

    Human illnesses and deaths caused by foodborne pathogens (e.g., Salmonella enterica, Listeria monocytogenes, Escherichia coli O157:H7, etc.) are of increasing concern globally in maintaining safe food supplies. At various stages of the food production, processing and supply chain antimicrobial agents are required to sanitize contact surfaces. Additionally, during outbreaks of contagious pathogenic microorganisms (e.g., H1N1 influenza), public health requires timely decontamination of extensive surfaces within public schools, mass transit systems, etc. Prior publications verify effectiveness of air-assisted, induction-charged (AAIC) electrostatic spraying of various chemical and biological agents to protect on-farm production of food crops...typically doubling droplet deposition efficiency with concomitant increases in biological control efficacy. Within a biosafety facility this present work evaluated the AAIC electrostatic-spraying process for application of antimicrobial liquids onto various pathogen-inoculated food processing and handling surfaces as a food safety intervention strategy. Fluoroanalysis of AAIC electrostatic sprays (-7.2 mC/kg charge-to-mass ratio) showed significantly greater (p<0.05) mass of tracer active ingredient (A.I.) deposited onto target surfaces at various orientations as compared both to a similar uncharged spray nozzle (0 mC/kg) and to a conventional hydraulic-atomizing nozzle. Per unit mass of A.I. dispensed toward targets, for example, A.I. mass deposited by AAIC electrostatic sprays onto difficult to coat backsides was 6.1-times greater than for similar uncharged sprays and 29.0-times greater than for conventional hydraulic-nozzle sprays. Even at the 56% reduction in peracetic acid sanitizer A.I. dispensed by AAIC electrostatic spray applications, they achieved equal or greater CFU population reductions of Salmonella on most target orientations and materials as compared to uncharged sprays and conventional full-rate hydraulic

  12. The HVOF process - the hottest topic in the thermal spray industry

    SciTech Connect

    Smith, R.W. . Center for the Plasma Processing of Materials); Irving, B.; Knight, R.

    1993-07-01

    High-velocity combustion or oxyfuel spraying started up more than 35 years ago with the development of the detonation gun or D-Gun process. Described as the newest and fastest growing member of the family of coating, or surfacing, technologies known collectively as thermal spray'', HVOF processes have carved out a significant, specialized niche in the thermal spray coating business, particularly for the deposition of wear-resistant carbide coatings. HVOF processes are able to deposit very dense coatings, typically with reduced changes in the phase composition of the material, compared with plasma arc spray processes. HVOF also offers a number of potential advantages over, and alternatives to, competing processes, including lower capital costs, portability, and ease of use in the field.

  13. Comparison of different hard, metal-like coatings sprayed by plasma and detonation gun processes

    SciTech Connect

    Vuoristo, P.; Niemi, K.; Maentylae, T.; Berger, L.M.; Nebelung, M.

    1995-12-31

    Structure and wear properties of atmospheric plasma sprayed and detonation gun sprayed coatings prepared from an experimental (Ti,Mo)C-28.4%NiCo powder were compared to coatings sprayed from commercially available WC-12%Co and Cr{sub 3}C{sub 2}-25%NiCr powders. All powders had an agglomerated (spray dried) and sintered structure and nearly the same content of the metallic binder of approximately 20 vol.-%. The powders were characterized by SEM (morphology and cross-sections) and X-ray diffraction (phase composition). The coatings were studied by optical microscope, microhardness measurements, X-ray diffraction analysis and by abrasion and erosion wear tests. The X-ray diffraction patterns of the coatings show that the (Ti,Mo)C-28.4%NiCo powder is characterized by high phase stability in both spray processes, whereas the WC-12%Co powder is prone to significant phase transformations during spraying. The results clearly show the high potential of the experimental (Ti,Mo)C-28.4%NiCo coatings in substituting the conventional systems in wear applications. For instance, it was found that plasma spraying of the (Ti,Mo)C-28.4%NiCo powder with an Ar-H{sub 2} plasma gas resulted in coatings with wear resistance comparable to WC-12%Co coatings. However, detonation gun sprayed WC-12%Co coatings showed somewhat better abrasion wear resistance.

  14. Deposition behavior and microstructural development of TiNi powder particles in low temperature-HVOF spraying process

    NASA Astrophysics Data System (ADS)

    Lin, Q. S.; Zhou, K. S.; Deng, C. M.; Liu, M.; Xiao, X. L.; Deng, C. G.

    2013-10-01

    TiNi alloy particles were deposited at high velocity on Q235 steel substrate in thermally softened solid state by the modified high-velocity oxygen fuel spraying process (so called low temperature HVOF). Microstructural developments and deposition behaviors of a deposited single particle were observed by high resolution scanning electron microscopy and transmission electron microscopy. A single TiNi particle sprayed onto the substrate was severely deformed and the jetting-out phenomenon occurred in the margin of the splat. Extremely fine grains were observed along the interfacial boundary of the deposited particles where the most severe deformation had taken place. The grain refinement at the high deformed region of a splat was arisen from dynamic recrystallization of heavily deformed grain during deformation.

  15. Acoustic effects of sprays

    NASA Technical Reports Server (NTRS)

    Pindera, Maciej Z.; Przekwas, Andrzej J.

    1994-01-01

    Since the early 1960's, it has been known that realistic combustion models for liquid fuel rocket engines should contain at least a rudimentary treatment of atomization and spray physics. This is of particular importance in transient operations. It has long been recognized that spray characteristics and droplet vaporization physics play a fundamental role in determining the stability behavior of liquid fuel rocket motors. This paper gives an overview of work in progress on design of a numerical algorithm for practical studies of combustion instabilities in liquid rocket motors. For flexibility, the algorithm is composed of semi-independent solution modules, accounting for different physical processes. Current findings are report and future work is indicated. The main emphasis of this research is the development of an efficient treatment to interactions between acoustic fields and liquid fuel/oxidizer sprays.

  16. Spray granulation: importance of process parameters on in vitro and in vivo behavior of dried nanosuspensions.

    PubMed

    Figueroa, Carlos E; Bose, Sonali

    2013-11-01

    The use of fluid bed granulation for drying of pharmaceutical nanoparticulates on micron-sized granule substrates is a relatively new technique, with limited understanding in the current literature of the effects of process parameters on the physical properties of the dried nanoparticle powders. This work evaluated the effects of spray mode, spray rate and atomizing pressure for spray granulation of drug nanosuspensions through a systematic study. Naproxen and a proprietary Novartis compound were converted into nanosuspensions through wet media milling and dried onto a mannitol based substrate using spray granulation. For naproxen, various physical properties of the granules, as well as the in vitro re-dispersion and dissolution characteristics of the nano-crystals, were measured. It was found that the spray mode had the most drastic effect, where top spray yielded smaller re-dispersed particle sizes and faster release rates of drug from granules than bottom spray. This was attributed to the co-current spraying in bottom spray resulting in denser, homogenous films on the substrate. Similar in vitro results were obtained for the proprietary molecule, Compound A. In vivo studies in beagle dogs with Compound A showed no significant difference between the liquid and the dried forms of the nanosuspension in terms of overall AUC, differences were observed in the tmax which correlated with the rank ordering observed from the in vitro dissolution profiles. These findings make spray granulation amenable to the production of powders with desired processing and handling properties, without compromising the overall exposure of the compound under investigation. PMID:23916460

  17. Processing sunflower oil for fuel

    SciTech Connect

    Backer, L.F.; Jacobsen, L.; Olson, C.

    1982-05-01

    Research on processing of sunflower seed for oil was initiated to evaluate the equipment that might adapt best to on-farm or small factory production facilities. The first devices identified for evaluation were auger press expeller units, primary oil cleaning equipment, and final filters. A series of standard finishing filtration tests were carried out on sunflower oil and sunflower oil - diesel fuel blends using sunflower oil from four different sources.

  18. Oxides of Nitrogen Emissions from the Combustion of Monodisperse Liquid Fuel Sprays. Ph.D. Thesis

    NASA Technical Reports Server (NTRS)

    Sarv, H.

    1985-01-01

    A study of NO sub x formation in a one dimensional monodisperse spray combustion system, which allowed independent droplet size variation, was conducted. Temperature, NO and NO sub x concentrations were measured in the transition region, encompassing a 26 to 74 micron droplet size range. Emission measurements of hydrocarbons, carbon monoxide, carbon dioxide and oxygen were also made. The equivalence ratio was varied between 0.8 and 1.2 for the fuels used, including methanol, isopropanaol, n-heptane and n-octane. Pyridine and pyrrole were added to n-heptane as nitrogen-containing additives in order to simulate synthetic fuels. Results obtained from the postflame regions using the pure fuels indicate an optimum droplet size in the range of 43 to 58 microns for minimizing NO sub x production. For the fuels examined, the maximum NO sub x reductions relative to the small droplet size limit were about 10 to 20% for lean and 20 to 30% for stoichiometric and rich mixtures. This behavior is attributed to droplet interactions and the transition from diffusive to premixed type of burning. Preflame vaporization controls the gas phase stoichiometry which has a significant effect on the volume of the hot gases surrounding a fuel droplet, where NO sub x is formed.

  19. Interior flow and near-nozzle spray development in a marine-engine diesel fuel injector

    NASA Astrophysics Data System (ADS)

    Hult, J.; Simmank, P.; Matlok, S.; Mayer, S.; Falgout, Z.; Linne, M.

    2016-04-01

    A consolidated effort at optically characterising flow patterns, in-nozzle cavitation, and near-nozzle jet structure of a marine diesel fuel injector is presented. A combination of several optical techniques was employed to fully transparent injector models, compound metal-glass and full metal injectors. They were all based on a common real-scale dual nozzle hole geometry for a marine two-stroke diesel engine. In a stationary flow rig, flow velocities in the sac-volume and nozzle holes were measured using PIV, and in-nozzle cavitation visualized using high-resolution shadowgraphs. The effect of varying cavitation number was studied and results compared to CFD predictions. In-nozzle cavitation and near-nozzle jet structure during transient operation were visualized simultaneously, using high-speed imaging in an atmospheric pressure spray rig. Near-nozzle spray formation was investigated using ballistic imaging. Finally, the injector geometry was tested on a full-scale marine diesel engine, where the dynamics of near-nozzle jet development was visualized using high-speed shadowgraphy. The range of studies focused on a single common geometry allows a comprehensive survey of phenomena ranging from first inception of cavitation under well-controlled flow conditions to fuel jet structure at real engine conditions.

  20. Characterization of the bone-like apatite precipitated on high velocity oxy-fuel (HVOF) sprayed calcium phosphate deposits.

    PubMed

    Khor, K A; Li, H; Cheang, P

    2003-02-01

    Bone-like apatite was precipitated on the surface of thermal sprayed calcium phosphate coatings following in vitro incubation in a simulated body fluid. The coatings were initially deposited on titanium alloy substrates by the high velocity oxy-fuel (HVOF) spray technique. Structural characterization and mechanical evaluation of the precipitated apatite layer were conducted. Results showed that the precipitation rate was directly influenced by the local Ca(2+) concentration in the vicinity of the coating's surface and that preferential dissolution of certain phases was found to accelerate the precipitation of the bone-like apatite. The dense precipitates exhibited a competitive Young's modulus value of approximately 120GPa, which was obtained through nanoindentation. This compared favorably to the calcium phosphate matrix. Differences in microstructure at various locations within the layer resulted in altered Young's modulus and microhardness values. Precipitation mechanism investigation was carried out through a comparative experiment. Chemical analysis showed that the precipitation of bone-like apatite on the calcium phosphate coating was quite conceivably a partial diffusion-controlled process. PMID:12485795

  1. Computational analysis of a three-dimensional High-Velocity Oxygen-Fuel (HVOF) Thermal Spray torch

    SciTech Connect

    Hassan, B.; Lopez, A.R.; Oberkampf, W.L.

    1995-07-01

    An analysis of a High-Velocity Oxygen-Fuel Thermal Spray torch is presented using computational fluid dynamics (CFD). Three-dimensional CFD results are presented for a curved aircap used for coating interior surfaces such as engine cylinder bores. The device analyzed is similar to the Metco Diamond Jet Rotating Wire torch, but wire feed is not simulated. To the authors` knowledge, these are the first published 3-D results of a thermal spray device. The feed gases are injected through an axisymmetric nozzle into the curved aircap. Argon is injected through the center of the nozzle. Pre-mixed propylene and oxygen are introduced from an annulus in the nozzle, while cooling air is injected between the nozzle and the interior wall of the aircap. The combustion process is modeled assuming instantaneous chemistry. A standard, two-equation, K-{var_epsilon} turbulence model is employed for the turbulent flow field. An implicit, iterative, finite volume numerical technique is used to solve the coupled conservation of mass, momentum, and energy equations for the gas in a sequential manner. Flow fields inside and outside the aircap are presented and discussed.

  2. Evaluation of Liquid Fuel Spray Models for Hybrid RANS/LES and DLES Prediction of Turbulent Reactive Flows

    NASA Astrophysics Data System (ADS)

    Afshar, Ali

    An evaluation of Lagrangian-based, discrete-phase models for multi-component liquid sprays encountered in the combustors of gas turbine engines is considered. In particular, the spray modeling capabilities of the commercial software, ANSYS Fluent, was evaluated. Spray modeling was performed for various cold flow validation cases. These validation cases include a liquid jet in a cross-flow, an airblast atomizer, and a high shear fuel nozzle. Droplet properties including velocity and diameter were investigated and compared with previous experimental and numerical results. Different primary and secondary breakup models were evaluated in this thesis. The secondary breakup models investigated include the Taylor analogy breakup (TAB) model, the wave model, the Kelvin-Helmholtz Rayleigh-Taylor model (KHRT), and the Stochastic secondary droplet (SSD) approach. The modeling of fuel sprays requires a proper treatment for the turbulence. Reynolds-averaged Navier-Stokes (RANS), large eddy simulation (LES), hybrid RANS/LES, and dynamic LES (DLES) were also considered for the turbulent flows involving sprays. The spray and turbulence models were evaluated using the available benchmark experimental data.

  3. Synthetic fuels handbook: properties, process and performance

    SciTech Connect

    Speight, J.

    2008-07-01

    The handbook is a comprehensive guide to the benefits and trade-offs of numerous alternative fuels, presenting expert analyses of the different properties, processes, and performance characteristics of each fuel. It discusses the concept systems and technology involved in the production of fuels on both industrial and individual scales. Chapters 5 and 7 are of special interest to the coal industry. Contents: Chapter 1. Fuel Sources - Conventional and Non-conventional; Chapter 2. Natural Gas; Chapter 3. Fuels From Petroleum and Heavy Oil; Chapter 4. Fuels From Tar Sand Bitumen; Chapter 5. Fuels From Coal; Chapter 6. Fuels From Oil Shale; Chapter 7. Fuels From Synthesis Gas; Chapter 8. Fuels From Biomass; Chapter 9. Fuels From Crops; Chapter 10. Fuels From Wood; Chapter 11. Fuels From Domestic and Industrial Waste; Chapter 12. Landfill Gas. 3 apps.

  4. Deposition of nanoparticle suspensions by aerosol flame spraying: Model of the spray and impact processes

    NASA Astrophysics Data System (ADS)

    Poirier, T.; Vardelle, A.; Elchinger, M. F.; Vardelle, M.; Grimaud, A.; Vesteghem, H.

    2003-09-01

    Aerosol flame spraying (AFS) combines the atomization of a colloidal suspension with the lateral injection of the aerosol in a flame. The aerosol droplets are partially dried when crossing the flame and then deposited as a coating onto a substrate. Afterwards, the coating is consolidated by heat treatment without extensive grain growth. In this paper a model of the trajectories, acceleration and vaporization of the droplets is used to predict the impact conditions of the in-flight dried droplets, as well as their size and water content when they impinge onto the substrate. From these calculations and the hydrodynamic properties (viscosity, surface tension, contact angle) of the suspensions, the morphology and size of the lamellae deposited on the substrate are determined by using classic impact models. In spite of the complexity of the mixing of the suspension spray with the flame and the diversity of the thermal histories of the droplets, the observation of the latter after impact shows that the results of the model are quite consistent with measurements. The relationship between droplet impact parameters and coating formation is discussed.

  5. Development of Universal Portable Spray Stand for Touch-Up Process in The Automotive Paintshop

    NASA Astrophysics Data System (ADS)

    Fatah Muhamed Mukhtar, Muhamed Abdul; Mohideen Shahul Hameed, Rasool

    2016-02-01

    A spray stand is a custom-made tool used to hold the automotive body parts as well as the devices used to facilitate the operator during the Touch Up process in Paint shop production. This paper discusses about the development of Universal Portable Spray Stand (UPSS) as a tool to hold various types of automotive body parts and model of car during the painting process. The main objective of this study is to determine the effective application of UPSS at the International College of Automotive (ICAM) and also in the automotive industry. This will be helpful to add features to the current spray stand in ICAM and to add value to the spray stand based on selected criteria which are universal, portable and cost saving. In addition, study in the UPSS is also expected to bring reduction in cycle time during the touch up process, in the paint defects and in the ergonomics issues among the operators.

  6. Linewidth Uniformity: A Critical Evaluation Of Spray Geometry And Process Interactions In Ultrasonic Nozzles

    NASA Astrophysics Data System (ADS)

    DeBruin, David; Hannifan, M. Richard; Ha, Marie; Sautter, Kenneth

    1987-08-01

    Spatial linewidth replication is a dominant yield limiting factor for most current photolithography processes, typically consuming,/ 50% of the total linewidth variation allowance. Therefore, the reduction of across wafer variation is critical to successful process development. In this study, the primary factors affecting spatial linewidth replication were investigated. These factors include agitation uniformity, wafer rotation rate, develop temperature control, and photo-optimization. Key results are: 1. Nitrogen assisted ultrasonic spray nozzles produced a spatial linewidth standard deviation of .03 μm, compared to .05 μm for a fan spray nozzle. 2. Developer consumption for ultrasonic spray nozzles is approximately 60% less than for standard fan spray nozzles. 3. Head positioning of ultrasonic nozzles is less critical relative to fan spray nozzles for standard organic and inorganic developers. Head positioning for both ultrasonic and fan spray is critical when using high contrast MIF developers. 4. Rotation speeds of 600 - 1000 rpm were found to be optimal for both ultrasonic and fan spray. 5. Developer temperature controls parallel CD variation trends and can be minimized by use of developer temperature controllers and/or exhaust controllers. 6. Photo-optimization typically produced a 3-fold or greater improvement in linewidth uniformity across the wafer. The effect upon linewidth uniformity is demonstrated in a systematic study of the predominant variables.

  7. Microbial fuel cell treatment of fuel process wastewater

    DOEpatents

    Borole, Abhijeet P; Tsouris, Constantino

    2013-12-03

    The present invention is directed to a method for cleansing fuel processing effluent containing carbonaceous compounds and inorganic salts, the method comprising contacting the fuel processing effluent with an anode of a microbial fuel ell, the anode containing microbes thereon which oxidatively degrade one or more of the carbonaceous compounds while producing electrical energy from the oxidative degradation, and directing the produced electrical energy to drive an electrosorption mechanism that operates to reduce the concentration of one or more inorganic salts in the fuel processing effluent, wherein the anode is in electrical communication with a cathode of the microbial fuel cell. The invention is also directed to an apparatus for practicing the method.

  8. Antistatic sprays

    NASA Technical Reports Server (NTRS)

    Ming, James E.

    1989-01-01

    Antistatic sprays from several different manufacturers are examined. The sprays are examined for contamination potential (i.e., outgassing and nonvolatile residue), corrosiveness on an aluminum mirror surface, and electrostatic effectiveness. In addition, the chemical composition of the antistatic sprays is determined by infrared spectrophotometry, mass spectrometry, and ultraviolet spectrophotometry. The results show that 12 of the 17 antistatic sprays examined have a low contamination potential. Of these sprays, 7 are also noncorrosive to an aluminum surface. And of these, only 2 demonstrate good electrostatic properties with respect to reducing voltage accumulation; these sprays did not show a fast voltage dissipation rate however. The results indicate that antistatic sprays can be used on a limited basis where contamination potential, corrosiveness, and electrostatic effectiveness is not critical. Each application is different and proper evaluation of the situation is necessary. Information on some of the properties of some antistatic sprays is presented in this document to aid in the evaluation process.

  9. Properly synchronized measurements of droplet sizes for high-pressure intermittent coal-water slurry fuel sprays

    SciTech Connect

    Kihm, K.D.; Terracina, D.P.; Payne, S.E.; Caton, J.A.

    1993-12-31

    Experiments were completed to study intermittent coal-water slurry (CWS) fuel sprays injected from an electronically-controlled accumulator injector system. A new synchronization technique was developed using the light extinction signal as a triggering source for the data taking initiation with a laser diffraction particle analyzing (LDPA) technique. This technique allowed measurement of SMDs near the spray tip where the light extinction was low and the data were free from the multiscattering bias. Coal-water slurry fuel with 50% coal loading in mass containing 5 {mu}m mass median diameter coal particulates was considered. A correlation of the SMD with the injection conditions was determined which should show a satisfactory agreement with the measured SMD data. The spray SMD showed an increase with the distance of the axial measurement location and with the ambient gas density, and showed a decrease with increasing injection pressure.

  10. Arc-Plasma Wire Spraying: An Optical Study of Process Phenomenology

    NASA Astrophysics Data System (ADS)

    Gulyaev, I. P.; Dolmatov, A. V.; Kharlamov, M. Yu.; Gulyaev, P. Yu.; Jordan, V. I.; Krivtsun, I. V.; Korzhyk, V. M.; Demyanov, O. I.

    2015-12-01

    In the present paper, we report on the results of an experimental study of heat- and mass-transfer processes in a Plazer 30-PL-W plasma-jet facility used for arc-plasma wire spraying. Using an original optical diagnostic system, we have studied melting behavior of the metal wire, break up and atomization of liquid metal. For the first time, experimental data on the in-flight velocity and temperature of spray particles in arc-plasma wire spraying were obtained. In spite of moderate particle velocities (about 50 m/s), the obtained steel coatings proved to have a low porosity of 1.5%. While studying the spraying process of tungsten wire, we observed the occurrence of anomalous high-velocity (over 4000 m/s) outbursts ejected from the surface of liquid metal droplets. The nature of such outbursts calls for further study.

  11. Bioactive Glass-Ceramic Coatings Synthesized by the Liquid Precursor Plasma Spraying Process

    NASA Astrophysics Data System (ADS)

    Xiao, Yanfeng; Song, Lei; Liu, Xiaoguang; Huang, Yi; Huang, Tao; Chen, Jiyong; Wu, Yao; Wu, Fang

    2011-03-01

    In this study, the liquid precursor plasma spraying process was used to manufacture P2O5-Na2O-CaO-SiO2 bioactive glass-ceramic coatings (BGCCs), where sol and suspension were used as feedstocks for plasma spraying. The effect of precursor and spray parameters on the formation and crystallinity of BGCCs was systematically studied. The results indicated that coatings with higher crystallinity were obtained using the sol precursor, while nanostructured coatings predominantly consisting of amorphous phase were synthesized using the suspension precursor. For coatings manufactured from suspension, the fraction of the amorphous phase increased with the increase in plasma power and the decrease in liquid precursor feed rate. The coatings synthesized from the suspension plasma spray process also showed a good in vitro bioactivity, as suggested by the fast apatite formation when soaking into SBF.

  12. Deposition of Electrically Conductive Coatings on Castable Polyurethane Elastomers by the Flame Spraying Process

    NASA Astrophysics Data System (ADS)

    Ashrafizadeh, H.; McDonald, A.; Mertiny, P.

    2016-02-01

    Deposition of metallic coatings on elastomeric polymers is a challenging task due to the heat sensitivity and soft nature of these materials and the high temperatures in thermal spraying processes. In this study, a flame spraying process was employed to deposit conductive coatings of aluminum-12silicon on polyurethane elastomers. The effect of process parameters, i.e., stand-off distance and air added to the flame spray torch, on temperature distribution and corresponding effects on coating characteristics, including electrical resistivity, were investigated. An analytical model based on a Green's function approach was employed to determine the temperature distribution within the substrate. It was found that the coating porosity and electrical resistance decreased by increasing the pressure of the air injected into the flame spray torch during deposition. The latter also allowed for a reduction of the stand-off distance of the flame spray torch. Dynamic mechanical analysis was performed to investigate the effect of the increase in temperature within the substrate on its dynamic mechanical properties. It was found that the spraying process did not significantly change the storage modulus of the polyurethane substrate material.

  13. Flow characteristic of in-flight particles in supersonic plasma spraying process

    NASA Astrophysics Data System (ADS)

    Wei, Pei; Wei, Zhengying; Zhao, Guangxi; Du, Jun; Bai, Y.

    2015-10-01

    In this paper, a computational model based on supersonic plasma spraying (SAPS) is developed to describe the plasma jet coupled with the injection of carrier gas and particles for SAPS. Based on a high-efficiency supersonic spraying gun, the 3D computational model of spraying gun was built to study the features of plasma jet and its interactions with the sprayed particles. Further the velocity and temperature of in-flight particles were measured by Spray Watch 2i, the shape of in-flight particles was observed by scanning electron microscope. Numerical results were compared with the experimental measurements and a good agreement has been achieved. The flight process of particles in plasma jet consists of three stages: accelerated stage, constant speed stage and decelerated stage. Numerical and experimental indicates that the H2 volume fraction in mixture gas of Ar + H2 should keep in the range of 23-26 %, and the distance of 100 mm is the optimal spraying distance in Supersonic atmosphere plasma spraying. Particles were melted and broken into small child particles by plasma jet and the diameters of most child particles were less than 30 μm. In general, increasing the particles impacting velocity and surface temperature can decrease the coating porosity.

  14. Semi-automated structural characterisation of high velocity oxy fuel thermally sprayed WC-Co based coatings

    NASA Astrophysics Data System (ADS)

    Fay, M. W.; Han, Y.; McCartney, G.; Korpiola, K.; Brown, P. D.

    2008-08-01

    The application of an automated procedure for the rapid assessment of selected area electron diffraction patterns is described. Comparison with complementary EDX spectra has enabled the thermal decomposition reactions within high velocity oxy-fuel thermally sprayed WC-Co coatings to be investigated.

  15. Investigation of erosion-resistant chromium carbide coatings sprayed with the high pressure HVOF process

    SciTech Connect

    Irons, G.; Kratochvil, W.R.; Bullock, W.R.; Roy, A.

    1994-12-31

    Eight different chromium carbide materials were sprayed at various conditions with the high pressure HVOF process. The coatings were erosion tested with both high and low angle impingement of erodent. All of the materials, including a less-expensive blended powder, exhibited excellent erosion resistance compared to standard plasma sprayed coatings. Other evaluations included metallographic examinations, macro and microhardness tests, bond tests, X-ray diffraction and chemical analyses. Several important correlations were investigated, including the effects of powder size and heat treatment.

  16. Dry process dependency of dupic fuel cycle

    SciTech Connect

    Park, Kwangheon; Whang, Juho; Kim, Yun-goo; Kim, Heemoon

    1996-12-31

    During the Dry Process, volatile and semi-volatile elements are released from the fuel. The effects of these released radioactive nuclides on DUPIC fuel cycle are analyzed from the view-point of radiation hazard, decay beat, and hazard index. Radiation hazard of fresh and spent DUPIC fuel is sensitive to the method of Dry Process. Decay beat of the fuel is also affected. Hazard index turned out not to be dependent on Dry Process.

  17. The freezing process of continuously sprayed water droplets on the superhydrophobic silicone acrylate resin coating surface

    NASA Astrophysics Data System (ADS)

    Hu, Jianlin; Xu, Ke; Wu, Yao; Lan, Binhuan; Jiang, Xingliang; Shu, Lichun

    2014-10-01

    This study conducted experiments on freezing process of water droplets on glass slides covered with superhydrophobic coatings under the continuous water spray condition in the artificial climatic chamber which could simulate low temperature and high humidity environments. The freezing mechanism and freezing time of water droplets under the condition of continuous spray were observed by the microscope and were compared with those of the single static droplet. Then, differences of freezing process between continuously sprayed droplets and single static droplet were analyzed. Furthermore, the effects of static contact angle (CA), contact angle hysteresis (CAH) and roughness of the superhydrophobic coating surface on the freezing time of continuously sprayed droplets were explored. Results show that the freezing process of the continuously sprayed droplets on the superhydrophobic coating started with the homogeneous nucleation at gas-liquid interfaces. In addition, the temperature difference between the location near the solid-liquid interface and the location near the gas-liquid interface was the key factor that influenced the ice crystallization mechanism of water droplets. Moreover, with the larger CA, the smaller CAH and the greater roughness of the surface, droplets were more likely to roll down the surface and the freezing duration on the surface was delayed. Based on the findings, continuous water spray is suggested in the anti-icing superhydrophobic coatings research.

  18. Spray forming process for producing molds, dies and related tooling

    DOEpatents

    McHugh, Kevin M.; Key, James F.

    1998-01-01

    A method for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers.

  19. Characterization of Magnesium Silicide Processed with Thermal Spray for Thermoelectric Energy Harvesting

    NASA Astrophysics Data System (ADS)

    Nie, Chao

    Mg2Si has long been recognized as one of the promising thermoelectric materials; the fabrication methods are hot press, spark plasma sintering, high temperature sintering, etc. however, application of thermoelectric materials requires large scale manufacturing but traditional manufacturing process cannot reach this goal by its nature; thus we employed thermal spray technology to fabricate such thermoelectric material. In collaboration with Thermal Spray Center in Stony Brook University, we manufactured Mg 2Si coatings on titanium substrate by plasma thermal spray technology. Samples were further characterized in various methods: scanning electron microscopy (SEM) exhibits the micro structures of sprayed Mg2Si coatings; X-ray spectroscopy (XRD) analysis examined the content and various thermoelectric properties by electrical conductivity measurement, thermal conductivity measurement, Seebeck Effect measurement and Hall Effect measurement. The result showed that vacuum plasma thermal spray so far has better thermoelectric properties than atmospheric plasma spray and Mg2Si has potential to increase its thermoelectric properties if proper fabrication environment and post-fabrication processes are employed.

  20. Plasma spray processing of TiC-based coatings for sliding wear resistance

    NASA Astrophysics Data System (ADS)

    Mohanty, Mahesh

    achieved by spraying under vacuum plasma spray conditions. VPS coating microstructures of synthesized 40, 60 and 80 v/o TiC in Ti10Ni10Cr5Al and 80 v/o TiC in Fe30Cr alloy matrices exhibited fine and uniform distributions of spheroidal carbides. High volume fraction carbides were also obtained with no segregation effects. It was also shown that coatings produced from mechanically blended powders of 50, 70 and 90 vol. % TiC and commercially pure (C.P.) Ti, using low pressure plasma spray process (VPS), had densities >98% and were well bonded to steel, aluminum alloy or titanium alloy substrates. Reductions in jet oxygen contents by the use of an inert gas shroud enabled Ti and TiC-based coatings to be produced which were cleaner and denser than air plasma sprayed and comparable to vacuum plasma sprayed coatings. Direct oxygen concentration measurements in shrouded plasma jets made using an enthalpy probe and a gas analyzer also showed significant reductions in the entrainment of atmospheric oxygen. VPS and shrouded plasma spraying minimized carbide-matrix interface oxidation and improved coating wear resistance. The sliding wear resistance of synthesized coatings was very high and comparable with standard HVOF sprayed WC/Co and Crsb3Csb2/NiCr coatings. Shrouded plasma spray deposits of Crsb3Csb2/NiCr also performed much better than similar air plasma sprayed coatings, as result of reduced oxidation.

  1. Effect of spray process conditions on uniformity of carbon nanotube thin films.

    PubMed

    Du Choi, Soon; Kim, Duckjong; Kang, Yong-Pil; Jang, Dong Hwan

    2012-07-01

    Industrial use of carbon nanotube (CNT) films is increasing rapidly due to their good physical properties and high economic feasibility. Spray coating process is one of feasible approaches for large area CNT films. Uniform spray coating is an important issue in applications requiring large area conductive films. In the present work, we developed a numerical model for the prediction of CNT deposition thickness distribution in the spray process and validated the numerical work by using experimental data obtained in this study. We investigated the deposition thickness distributions according to various process parameters by using the numerical model. We found that the pitch of the nozzle path is a key parameter affecting the deposition thickness uniformity and that there is optimal pitch value for unfirom and productive coating. We also discussed future research direction for improved numerical simulation tool. Since the present numerical model is also applicable to simulation of spray process on curvy substrate, the numerical model could be an imporatnt step toward a powerful simulation tool for design and optimization of the nanomaterial spray process. PMID:22966559

  2. Spray forming process for producing molds, dies and related tooling

    DOEpatents

    McHugh, K.M.; Key, J.F.

    1998-02-17

    A method is disclosed for spray forming manufacturing of near-net-shape molds, dies and related toolings, wherein liquid material such as molten metal, metallic alloys, or polymers are atomized into fine droplets by a high temperature, high velocity gas and deposited onto a pattern. Quenching of the atomized droplets provides a heat sink, thereby allowing undercooled and partially solidified droplets to be formed in-flight. Composites can be formed by combining the atomized droplets with solid particles such as whiskers or fibers. 17 figs.

  3. The N.A.C.A. Apparatus for Studying the Formation and Combustion of Fuel Sprays and the Results from Preliminary Tests

    NASA Technical Reports Server (NTRS)

    Rothrock, A M

    1931-01-01

    Described here is an apparatus for studying the formation and combustion of fuel sprays under conditions closely simulating those in a high speed compression-ignition engine. The apparatus consists of a single-cylinder modified test engine, a fuel injection system so designed that a single charge of fuel can be injected into the combustion chamber, an electric driving motor, and a high-speed photographic apparatus. The cylinder head of the engine has a vertical disk form of combustion chamber whose sides are glass windows. When the fuel is injected into the combustion chamber, motion pictures at the rate of 2000 per second are taken of the spray formation by means of spark discharges. When combustion takes place, the light of combustion is recorded on the same photographic film as the spray photographs. Included here are the results of some tests to determine the effect of air temperature, air flow, and nozzle design on the spray formation. The results show that the compression temperature has little effect on the penetration of the fuel spray, but does not affect the dispersion, that air velocities of about 300 feet per second are necessary to destroy the core of the spray, and that the effect of air flow on the spray is controlled to a certain extent by the design of the injection nozzle. The results on the combustion of the spray show that when ignition does not take place until after spray cut-off, the ignition may start almost simultaneously throughout the combustion chamber or at different points throughout the chamber. When ignition takes place before spray cut-off, the combustion starts around the edge of the spray and then spreads throughout the chamber.

  4. Processing Conditions Affecting Grain Size and Mechanical Properties in Nanocomposites Produced via Cold Spray

    NASA Astrophysics Data System (ADS)

    Cavaliere, P.; Perrone, A.; Silvello, A.

    2014-10-01

    Cold spray is a coating technology based on aerodynamics and high-speed impact dynamics. In this process, spray particles (usually 1-50 μm in diameter) are accelerated to a high velocity (typically 300-1200 m/s) by a high-speed gas (pre-heated air, nitrogen, or helium) flow that is generated through a convergent-divergent de Laval-type nozzle. A coating is formed through the intensive plastic deformation of particles impacting on a substrate at a temperature below the melting point of the spray material. In the present paper the main processing parameters affecting the microstructural and mechanical behavior of metal-metal cold spray deposits are described. The effect of process parameters on grain refinement and mechanical properties were analyzed for composite particles of Al-Al2O3, Ni-BN, Cu-Al2O3, and Co-SiC. The properties of the formed nanocomposites were compared with those of the parent materials sprayed under the same conditions. The process conditions, leading to a strong grain refinement with an acceptable level of the deposit mechanical properties such as porosity and adhesion strength, are discussed.

  5. NOx formation from the combustion of monodisperse n-heptane sprays doped with fuel-nitrogen additives

    NASA Technical Reports Server (NTRS)

    Sarv, Hamid; Cernansky, Nicholas P.

    1989-01-01

    A series of experiments with simulated synthetic fuels were conducted in order to investigate the effect of droplet size on the conversion of fuel-nitrogen to NOx. Pyridine and pyrrole were added to n-heptane as nitrogen-containing additives and burned as monodisperse fuel droplets under various operating conditions in a spray combustion facility. The experimental results indicate that under stoichiometric and fuel-rich conditions, reducing the droplet size increases the efficiency of fuel-N conversion to NOx. This observation is associated with improved oxidation of the pyrolysis fragments of the additive by better oxygen penetration through the droplet flame zone. The dominant reactions by which fuel-N is transformed to NOx were also considered analytically by a premixed laminar flame code. The calculations are compared to the small droplet size results.

  6. Microstructural Development and Deposition Behavior of Titanium Powder Particles in Warm Spraying Process: From Single Splat to Coating

    NASA Astrophysics Data System (ADS)

    Kim, Keehyun; Kuroda, Seiji; Watanabe, Makoto

    2010-12-01

    Warm spraying has been developed by NIMS, in which powder particles are accelerated and simultaneously heated, and deposited onto a suitable substrate in thermally softened solid state. In this study, commercially available titanium powder was sprayed onto steel substrate by the spraying process. Microstructural developments and deposition behaviors from a deposited single particle to a thick coating layer were observed by high resolution electron microscopes. A single titanium particle sprayed onto the substrate was severely deformed and grain-refined mainly along the interfacial boundary of particle/substrate by the impact of the sprayed particle. A successive impact by another particle further deformed the previously deposited particle and induced additional grain refinement of the remaining part. In a thick coating layer, the severe deformation and grain refinement were also observed. The results have demonstrated the complex deposition behavior of sprayed particles in the warm spraying using thermally softened metallic powder particles.

  7. Numerical modeling of in-flight characteristics of inconel 625 particles during high-velocity oxy-fuel thermal spraying

    NASA Astrophysics Data System (ADS)

    Gu, S.; McCartney, D. G.; Eastwick, C. N.; Simmons, K.

    2004-06-01

    A computational fluid dynamics (CFD) model is developed to predict particle dynamic behavior in a high-velocity oxyfuel (HVOF) thermal spray gun in which premixed oxygen and propylene are burnt in a combustion chamber linked to a long, parallel-sided nozzle. The particle transport equations are solved in a Lagrangian manner and coupled with the two-dimensional, axisymmetric, steady state, chemically reacting, turbulent gas flow. Within the particle transport model, the total flow of the particle phase is modeled by tracking a small number of particles through the continuum gas flow, and each of these individual particles is tracked independently through the continuous phase. Three different combustion chamber designs were modeled, and the in-flight particle characteristics of Inconel were 625 studied. Results are presented to show the effect of process parameters, such as particle injection speed and location, total gas flow rate, fuel-to-oxygen gas ratio, and particle size on the particle dynamic behavior for a parallel-sided, 12 mm long combustion chamber. The results indicate that the momentum and heat transfer to particles are primarily influenced by total gas flow. The 12 mm long chamber can achieve an optimum performance for Inconel 625 powder particles ranging in diameter from 20 to 40 µm. At a particular spraying distance, an optimal size of particles is observed with respect to particle temperature. The effect of different combustion chamber dimensions on particle dynamics was also investigated. The results obtained for both a 22 mm long chamber and also one with a conical, converging design are compared with the baseline data for the 12 mm chamber.

  8. Screening Design of Supersonic Air Fuel Processing for Hard Metal Coatings

    NASA Astrophysics Data System (ADS)

    Lyphout, C.; Björklund, S.; Karlsson, M.; Runte, M.; Reisel, G.; Boccaccio, P.

    2014-12-01

    Replacement of electrolytic hard chromium method by thermal spray technology has shown a growing interest in the past decades, mainly pioneered by depositing WC-based material by conventional HVOF processes. Lower thermal energy and higher kinetic energy of sprayed particles achieved by newly developed Supersonic Air Fuel system, so-called HVAF-M3, significantly reduces decarburization, and increases wear and corrosion resistance properties, making HVAF-sprayed coatings attractive both economically and environmentally. In the present work, full factorial designs of experiments have been extensively utilized to establish relationships between hardware configurations, process and engineering variables, and coatings properties. The relevance of those process factors is emphasized and their significance is discussed in the optimization of coatings for improved abrasion wear and corrosion performances.

  9. Process of high temperature synthesis in producing composite carbide powders for thermally sprayed coatings

    NASA Astrophysics Data System (ADS)

    Szymański, K.; Formanek, B.

    2011-05-01

    The paper presents the characterization of powders containing hard phases of chromium carbides in a NiCr matrix, intended for thermal spraying coatings. The synthesized composite powder containing hard phases and plastic matrix, produced in high-temperature synthesis with chosen powder metallurgy processes has been presented. Commercial materials, such as NiCr- CrxCy, are fabricated by means of agglomeration and sintering method. Processes of high temperature synthesis of Cr3C2, Cr7C3, Cr23C6 carbides combined with NiCr powder mechanical alloying are presented in the article. Parameters of the carbides synthesis were determined in the reactive -protective atmosphere. In the rotation- vibration mill, processes were conducted using grinding and appropriate mechanical alloying at variable amplitude. The standard and synthesized powders were thermally sprayed by HVOF method in Jet Kote II and Diamond Jet system. The structure and phase composition of the powders and coatings were determined by: light and scanning microscopy, X-ray phase analysis (RTG) and energy dispersive X-ray analysis (EDX). The structure and wear properties of HVOF sprayed coatings containing chromium carbides has been presented. The thermally sprayed coatings are characterized of wear resistance in abrasion and erosion tests. The sprayed coatings characterized high resistance in wear conditions.

  10. Effect of spray drying processing parameters on the insecticidal activity of two encapsulated formulations of baculovirus

    Technology Transfer Automated Retrieval System (TEKTRAN)

    The aim of this work was to evaluate the effect of spray dryer processing parameters on the process yield and insecticidal activity of baculovirus to support the development of this beneficial group of microbes as biopesticides. For each of two baculoviruses [granulovirus (GV) from Pieris rapae (L....

  11. Mechanical property and wear performance dependence on processing condition for cold-sprayed WC-(nanoWC-Co)

    NASA Astrophysics Data System (ADS)

    Yang, Guan-Jun; Gao, Pei-Hu; Li, Cheng-Xin; Li, Chang-Jiu

    2015-03-01

    WC-(nanoWC-Co) with micro-WC reinforcing particles in nanoWC-Co cermet matrix was cold-sprayed by using WC-Co with bimodal sized WC particles (with both micro-sized WC particles and nano-sized WC particles). The effect of spray powder property and post-spray treatment on the mechanical properties and wear performance of cold-sprayed WC-(nanoWC-Co) coating were examined in comparison to the conventional high-velocity oxy-fuel (HVOF)-sprayed WC-Co coating. Results showed that both hardness and toughness were influenced by the spray powder properties and the post-spray heat treatment. Compared to the HVOF-sprayed WC-Co coating with micro-sized WC particles, WC-(nanoWC-Co) exhibited much higher hardness and toughness and thereby much higher wear resistance. The further toughening of WC-(nanoWC-Co) by post-spray heat treatment significantly doubled the wear performance. The excellent wear resistance of WC-(nanoWC-Co) is attributed to the simultaneous strengthening and toughening effects resulting from the microstructure design of bimodal WC particle size distribution composed of both micro-sized and nano-sized WC particles.

  12. Connecting marine productivity to sea-spray via nanoscale biological processes: Phytoplankton Dance or Death Disco?

    PubMed

    O'Dowd, Colin; Ceburnis, Darius; Ovadnevaite, Jurgita; Bialek, Jakub; Stengel, Dagmar B; Zacharias, Merry; Nitschke, Udo; Connan, Solene; Rinaldi, Matteo; Fuzzi, Sandro; Decesari, Stefano; Facchini, Maria Cristina; Marullo, Salvatore; Santoleri, Rosalia; Dell'Anno, Antonio; Corinaldesi, Cinzia; Tangherlini, Michael; Danovaro, Roberto

    2015-01-01

    Bursting bubbles at the ocean-surface produce airborne salt-water spray-droplets, in turn, forming climate-cooling marine haze and cloud layers. The reflectance and ultimate cooling effect of these layers is determined by the spray's water-uptake properties that are modified through entrainment of ocean-surface organic matter (OM) into the airborne droplets. We present new results illustrating a clear dependence of OM mass-fraction enrichment in sea spray (OMss) on both phytoplankton-biomass, determined from Chlorophyll-a (Chl-a) and Net Primary Productivity (NPP). The correlation coefficient for OMss as a function of Chl-a increased form 0.67 on a daily timescale to 0.85 on a monthly timescale. An even stronger correlation was found as a function of NPP, increasing to 0.93 on a monthly timescale. We suggest the observed dependence is through the demise of the bloom, driven by nanoscale biological processes (such as viral infections), releasing large quantities of transferable OM comprising cell debris, exudates and other colloidal materials. This OM, through aggregation processes, leads to enrichment in sea-spray, thus demonstrating an important coupling between biologically-driven plankton bloom termination, marine productivity and sea-spray modification with potentially significant climate impacts. PMID:26464099

  13. Styrene emissions from the spray-up and vacuum injection processes--a quantitative comparison.

    PubMed

    Lindgren, Maria; Skrifvars, Mikael; Sandlund, Erik; Pettersson, Joakim

    2002-01-01

    Styrene emissions were studied during manufacturing of two identical glass-fiber reinforced plastic boats by two different manufacturing methods. The manufacturing methods were spray-up, which is an open method, and vacuum injection, which is a closed method. Changing the manufacturing process from an open method to a closed method decreased the styrene evaporation dramatically in this particular case. By using vacuum injection, the styrene emission during the laminate application was reduced by 98% compared with the styrene emission during laminate application by spray-up. Gel coat application by spraying will remain a major source for styrene emissions. The greatest environmental benefit is achieved with closed manufacturing methods when products without gel coat are made. The whole manufacturing process can then be performed in a closed system virtually free from emissions. PMID:11975655

  14. Evaluation of a Heat Flux Sensor for Spray Cooling for the Die Casting Processes

    SciTech Connect

    Sabau, Adrian S; Wu, Zhuoxi

    2007-02-01

    During the die casting process, lubricants are sprayed in order to cool the dies and facilitate the ejection of the casting. In this paper, a new technique for measuring the heat flux during lubricant application is evaluated. Data from experiments conducted using water spray are first presented. Water spray experiments were conducted for different initial plate temperatures. Measurements were conducted for the application of two different lubricants, of dilution ratios of 1/15 and 1/50 of lubricant in water. The measurement uncertainties were documented. The results show that the surface temperature decreases initially very fast. Numerical simulation results confirmed that the abrupt temperature drop is not an artifact but illustrates the thermal shock experienced by the dies during the initial stages of lubricant application. The lubricant experiments show that the sensor can be successfully used for testing die lubricants with typical dilution ratios encountered in the die casting process.

  15. Synthesis of nanostructured WC-12 pct Co coating using mechanical milling and high velocity oxygen fuel thermal spraying

    SciTech Connect

    He, J. Ice, M.; Dallek, S.; Lavernia, E.J.

    2000-02-01

    A nanostructured WC-12 pct Co coating was synthesized using mechanical milling and high velocity oxygen fuel (HVOF) thermal spraying. The variation of powder characteristics with milling time and the performance of the coatings were investigated using scanning electron microscope (SEM), X-ray, transmission electron microscope (TEM), thermogravimetric analyzer (TGA), and microhardness measurements. There is no evidence that indicates the presence of an amorphous phase in the sintered WC-12 pct Co powder, and the binder phase in this powder is still crystalline Co. Mechanical milling of up to 20 hours did not lead to the formation of an amorphous phase in the sintered WC-12 pct Co powder. During the initial stages of the milling, the brittle carbide particles were first fractured into fragments and then embedded into the binder phase. This process gradually formed polycrystal nanocomposite powders of the Co binder phase and W carbide particles. The conventional cold welding and fracturing processes primarily occurred among the Co binder powders and polycrystal composite powders. The nanostructured WC-12 pct Co coatings, synthesized in the present study, consist of an amorphous matrix and carbides with an average particle diameter of 35 nm. The coating possesses an average microhardness of 1135 HV and higher resistance to indentation fracture than that of its conventional counterpart.

  16. Fuel quality processing study, volume 1

    NASA Astrophysics Data System (ADS)

    Ohara, J. B.; Bela, A.; Jentz, N. E.; Syverson, H. T.; Klumpe, H. W.; Kessler, R. E.; Kotzot, H. T.; Loran, B. L.

    1981-04-01

    A fuel quality processing study to provide a data base for an intelligent tradeoff between advanced turbine technology and liquid fuel quality, and also, to guide the development of specifications of future synthetic fuels anticipated for use in the time period 1985 to 2000 is given. Four technical performance tests are discussed: on-site pretreating, existing refineries to upgrade fuels, new refineries to upgrade fuels, and data evaluation. The base case refinery is a modern Midwest refinery processing 200,000 BPD of a 60/40 domestic/import petroleum crude mix. The synthetic crudes used for upgrading to marketable products and turbine fuel are shale oil and coal liquids. Of these syncrudes, 50,000 BPD are processed in the existing petroleum refinery, requiring additional process units and reducing petroleum feed, and in a new refinery designed for processing each syncrude to produce gasoline, distillate fuels, resid fuels, and turbine fuel, JPGs and coke. An extensive collection of synfuel properties and upgrading data was prepared for the application of a linear program model to investigate the most economical production slate meeting petroleum product specifications and turbine fuels of various quality grades. Technical and economic projections were developed for 36 scenarios, based on 4 different crude feeds to either modified existing or new refineries operated in 2 different modes to produce 7 differing grades of turbine fuels. A required product selling price of turbine fuel for each processing route was calculated. Procedures and projected economics were developed for on-site treatment of turbine fuel to meet limitations of impurities and emission of pollutants.

  17. Fuel quality processing study, volume 1

    NASA Technical Reports Server (NTRS)

    Ohara, J. B.; Bela, A.; Jentz, N. E.; Syverson, H. T.; Klumpe, H. W.; Kessler, R. E.; Kotzot, H. T.; Loran, B. L.

    1981-01-01

    A fuel quality processing study to provide a data base for an intelligent tradeoff between advanced turbine technology and liquid fuel quality, and also, to guide the development of specifications of future synthetic fuels anticipated for use in the time period 1985 to 2000 is given. Four technical performance tests are discussed: on-site pretreating, existing refineries to upgrade fuels, new refineries to upgrade fuels, and data evaluation. The base case refinery is a modern Midwest refinery processing 200,000 BPD of a 60/40 domestic/import petroleum crude mix. The synthetic crudes used for upgrading to marketable products and turbine fuel are shale oil and coal liquids. Of these syncrudes, 50,000 BPD are processed in the existing petroleum refinery, requiring additional process units and reducing petroleum feed, and in a new refinery designed for processing each syncrude to produce gasoline, distillate fuels, resid fuels, and turbine fuel, JPGs and coke. An extensive collection of synfuel properties and upgrading data was prepared for the application of a linear program model to investigate the most economical production slate meeting petroleum product specifications and turbine fuels of various quality grades. Technical and economic projections were developed for 36 scenarios, based on 4 different crude feeds to either modified existing or new refineries operated in 2 different modes to produce 7 differing grades of turbine fuels. A required product selling price of turbine fuel for each processing route was calculated. Procedures and projected economics were developed for on-site treatment of turbine fuel to meet limitations of impurities and emission of pollutants.

  18. Liquid fuel spray processes in high-pressure gas flow

    NASA Technical Reports Server (NTRS)

    Ingebo, R. D.

    1986-01-01

    Atomization of single liquid jets injected downstream in high pressure and high velocity airflow was investigated to determine the effect of airstream pressure on mean drop size as measured with a scanning radiometer. For aerodynamic - wave breakup of liquid jets, the ratio of orifice diameter D sub o to measured mean drop diameter D sub m which is assumed equal to D sub 32 or Sauter mean diameter, was correlated with the product of the Weber and Reynolds numbers WeRe and the dimensionless group G1/square root of c, where G is the gravitational acceleration, 1 the mean free molecular path, and square root of C the root mean square velocity, as follows; D sub o/D sub 32 = 1.2 (WeRe) to the 0.4 (G1/square root of c) to the 0.15 for values of WeRe 1 million and an airstream pressure range of 0.10 to 2.10 MPa.

  19. Liquid fuel spray processes in high-pressure gas flow

    NASA Technical Reports Server (NTRS)

    Ingebo, R. D.

    1985-01-01

    Atomization of single liquid jets injected downstream in high pressure and high velocity airflow was investigated to determine the effect of airstream pressure on mean drop size as measured with a scanning radiometer. For aerodynamic - wave breakup of liquid jets, the ratio of orifice diameter D sub o to measured mean drop diameter D sub m which is assumed equal to D sub 32 or Sauter mean diameter, was correlated with the product of the Weber and Reynolds numbers WeRe and the dimensionless group G1/square root of c, where G is the gravitational acceleration, 1 the mean free molecular path, and square root of C the root mean square velocity, as follows; D sub o/D sub 32 = 1.2 (WeRe) to the 0.4 (G1/square root of c) to the 0.15 for values of WeRe 1 million and an airstream pressure range of 0.10 to 2.10 MPa.

  20. Optimization and scale-up of a fluid bed tangential spray rotogranulation process.

    PubMed

    Bouffard, J; Dumont, H; Bertrand, F; Legros, R

    2007-04-20

    The production of pellets in the pharmaceutical industry generally involves multi-step processing: (1) mixing, (2) wet granulation, (3) spheronization and (4) drying. While extrusion-spheronization processes have been popular because of their simplicity, fluid-bed rotogranulation (FBRG) is now being considered as an alternative, since it offers the advantages of combining the different steps into one processing unit, thus reducing processing time and material handling. This work aimed at the development of a FBRG process for the production of pellets in a 4.5-l Glatt GCPG1 tangential spray rotoprocessor and its optimization using factorial design. The factors considered were: (1) rotor disc velocity, (2) gap air pressure, (3) air flow rate, (4) binder spray rate and (5) atomization pressure. The pellets were characterized for their physical properties by measuring size distribution, roundness and flow properties. The results indicated that: pellet mean particle size is negatively affected by air flow rate and rotor plate speed, while binder spray rate has a positive effect on size; pellet flow properties are enhanced by operating with increased air flow rate and worsened with increased binder spray rate. Multiple regression analysis enabled the identification of an optimal operating window for production of acceptable pellets. Scale-up of these operating conditions was tested in a 30-l Glatt GPCG15 FBRG. PMID:17166677

  1. Production of dissolvable microneedles using an atomised spray process: effect of microneedle composition on skin penetration.

    PubMed

    McGrath, Marie G; Vucen, Sonja; Vrdoljak, Anto; Kelly, Adam; O'Mahony, Conor; Crean, Abina M; Moore, Anne

    2014-02-01

    Dissolvable microneedles offer an attractive delivery system for transdermal drug and vaccine delivery. They are most commonly formed by filling a microneedle mold with liquid formulation using vacuum or centrifugation to overcome the constraints of surface tension and solution viscosity. Here, we demonstrate a novel microneedle fabrication method employing an atomised spray technique that minimises the effects of the liquid surface tension and viscosity when filling molds. This spray method was successfully used to fabricate dissolvable microneedles (DMN) from a wide range of sugars (trehalose, fructose and raffinose) and polymeric materials (polyvinyl alcohol, polyvinylpyrrolidone, carboxymethylcellulose, hydroxypropylmethylcellulose and sodium alginate). Fabrication by spraying produced microneedles with amorphous content using single sugar compositions. These microneedles displayed sharp tips and had complete fidelity to the master silicon template. Using a method to quantify the consistency of DMN penetration into different skin layers, we demonstrate that the material of construction significantly influenced the extent of skin penetration. We demonstrate that this spraying method can be adapted to produce novel laminate-layered as well as horizontally-layered DMN arrays. To our knowledge, this is the first report documenting the use of an atomising spray, at ambient, mild processing conditions, to create dissolvable microneedle arrays that can possess novel, laminate layering. PMID:23727511

  2. Fabrication of flexible ultraviolet photodetectors using an all-spray-coating process

    NASA Astrophysics Data System (ADS)

    Han, Junebeom; Lee, Jonghun; Ju, Sanghyun

    2016-04-01

    We report on a flexible ultraviolet (UV) photodetector fabricated using an all-spray-coating process. Two spray coating units were utilized to deposit semiconducting tin oxide nanowires as an active channel layer and metallic silver nanowires as an electrode layer. The device was mounted on the back of a human hand, and the UV intensities in sunlight were monitored over time. The fabricated flexible UV photodetector showed highly sensitive, stable, and reproducible detection properties. The main advantage of the proposed fabrication method is the extension of the integration environment by allowing direct application on various substrates, such as clothes and human skin, with varying device size and shape.

  3. The Transient to Steady-State Transition during the Spray-Rolling Process

    SciTech Connect

    Yaojun Lin; Kevin M. McHugh; Yizhang Zhou; Enrique J. Lavernia

    2004-11-01

    From the geometrical standpoint, this article presents a qualitative theoretical analysis and prediction of the transient to steady-state transition during the spray-rolling process, a novel manufacturing technique for aluminum strips. The analytical results indicate that, when the deposited materials at the specific points on one roll surface overlap their counter-parts on the other roll surface, spray rolling transits from the transient state to the steady state. The specific points are the limiting depositon position of the atomized droplets on the roll surface initially.

  4. Effect of Nozzle Design on Fuel Spray and Flame Formation in a High-Speed Compression-Ignition Engine

    NASA Technical Reports Server (NTRS)

    Rothrock, A M; Waldron, C D

    1937-01-01

    Fuel was injected from different type of injection nozzles into the combustion chamber of the NACA combustion apparatus, operated as a compression-ignition engine. High speed motion pictures were taken of the fuel sprays and combustion. Single-orifice nozzles of 0.008, 0.020, and 0.040 inch diameter, and multiorifice nozzles having 2, 6, and 16 orifices were tested. Nozzles having impinging jets and slit orifices were also included. The photographs indicate that the rate of vapor diffusion from the spray is comparatively slow and that this slow rate of diffusion for combustion chambers with little or no air flow prevents the compression-ignition engine from giving the high performance inherent in the high compression ratios. The sprays from the multiorifice nozzles destroyed the air movement to a greater extent than did those from single orifice nozzles. It is concluded that high performance cannot be realized until the methods of distributing the fuel are improved by means of the injection-nozzle design, air flow, or both.

  5. Original use of a direct injection high efficiency nebulizer for the standardization of liquid fuels spray flames

    NASA Astrophysics Data System (ADS)

    Lemaire, R.; Maugendre, M.; Schuller, T.; Therssen, E.; Yon, J.

    2009-10-01

    It is of practical importance to lead laboratory-scale experiments allowing a better understanding of the impact of commercial fuels composition on the formation of combustion residues such as soot particles. To this end, a hybrid burner has been designed recently to burn high-speed sprays of small liquid fuel droplets. It consists of a Holthuis (previously McKenna) burner originally equipped with a direct injection high efficiency nebulizer for the atomization of liquid hydrocarbons. A detailed description of this original setup is given in this paper. A priori estimations of atomization and evaporation times and length scales are then proposed and compared with experimental data. Droplet-size distribution measurements obtained in nonreacting conditions using a Malvern Spraytec particle sizer are presented and compared with values estimated by calculation. Cold sprays contours and liquid jet lengths in flames determined by Mie scattering at 532 and 1064 nm, respectively, are also presented. The results discussed in this work indicate that the hydrodynamic characteristics of the sprays generated with our system are relatively independent of the physical properties of fuels leading to comparable flames with identical liquid jet lengths, dimensions, and global structure. This feature facilitates an accurate comparison of flames burning various liquid hydrocarbons, which is of interest to emphasize differences in pollutants emissions and to highlight chemical effects for soot formation analysis.

  6. The effect of processing parameters on plasma sprayed beryllium for fusion applications

    SciTech Connect

    Castro, R.G.; Stanek, P.W.; Jacobson, L.A.; Cowgill, D.F.; Snead, L.L.

    1993-10-01

    Plasma spraying is being investigated as a potential coating technique for applying thin (0.1--5mm) layers of beryllium on plasma facing surfaces of blanket modules in ITER and also as an in-situ repair technique for repairing eroded beryllium surfaces in high heat flux divertor regions. High density spray deposits (>98% of theoretical density) of beryllium will be required in order to maximize the thermal conductivity of the beryllium coatings. A preliminary investigation was done to determine the effect of various processing parameters (particle size, particle morphology, secondary gas additions and reduced chamber pressure) on the as-deposited density of beryllium. The deposits were made using spherical beryllium feedstock powder which was produced by centrifugal atomization at Los Alamos National Laboratory (LANL). Improvements in the as-deposited densities and deposit efficiencies of the beryllium spray deposits will be discussed along with the corresponding thermal conductivity and outgassing behavior of these deposits.

  7. Study of thermite mixtures consolidated by cold gas dynamic spray process

    NASA Astrophysics Data System (ADS)

    Bacciochini, Antoine; Maines, Geoffrey; Poupart, Christian; Radulescu, Matei; Jodoin, Bertrand; Lee, Julian

    2013-06-01

    The present study focused on the cold gas dynamic spray process for manufacturing finely structured energetic materials with high reactivity, vanishing porosity, as well as structural integrity and arbitrary shape. The experiments have focused the reaction between the aluminum and metal oxides, such as Al-CuO and Al-MoO3 systems. To increase the reactivity, an initial mechanical activation was achieved through interrupted ball milling. The consolidation of the materials used the supersonic cold gas spray technique, where the particles are accelerated to high speeds and consolidated via plastic deformation upon impact, forming activated nano-composites in arbitrary shapes with close to zero porosity. This technique permits to retain the feedstock powder micro-structure and prevents any reactions during the consolidation phase. Reactivity of mixtures has been investigated through flame propagation analysis on cold sprayed samples and compacted powder mixture. Deflagration tests showed the influence of porosity on the reactivity.

  8. Study of thermite mixture consolidated by the cold gas dynamic spray process

    NASA Astrophysics Data System (ADS)

    Bacciochini, A.; Maines, G.; Poupart, C.; Akbarnejad, H.; Radulescu, M.; Jodoin, B.; Zhang, F.; Lee, J. J.

    2014-05-01

    The present study focused on the cold gas dynamic spray process for manufacturing porosity free, finely structured energetic materials with high reactivity and structural integrity. The experiments have focused the reaction between the aluminium and metal oxide, such as Al-CuO system. The consolidation of the materials used the cold gas dynamic spray technique, where the particles are accelerated to high speeds and consolidated via plastic deformation upon impact. Reactive composites are formed in arbitrary shapes with close to zero porosity and without any reactions during the consolidation phase. Reactivity of mixtures has been investigated through flame propagation analysis on cold sprayed samples and compacted powder mixture. Deflagration tests showed the influence of porosity on the reactivity.

  9. The evaporation of dense sprays as a mixing process

    NASA Astrophysics Data System (ADS)

    de Rivas, Alois; Villermaux, Emmanuel

    2014-11-01

    A dense spray of micron-sized droplets (water or ethanol) is formed in air by a pneumatic atomizer in a closed chamber, and is then conveyed through a nozzle in ambient air, forming a plume whose extension depends on the relative humidity of the diluting medium. We focus on the dry ambient medium, and large plume Reynolds number limit. Standard shear instabilities develop at the plume edge, forming the stretched lamellar structures familiar with passive scalars, except that these vanish in a finite time, because individual droplets evaporate at their border. Experiments also demonstrate that the lifetime of an individual droplet embedded in a lamellae is much larger than expected from the usual d-square law for an isolated droplet. By analogy with the way mixing times are understood from the convection-diffusion equation for passive scalars, we show that the lifetime of a lamellae stretched at a rate γ is tv =1/γ ln (1/+ ϕ ϕ ) where ϕ is a parameter which incorporates the thermodynamic and diffusional properties of the vapor in the diluting phase. The droplets field thus behaves as a -non conserved- passive scalar.

  10. SUMMARY REPORT: SULFUR OXIDES CONTROL TECHNOLOGY SERIES: FLUE GAS DESULFURIZATION - SPRAY DRYER PROCESS

    EPA Science Inventory

    Described spray dryer flue gas desulfurization (FGD), which is a throwaway process in which sulfur dioxide (SO2) is removed from flue gas by an atomized lime slurry [Ca(OH)2]. he hot flue gas dries the droplets to form a dry waste product, while the absorbent reacts with sulfur d...

  11. DESIGN AND APPLICATION OF A SPRAY RINSING SYSTEM FOR RECYCLE OF PROCESS WATERS

    EPA Science Inventory

    This research demonstrates the effectiveness of an innovative application of a multiple spray rinsing system in an electroplating process. A joint study was conducted by NCR and the U.S. EPA at NCR's printed circuit board facility in Cambridge, Ohio. Engineering evaluations were ...

  12. Dry Processing of Used Nuclear Fuel

    SciTech Connect

    K. M. Goff; M. F. Simpson

    2009-09-01

    Dry (non-aqueous) separations technologies have been used for treatment of used nuclear fuel since the 1960s, and they are still being developed and demonstrated in many countries. Dry technologies offer potential advantages compared to traditional aqueous separations including: compactness, resistance to radiation effects, criticality control benefits, compatibility with advanced fuel types, and ability to produce low purity products. Within the Department of Energy’s Advanced Fuel Cycle Initiative, an electrochemical process employing molten salts is being developed for recycle of fast reactor fuel and treatment of light water reactor oxide fuel to produce a feed for fast reactors. Much of the development of this technology is based on treatment of used Experimental Breeder Reactor II (EBR-II) fuel, which is metallic. Electrochemical treatment of the EBR-II fuel has been ongoing in the Fuel Conditioning Facility, located at the Materials and Fuel Complex of Idaho National Laboratory since 1996. More than 3.8 metric tons of heavy metal of metallic fast reactor fuel have been treated using this technology. This paper will summarize the status of electrochemical development and demonstration activities with used nuclear fuel, including high-level waste work. A historic perspective on the background of dry processing will also be provided.

  13. Process engineering variables in the spray washing of meat and produce.

    PubMed

    Pordesimo, L O; Wilkerson, E G; Womac, A R; Cutter, C N

    2002-01-01

    Recently, much attention has been focused on the safety of fruits and vegetables. Washing is a fundamental operation in the processing of produce. Aqueous spray energy can be, and often is, used to remove mineral, chemical, or biological contaminants from produce. A few advantages of spray washing over washing by dipping, soaking, or gravity rinse are increased energy directed to contaminants, reduced volume of water use and wastewater generation, and reduced water uptake by produce. The kinetic energy of the spray droplets produces the cleaning action. Increased spray pressure increases energy. If the energy is too great, produce may be physically damaged. If the energy is too little, the surface may not be cleaned. Indeed, studies on meat have shown that water pressures ranging from 1,379 to 2,070 kPa (200 to 300 psi) are effective in reducing microbial contamination, and a water flow rate of 7.5 liters/min is recommended. Water temperature >70 degrees C has been found to reduce bacterial counts in carcass tissue by 2 to 3 log CFU/cm2. These levels are likely too high for the fragile produce; hence, the main function of spray washing in produce applications will probably shift to being a delivery system for antimicrobial agents. Several other equipment, process, and product variables are relevant to the optimization of such a system. Qualities of the spray, such as droplet spectrum, droplet velocity, angle of droplet impingement, number and orientation of nozzles, spray rate, and resident time of the produce in the sprayer, also can be manipulated to adjust the amount of energy directed to the surface. There is a need to scientifically investigate the effects of these processes and equipment parameters on the removal of microbiological contaminants on meats and produce. Such empirical investigations guided by the results from fundamental studies about produce surface characteristics and the mechanism of bacterial attachment to plant tissue surfaces would allow

  14. Role of process conditions on the microstructure, stoichiometry and functional performance of atmospheric plasma sprayed La(Sr)MnO3 coatings

    NASA Astrophysics Data System (ADS)

    Han, Su Jung; Chen, Yikai; Sampath, Sanjay

    2014-08-01

    Strontium doped lanthanum manganite (LSM) perovskite coatings were produced via atmospheric plasma spray technique to examine their applicability as electrically conductive coatings to protect chromium-poisoning of cathode side metallic interconnects in solid oxide fuel cells. Various plasma spray process conditions were manipulated including plasma power, total gas flow and content of H2 in the plasma gas in order to understand their effects on coating properties as well as efficacy as a protectant against Cr-poisoning. In-flight temperatures and velocities of spray particles were monitored for the various plasma spray conditions enabling assessment of thermal and kinetic energies of LSM particles. As anticipated, coating density improves with increasing thermal and/or kinetic energies of the LSM particles. However, the LSM particles also experienced significant phase decomposition at higher thermal exposure and longer residence time conditions. Due to preferential loss of oxygen and manganese, La2O3 phase is also formed under certain processing regimes. The resultant mixed-phase coating is ineffective both from electrical transport and as a protective coating for the metallic interconnect. Concomitantly, coatings with limited decomposition show excellent conductivity and protection characteristics demonstrating the need for mechanism driven process optimization for these functional oxide coatings.

  15. Computational fluid dynamics analysis of a wire-feed, high-velocity oxygen-fuel (HVOF) thermal spray torch

    SciTech Connect

    Lopez, A.R.; Hassan, B.; Oberkampf, W.L.; Neiser, R.A.; Roemer, T.J.

    1996-09-01

    The fluid and particle dynamics of a High-Velocity Oxygen-Fuel Thermal Spray torch are analyzed using computational and experimental techniques. Three-dimensional Computational Fluid Dynamics (CFD) results are presented for a curved aircap used for coating interior surfaces such as engine cylinder bores. The device analyzed is similar to the Metco Diamond Jet Rotating Wire (DJRW) torch. The feed gases are injected through an axisymmetric nozzle into the curved aircap. Premixed propylene and oxygen are introduced from an annulus in the nozzle, while cooling air is injected between the nozzle and the interior wall of the aircap. The combustion process is modeled using a single-step finite-rate chemistry model with a total of 9 gas species which includes dissociation of combustion products. A continually-fed steel wire passes through the center of the nozzle and melting occurs at a conical tip near the exit of the aircap. Wire melting is simulated computationally by injecting liquid steel particles into the flow field near the tip of the wire. Experimental particle velocity measurements during wire feed were also taken using a Laser Two-Focus (L2F) velocimeter system. Flow fields inside and outside the aircap are presented and particle velocity predictions are compared with experimental measurements outside of the aircap.

  16. Development of self-lubricating coatings via cold spray process: Feedstock formulation and deformation modeling

    NASA Astrophysics Data System (ADS)

    Aggarwal, Gaurav

    Because of their low density, high specific strength and high stiffness, titanium alloys are one of the prime candidates for structural application often requiring specific tribological properties. However, their relatively high friction coefficients and low wear resistance are limiting their application over a wider temperature range. Various coatings deposited with technologies like high velocity oxy flame (HVOF), detonation gun (DGun), electron beam physical vapor deposition (EB-PVD), etc., can improve wear performance and decrease corrosion damage. These technologies require high processing temperatures precluding the integration of thermally vulnerable lubricants. This research looks at a relatively new coating process called Cold Spray for self-lubricating coatings on Ti-6Al-4V alloys. Cold Spray can produce coatings without significant heating of the sprayed powder or substrate. The particles are in solid state as they hit the substrate, and the formation of coatings occurs mainly due to the kinetic energy of the particles. Therefore, the impact velocity plays an important role. Below a critical value, the particles can cause densification and abrasion of the substrate. The focus of this study is to design composite coatings for the cold spray process and determination of the critical velocity through finite element modeling. Different powders and feedstock formulation techniques are discussed in order to find an optimum formulation for self-lubricating coatings. A composite powder (Ni coated hBN) was found to be the best candidate for the feedstock. The deformation of composite particles upon impact on the substrate was modeled and compared to the experiments. A number of approaches involving different modeling platforms, particle-substrate geometries, and material models have been tried. This work presents the results of ANSYS (version 10.0) analysis using an axisymmetric model of the particle impact. Stress and strain distributions in the particle

  17. Analytical methods to characterize heterogeneous raw material for thermal spray process: cored wire Inconel 625

    NASA Astrophysics Data System (ADS)

    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.

  18. Effects of process variables on the powder yield of spray-dried trehalose on a laboratory spray-dryer.

    PubMed

    Maury, Michael; Murphy, Keith; Kumar, Sandeep; Shi, Lei; Lee, Geoffrey

    2005-04-01

    A systematic examination is presented of the effects of process variables on the powder yield of amorphous trehalose obtained from the Buchi Model 191 laboratory-scale mini spray dryer. By using a specially made, narrow cyclone the powder yield could be greatly improved at all process temperatures examined. Calculations of the separation efficiencies of the improved cyclone and the manufacturer's standard cyclone are given, which show that the former's higher tangential particle velocity at the radius of the exit duct is responsible for the improved performance. The powder yield increases with higher process temperatures, owing to improved droplet drying and reduced droplet/particle deposition on the walls of the drying chamber. A maximum in the powder yield is reached, however, after which it decreases sharply. This is caused by heating of the cyclone wall to >10 degrees C above the so-called 'sticky point' of the trehalose, causing increased particle deposits on the walls of the tower and cyclone. Increasing liquid feed flow rate or decreasing atomizing air flow rate too extensively were both detrimental to powder yield. The drying air flow rate should be as high as possible to ensure sufficient enthalpy throughput to dry the trehalose adequately to give a high powder yield. The enthalpy balance calculation for drying trehalose with the new cyclone was used successfully to interpret the results obtained. Some recommendations for optimizing powder yield of an amorphous material are given. PMID:15760738

  19. Characterization of sprays

    NASA Astrophysics Data System (ADS)

    Chigier, N.; Mao, C.-P.

    It is pointed out that most practical power generation and propulsion systems involve the burning of different types of fuel sprays, taking into account aircraft propulsion, industrial furnaces, boilers, gas turbines, and diesel engines. There has been a lack of data which can serve as a basis for spray model development and validation. A major aim of the present investigation is to fill this gap. Experimental apparatus and techniques for studying the characteristics of fuel sprays are discussed, taking into account two-dimensional still photography, cinematography, holography, a laser diffraction particle sizer, and a laser anemometer. The considered instruments were used in a number of experiments, taking into account three different types of fuel spray. Attention is given to liquid fuel sprays, high pressure pulsed diesel sprays, and coal-water slurry sprays.

  20. Characterization of sprays

    NASA Technical Reports Server (NTRS)

    Chigier, N.; Mao, C.-P.

    1984-01-01

    It is pointed out that most practical power generation and propulsion systems involve the burning of different types of fuel sprays, taking into account aircraft propulsion, industrial furnaces, boilers, gas turbines, and diesel engines. There has been a lack of data which can serve as a basis for spray model development and validation. A major aim of the present investigation is to fill this gap. Experimental apparatus and techniques for studying the characteristics of fuel sprays are discussed, taking into account two-dimensional still photography, cinematography, holography, a laser diffraction particle sizer, and a laser anemometer. The considered instruments were used in a number of experiments, taking into account three different types of fuel spray. Attention is given to liquid fuel sprays, high pressure pulsed diesel sprays, and coal-water slurry sprays.

  1. Powder handling for automated fuel processing

    SciTech Connect

    Frederickson, J.R.; Eschenbaum, R.C.; Goldmann, L.H.

    1989-04-09

    Installation of the Secure Automated Fabrication (SAF) line has been completed. It is located in the Fuel Cycle Plant (FCP) at the Department of Energy's (DOE) Hanford site near Richland, Washington. The SAF line was designed to fabricate advanced reactor fuel pellets and assemble fuel pins by automated, remote operation. This paper describes powder handling equipment and techniques utilized for automated powder processing and powder conditioning systems in this line. 9 figs.

  2. Mathematical modeling of biomass fuels formation process

    SciTech Connect

    Gaska, Krzysztof Wandrasz, Andrzej J.

    2008-07-01

    The increasing demand for thermal and electric energy in many branches of industry and municipal management accounts for a drastic diminishing of natural resources (fossil fuels). Meanwhile, in numerous technical processes, a huge mass of wastes is produced. A segregated and converted combustible fraction of the wastes, with relatively high calorific value, may be used as a component of formed fuels. The utilization of the formed fuel components from segregated groups of waste in associated processes of co-combustion with conventional fuels causes significant savings resulting from partial replacement of fossil fuels, and reduction of environmental pollution resulting directly from the limitation of waste migration to the environment (soil, atmospheric air, surface and underground water). The realization of technological processes with the utilization of formed fuel in associated thermal systems should be qualified by technical criteria, which means that elementary processes as well as factors of sustainable development, from a global viewpoint, must not be disturbed. The utilization of post-process waste should be preceded by detailed technical, ecological and economic analyses. In order to optimize the mixing process of fuel components, a mathematical model of the forming process was created. The model is defined as a group of data structures which uniquely identify a real process and conversion of this data in algorithms based on a problem of linear programming. The paper also presents the optimization of parameters in the process of forming fuels using a modified simplex algorithm with a polynomial worktime. This model is a datum-point in the numerical modeling of real processes, allowing a precise determination of the optimal elementary composition of formed fuels components, with assumed constraints and decision variables of the task.

  3. Fuel quality/processing study. Volume 3: Fuel upgrading studies

    NASA Technical Reports Server (NTRS)

    Jones, G. E., Jr.; Bruggink, P.; Sinnett, C.

    1981-01-01

    The methods used to calculate the refinery selling prices for the turbine fuels of low quality are described. Detailed descriptions and economics of the upgrading schemes are included. These descriptions include flow diagrams showing the interconnection between processes and the stream flows involved. Each scheme is in a complete, integrated, stand alone facility. Except for the purchase of electricity and water, each scheme provides its own fuel and manufactures, when appropriate, its own hydrogen.

  4. Controlling the Twin Wire Arc Spray Process Using Artificial Neural Networks (ANN)

    NASA Astrophysics Data System (ADS)

    Hartz-Behrend, K.; Schaup, J.; Zierhut, J.; Schein, J.

    2016-01-01

    One approach for controlling the twin wire arc spray process is to use optical properties of the particle beam as input parameters for a process control. The idea is that changes in the process like eroded contact nozzles or variations of current, voltage, and/or atomizing gas pressure may be detected through observation of the particle beam. It can be assumed that if these properties deviate significantly from those obtained from a beam recorded for an optimal coating process, the spray particle and thus the coating properties change significantly. The goal is to detect these deviations and compensate the occurring errors by adjusting appropriate process parameters for the wire arc spray unit. One method for monitoring optical properties is to apply the diagnostic system particle flux imaging (PFI): PFI fits an ellipse to an image of a particle beam thereby defining easy to analyze characteristical parameters by relating optical beam properties to ellipse parameters. Using artificial neural networks (ANN), mathematical relations between ellipse and process parameters can be defined. It will be shown that in the case of a process disturbance through the use of an ANN-based control new process parameters can be computed to compensate particle beam deviations.

  5. The Solution Precursor Plasma Spray (SPPS) Process: A Review with Energy Considerations

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

    Solution precursor plasma spray (SPPS) is a coating deposition process that uses conventional plasma spray equipment, and solution precursors, rather than ceramic or metal powders, as starting materials. Because the process is exposed to oxygen at high temperatures, nearly all coatings, to date, are oxide ceramics. In this review, both the advantages and the disadvantages of the SPPS process and some comparisons made to the suspension plasma spray (SPS) process will be discussed. The advantages of the SPPS process include rapid exploration of compositions and fabrication of advanced coatings with unique microstructural features. Examples presented span densities from porous thermal barrier coatings (TBCs) to dense TiO2 coatings. Two TBCs are in an advanced development stage: (1) a low thermal conductivity YSZ TBC and (2) a high-temperature yttrium aluminum garnet TBC. As for disadvantages, there are (1) the additional development work for each new precursor and (2) a lower standoff distance and deposition rate than the APS process, related to the evaporation of the solvent. The SPS process shares the same disadvantages. In developing new coatings, a number of factors should be considered and understood, which would help to shorten future development efforts. Future directions of the SPPS process will also be discussed.

  6. Connecting marine productivity to sea-spray via nanoscale biological processes: Phytoplankton Dance or Death Disco?

    PubMed Central

    O’Dowd, Colin; Ceburnis, Darius; Ovadnevaite, Jurgita; Bialek, Jakub; Stengel, Dagmar B.; Zacharias, Merry; Nitschke, Udo; Connan, Solene; Rinaldi, Matteo; Fuzzi, Sandro; Decesari, Stefano; Cristina Facchini, Maria; Marullo, Salvatore; Santoleri, Rosalia; Dell’Anno, Antonio; Corinaldesi, Cinzia; Tangherlini, Michael; Danovaro, Roberto

    2015-01-01

    Bursting bubbles at the ocean-surface produce airborne salt-water spray-droplets, in turn, forming climate-cooling marine haze and cloud layers. The reflectance and ultimate cooling effect of these layers is determined by the spray’s water-uptake properties that are modified through entrainment of ocean-surface organic matter (OM) into the airborne droplets. We present new results illustrating a clear dependence of OM mass-fraction enrichment in sea spray (OMss) on both phytoplankton-biomass, determined from Chlorophyll-a (Chl-a) and Net Primary Productivity (NPP). The correlation coefficient for OMss as a function of Chl-a increased form 0.67 on a daily timescale to 0.85 on a monthly timescale. An even stronger correlation was found as a function of NPP, increasing to 0.93 on a monthly timescale. We suggest the observed dependence is through the demise of the bloom, driven by nanoscale biological processes (such as viral infections), releasing large quantities of transferable OM comprising cell debris, exudates and other colloidal materials. This OM, through aggregation processes, leads to enrichment in sea-spray, thus demonstrating an important coupling between biologically-driven plankton bloom termination, marine productivity and sea-spray modification with potentially significant climate impacts. PMID:26464099

  7. Connecting marine productivity to sea-spray via nanoscale biological processes: Phytoplankton Dance or Death Disco?

    NASA Astrophysics Data System (ADS)

    O'Dowd, Colin; Ceburnis, Darius; Ovadnevaite, Jurgita; Bialek, Jakub; Stengel, Dagmar B.; Zacharias, Merry; Nitschke, Udo; Connan, Solene; Rinaldi, Matteo; Fuzzi, Sandro; Decesari, Stefano; Cristina Facchini, Maria; Marullo, Salvatore; Santoleri, Rosalia; Dell'Anno, Antonio; Corinaldesi, Cinzia; Tangherlini, Michael; Danovaro, Roberto

    2015-10-01

    Bursting bubbles at the ocean-surface produce airborne salt-water spray-droplets, in turn, forming climate-cooling marine haze and cloud layers. The reflectance and ultimate cooling effect of these layers is determined by the spray’s water-uptake properties that are modified through entrainment of ocean-surface organic matter (OM) into the airborne droplets. We present new results illustrating a clear dependence of OM mass-fraction enrichment in sea spray (OMss) on both phytoplankton-biomass, determined from Chlorophyll-a (Chl-a) and Net Primary Productivity (NPP). The correlation coefficient for OMss as a function of Chl-a increased form 0.67 on a daily timescale to 0.85 on a monthly timescale. An even stronger correlation was found as a function of NPP, increasing to 0.93 on a monthly timescale. We suggest the observed dependence is through the demise of the bloom, driven by nanoscale biological processes (such as viral infections), releasing large quantities of transferable OM comprising cell debris, exudates and other colloidal materials. This OM, through aggregation processes, leads to enrichment in sea-spray, thus demonstrating an important coupling between biologically-driven plankton bloom termination, marine productivity and sea-spray modification with potentially significant climate impacts.

  8. Method and Process Development of Advanced Atmospheric Plasma Spraying for Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    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.

  9. Effects of different additives on the performance of spray dryer system during incineration process.

    PubMed

    Wey, M Y; Peng, C Y; Wu, H Y; Chiang, B C; Liu, Z S

    2002-06-01

    The spray dryer system was conventionally employed to remove the SOx, NOx, and HCl in the flue gas. However, the removal efficiency of acid gas in the practical incineration flue gas, which contains dust, heavy metals, and acid gas itself, was seldom mentioned in the literature. The alkaline sorbents possess large specific surface that was a main factor on the adsorption of heavy metals and acid gas. Therefore, the primary objective of this study was focused on the effect of different additives on the removal efficiency of acid gas and heavy metals (Cr, Cd and Pb). The mass and element size distribution of heavy metals in fly ash under different additives were also investigated. The results indicated that the removal efficiency of HCl in the spray dryer system was higher than 97.8%. The effects of additives on the removal efficiency of HCl, however, were undistinguished. In the desulfurization process, the highest removal efficiency was 71.3% when the additive of amorphous SiO2 was added in the spray dryer system. The removal efficiency was 66.0% with the additive of CaCl2 and 63.1% without any additives, respectively. It was also found that the spray dryer system could decrease the concentration of metal in fly ash but increase the amount of fly ash. In addition, amorphous SiO2 in the alkaline sorbent tended to increase the adsorption of heavy metal on reactant, because it could enhance the dispersion of alkaline sorbent. PMID:12118621

  10. Real-time imaging for thermal spray process development and control

    NASA Astrophysics Data System (ADS)

    Agapakis, J.; Hoffman, T.

    1992-03-01

    Thermal spray and other high-temperature industrial processes are quite difficult to monitor with the human eye, because the luminous volume of the plasma or flame obscures the behavior of the solid or molten material in the heat-affected area. When a photographic or video camera is used, viewing is further degraded by the extreme contrast variation across the image area, making it impossible to achieve proper exposure throughout the image—except possibly for small areas of comparable brightness. Optical filtering with neutral density filters, such as those used in a welder’s helmet, are of no practical benefit. With thermal spray processes, the injection and flow of particles within the plasma flame is almost totally concealed by the extreme brightness of the plasma, flame, or arc. In addition, the particles quickly accelerate to very high speeds, making their detection even more difficult. This article discusses the development of integrated thermal spray process monitoring and analysis techniques based on two principles. The first is a unique vision sensing system that suppresses the flame, plasma, arc, or other high-luminosity phenomena in the video image. A further improvement is the use of dedicated image and analysis processing to enhance the sensor images and extract features of interest or dimensional measurements. These experimental techniques can be used as feedback for automated process monitoring and control.

  11. Effect of High-Velocity Oxy-Fuel (HVOF) Thermal Spraying on Physical and Mechanical Properties of Type 316 Stainless Steel

    SciTech Connect

    Terry C. Totemeier

    2005-09-01

    Data on the microstructural, physical, and mechanical characteristics of high-velocity oxygen-fuel (HVOF)-sprayed type 316 stainless steel coatings are presented and compared with properties of wrought 316 stainless steel. Coatings were prepared at three different spray particle velocities; coating characteristics are presented as a function of velocity. The coatings had relatively low porosity and oxide contents and were significantly harder than annealed, wrought 316 stainless steel. The hardness difference is primarily attributed to high dislocation densities resulting from peening imparted by high-velocity spray particles. The coating hardness increased with increasing spray particle velocity, reflecting increased peening effects. The elastic modulus of the coatings was essentially identical to wrought material. The mean coefficient of thermal expansion of as-sprayed coatings was lower than wrought material, but the expansion of annealed coatings matched the wrought behavior.

  12. Process for vaporizing a liquid hydrocarbon fuel

    DOEpatents

    Szydlowski, Donald F.; Kuzminskas, Vaidotas; Bittner, Joseph E.

    1981-01-01

    The object of the invention is to provide a process for vaporizing liquid hydrocarbon fuels efficiently and without the formation of carbon residue on the apparatus used. The process includes simultaneously passing the liquid fuel and an inert hot gas downwardly through a plurality of vertically spaed apart regions of high surface area packing material. The liquid thinly coats the packing surface, and the sensible heat of the hot gas vaporizes this coating of liquid. Unvaporized liquid passing through one region of packing is uniformly redistributed over the top surface of the next region until all fuel has been vaporized using only the sensible heat of the hot gas stream.

  13. Dust Explosion Characteristics of Aluminum, Titanium, Zinc, and Iron-Based Alloy Powders Used in Cold Spray Processing

    NASA Astrophysics Data System (ADS)

    Sakata, K.; Tagomori, K.; Sugiyama, N.; Sasaki, S.; Shinya, Y.; Nanbu, T.; Kawashita, Y.; Narita, I.; Kuwatori, K.; Ikeda, T.; Hara, R.; Miyahara, H.

    2014-01-01

    Compared to conventional thermal spray coating, cold spray processing typically employs finer, smaller-diameter metal powders. Furthermore, cold-sprayed particles exhibit fewer surface oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is important to consider the potential for dust explosions or fires during cold spray processing, for both industrial and R&D applications. This work examined the dust explosion characteristics of metal powders typically used in cold spray coating, for the purpose of preventing dust explosions and fires and thus protecting the health and safety of workers and guarding against property damage. In order to safely make use of the new cold spray technology in industrial settings, it is necessary to manage the risks based on an appropriate assessment of the hazards. However, there have been few research reports focused on such risk management. Therefore, in this study, the dust explosion characteristics of aluminum, titanium, zinc, carbonyl iron, and eutectoid steel containing chromium at 4 wt.% (4 wt.% Cr-eutectoid steel) powders were evaluated according to the standard protocols JIS Z 8818, IEC61241-2-3(1994-09) section 3, and JIS Z 8817. This paper reports our results concerning the dust explosion properties of the above-mentioned metal powders.

  14. Experimental and numerical evaluation of the performance of supersonic two-stage high-velocity oxy-fuel thermal spray (Warm Spray) gun

    NASA Astrophysics Data System (ADS)

    Katanoda, H.; Morita, H.; Komatsu, M.; Kuroda, S.

    2011-03-01

    The water-cooled supersonic two-stage high-velocity oxy-fuel (HVOF) thermal spray gun was developed to make a coating of temperature-sensitive material, such as titanium, on a substrate. The gun has a combustion chamber (CC) followed by a mixing chamber (MC), in which the combustion gas is mixed with the nitrogen gas at room temperature. The mixed gas is accelerated to supersonic speed through a converging-diverging (C-D) nozzle followed by a straight passage called the barrel. This paper proposes an experimental procedure to estimate the cooling rate of CC, MC and barrel separately. Then, the mathematical model is presented to predict the pressure and temperature in the MC for the specific mass flow rates of fuel, oxygen and nitrogen by assuming chemical equilibrium with water-cooling in the CC and MC, and frozen flow with constant specific heat from stagnant condition to the throat in the CC and MC. Finally, the present mathematical model was validated by comparing the calculated and measured stagnant pressures of the CC of the two-stage HVOF gun.

  15. Influence of Process Parameter on Grit Blasting as a Pretreatment Process for Thermal Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.; Linke, T. F.; Sommer, J.; Liao, X.

    2016-01-01

    In thermal spraying, uncoated substrates usually require roughening. As the most common roughening method, grit blasting increases the surface area and produces undercuts in almost all cases, which facilitate mechanical interlocking and thus promote the bonding between the substrate and coating. The effects of grit blasting parameters, i.e., the particle size, the blasting angle, the stand-off distance, and the pressure, on the resulting surface topography are investigated. Furthermore, the efficiency and wear behavior of the blasting media are analyzed. Influences of three different blasting media, corundum, alumina zirconia, and steel shot, on the surface roughening, are compared. By varying adjusted blasting parameters, different initial conditions (surface topography) are created. Subsequently, the substrate is coated, and the coating bond strength is measured. One of the main results of this publication is that alumina zirconia and steel grit show a longer lifetime than pure alumina as a blasting media. Moreover, it has been shown that the blasting parameters such as grain size, working pressure, and history (wear status) of the abrasive particles have a significant effect on the resulting surface topography. Additionally, systematical analysis in this study shows that the blasting parameters such as stand-off distance and blasting angle have a small influence on the results of the blasting process. Another important conclusion of this study is that the conventional surface parameters that have been analyzed in this study did not turn out to be suitable for describing the relationship between the surface topography of the substrate and resulting bond strength.

  16. Process Conditions and Microstructures of Ceramic Coatings by Gas Phase Deposition Based on Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Hospach, A.; Zotov, N.; Vaßen, R.

    2013-03-01

    Plasma spraying at very low pressure (50-200 Pa) is significantly different from atmospheric plasma conditions (APS). By applying powder feedstock, it is possible to fragment the particles into very small clusters or even to evaporate the material. As a consequence, the deposition mechanisms and the resulting coating microstructures could be quite different compared to conventional APS liquid splat deposition. Thin and dense ceramic coatings as well as columnar-structured strain-tolerant coatings with low thermal conductivity can be achieved offering new possibilities for application in energy systems. To exploit the potential of such a gas phase deposition from plasma spray-based processes, the deposition mechanisms and their dependency on process conditions must be better understood. Thus, plasma conditions were investigated by optical emission spectroscopy. Coating experiments were performed, partially at extreme conditions. Based on the observed microstructures, a phenomenological model is developed to identify basic growth mechanisms.

  17. Effect of plastic viscosity and yield value on spray characteristics of magnesium-slurry fuel

    NASA Technical Reports Server (NTRS)

    Prok, George M

    1957-01-01

    Magnesium slurries were sprayed onto a sheet of paper from an air-atomizing injector. Drop sizes and distributions were then determined from photomicrographs. Four different surface-active additives were used in preparing the slurries to give plastic viscosities between 0.22 and 0.51 poise and yield values between 150 and 810 dynes-cm(exp 2). It was found that there was no significant variation in the spray characteristics of these slurries when tested under the same conditions.

  18. Charge generation associated with liquid spraying in tank cleaning and comparable processes - preliminary experiments

    NASA Astrophysics Data System (ADS)

    Blum, Carsten; Losert, Oswald F. J.

    2015-10-01

    The BG RCI has initiated investigations in order to improve the data basis for assessing the ignition hazard by electrostatic charging processes associated with the spraying of liquids. On the base of preliminary experiments, we established procedures for measurements of electric field strength and charging current in the presence of aerosol particles. Results obtained with three different nozzle types, variation of pressure and with built-in deflecting plate are presented.

  19. Modeling atomization processes in high-pressure vaporizing sprays

    NASA Astrophysics Data System (ADS)

    Reitz, Rolf D.

    The theoretical basis and numerical implementation of KIVA, a multidimensional computer code for the simulation of atomization and vaporization processes in the injection of a liquid through a round hole into a compressed gas, are described. KIVA is based on the blob-injection model of Reitz and Diwakar (1987), taking into account the effects of liquid inertia, surface tension, and the aerodynamic forces on the jet, as well as drop collision and coalescence and the effect of drops on turbulence in the gas. The predictions of KIVA for different injection regimes are compared with published experimental data in extensive graphs, and good agreement is demonstrated.

  20. Processing-microstructure-properties relationships in small-particle plasma-sprayed ceramic coatings

    NASA Astrophysics Data System (ADS)

    Mawdsley, Jennifer Renee

    The objective of this study was to determine processing-microstructure-properties relationships for small-particle plasma-sprayed (SPPS) ceramic coatings. Plasma-sprayed yttria partially-stabilized zirconia (YSZ) coatings, which are used to protect superalloys from heat and the environment in turbine engines, and plasma-sprayed alumina coatings, which are being investigated as a potential replacement for chrome in corrosion protection applications, were fabricated using SPPS technology and their microstructure and pertinent properties were examined. The properties of plasma-sprayed YSZ and alumina coatings were investigated with designed experiments. The parameters varied include power, spray distance, total plasma gas flow, percent hydrogen in the plasma gas, injector angle, injector offset and carrier gas flow. The variations in thermal diffusivity, thermal conductivity, elastic modulus, and hardness for the YSZ SPPS coatings were found to correlate to the variations in density, which were related to the processing variables. It was found that surface roughness was related to the amount of splashing and debris associated with the single splats. In four-point bending strain tolerance and fatigue tests, the SPPS YSZ coatings showed very little acoustic emission activity, except in the case of tensile fatigue of a coating without network cracks. Small angle X-ray scattering experiments revealed that SPPS YSZ coatings have significantly less submicron intersplat porosity than conventional plasma-sprayed coatings, and that the pore and microcrack scattering area decreases with heat treatment due to the sintering of microcracks and small pores. The SPPS alumina coatings were optimized to produce a coating with excellent corrosion protection capabilities. It was found that the hardest SPPS alumina coatings did not provide the best corrosion protection due to unique porosity defect structures associated with surface bumps in the coatings. The surface bumps were

  1. Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank

    2000-01-01

    The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners

  2. Optimization of the Büchi B-90 spray drying process using central composite design for preparation of solid dispersions.

    PubMed

    Gu, Bing; Linehan, Brian; Tseng, Yin-Chao

    2015-08-01

    A central composite design approach was applied to study the effect of polymer concentration, inlet temperature and air flow rate on the spray drying process of the Büchi B-90 nano spray dryer (B-90). Hypromellose acetate succinate-LF was used for the Design of Experiment (DoE) study. Statistically significant models to predict the yield, spray rate, and drying efficiency were generated from the study. The spray drying conditions were optimized according to the models to maximize the yield and efficiency of the process. The models were further validated using a poorly water-soluble investigational compound (BI064) from Boehringer Ingelheim Pharmaceuticals. The polymer/drug ratio ranged from 1/1 to 3/1w/w. The spray dried formulations were amorphous determined by differential scanning calorimetry and X-ray powder diffraction. The particle size of the spray dried formulations was 2-10 μm under polarized light microscopy. All the formulations were physically stable for at least 3h when suspended in an aqueous vehicle composed of 1% methyl cellulose. This study demonstrates that DoE is a useful tool to optimize the spray drying process, and the B-90 can be used to efficiently produce amorphous solid dispersions with a limited quantity of drug substance available during drug discovery stages. PMID:26070248

  3. Process for preparing a liquid fuel composition

    DOEpatents

    Singerman, Gary M.

    1982-03-16

    A process for preparing a liquid fuel composition which comprises liquefying coal, separating a mixture of phenols from said liquefied coal, converting said phenols to the corresponding mixture of anisoles, subjecting at least a portion of the remainder of said liquefied coal to hydrotreatment, subjecting at least a portion of said hydrotreated liquefied coal to reforming to obtain reformate and then combining at least a portion of said anisoles and at least a portion of said reformate to obtain said liquid fuel composition.

  4. Characterization of thermal spray coatings

    SciTech Connect

    Schorr, B.S.; Stein, K.J.; Marder, A.R.

    1999-02-01

    The ability to characterize fully the microstructure of a coating is paramount for understanding the in-service properties and eventual optimization of the coating. This article discusses sample preparation and subsequent analytical techniques (LOM, SEM, XRD, WDS, and QIA) for several cermet thermal spray coatings and provides a detailed analysis of as-sprayed microstructures in addition to processing trends for several FeCrAIY-carbide coatings. It was found that the splats produced in these high velocity oxy-fuel (HVOF) coatings tended to exhibit a predominantly dendritic structure most likely retained from the gas atomization process that produced the original powder. Chemical analysis showed that the carbides tend to break down during spraying producing a complex mixture of oxides and various carbides. Finally, image analysis revealed that as the carbides in the pre-sprayed powder were increased, more carbides and oxides with less FeCrAIY and thinner coatings were found. These techniques allow the thorough characterization of thermal spray cermet coatings, which in turn should further the understanding of the thermal spray processes and help provide superior coatings in the future.

  5. Biomass conversion processes for energy and fuels

    NASA Astrophysics Data System (ADS)

    Sofer, S. S.; Zaborsky, O. R.

    The book treats biomass sources, promising processes for the conversion of biomass into energy and fuels, and the technical and economic considerations in biomass conversion. Sources of biomass examined include crop residues and municipal, animal and industrial wastes, agricultural and forestry residues, aquatic biomass, marine biomass and silvicultural energy farms. Processes for biomass energy and fuel conversion by direct combustion (the Andco-Torrax system), thermochemical conversion (flash pyrolysis, carboxylolysis, pyrolysis, Purox process, gasification and syngas recycling) and biochemical conversion (anaerobic digestion, methanogenesis and ethanol fermentation) are discussed, and mass and energy balances are presented for each system.

  6. Transport phenomena relevant to the impact regime of the process of spray deposition: A review. Part 1: Heat transfer

    SciTech Connect

    Poulikakos, D.; Waldvogel, J.M.

    1995-12-31

    Spray deposition is a novel rapid solidification technology for the creation of advanced metals and metal composites. This technology is particularly attractive to manufacturing because it shows promise to provide materials and products that combine superior properties and near net shape. With reference to the former, the extremely high cooling rates present in the process of spray deposition capture non equilibrium states that cannot be captured by more conventional casting methods because the atomic mobility in the liquid phase of a metal is far greater than that in the solid phase. To this end, the cooling rates at the early stages of the spray deposition process are of the order of (10{sup 6} to 10{sup 8}) {sup 0}C/s. With reference to the latter, the spray deposition process has been shown to produce near net shape products which eliminates the need for additional finishing steps in the manufacturing process. Moreover, the fine and homogeneous microstructure that appears to be resulting from the spray deposition process may eliminate the need for additional mechanical working. In this, as well as its companion paper appearing subsequently in this volume, a review is presented of the existing knowledge base of the impact regime of the process of spray deposition, focusing on issues in which transport phenomena are relevant. Further, this paper addresses only heat transfer aspects of the process which do not involve sophisticated modeling of the accompanying complex fluid dynamics.

  7. Titanium Dioxide Coating Prepared by Use of a Suspension-Solution Plasma-Spray Process

    NASA Astrophysics Data System (ADS)

    Du, Lingzhong; Coyle, Thomas W.; Chien, Ken; Pershin, Larry; Li, Tiegang; Golozar, Mehdi

    2015-08-01

    Titanium dioxide coatings were prepared from titanium isopropoxide solution containing nano TiO2 particles by use of a plasma-spray process. The effects of stand-off distance on coating composition and microstructure were investigated and compared with those for pure solution precursor and a water-based suspension of TiO2. The results showed that the anatase content of the coating increased with increasing stand-off distance and the rate of deposition decreased with increasing spray distance. Anatase nanoparticles in solution were incorporated into the coatings without phase transformation whereas most of the TiO2 in the precursor solution was transformed into rutile. The microstructure of preserved anatase particles bound by rutile improved the efficiency of deposition of the coating. The amount of anatase phase can be adjusted by variation of the ratio of solution to added anatase TiO2 nanoparticles.

  8. Formation of molybdenum boride cermet coating by the detonation spray process

    NASA Astrophysics Data System (ADS)

    Yang, Gao; Zu-Kun, Hei; Xiaolei, Xu; Gang, Xin

    2001-09-01

    The effects of the powder particle size and the acetylene/oxygen gas flow ratio during the detonation spray process on the amount of molybdenum phase, porosity, and hardness of the coatings using MoB powder were investigated by x-ray diffraction (XRD), scanning electron microscopy (SEM), etc. The results show that the presence of metallic molybdenum in the coating results from decomposition of MoB powder during thermal spray. The compositions of the coatings are metallic Mo, MoB, and Mo2B, which are different from the phases of the original powder. The amount of molybdenum phase increases monotonously with the oxygen/acetylene ratio, but the increasing rate for the fine powder is faster than that for the coarse powder. The porosity and hardness of the coating are related to the amount of molybdenum phase. The phase constitution of the coating is discussed.

  9. Fabrication of Nanosized Lanthanum Zirconate Powder and Deposition of Thermal Barrier Coating by Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Mishra, S. K.; Jagdeesh, N.; Pathak, L. C.

    2016-07-01

    The present manuscript discusses our findings on fabrication of nanosized lanthanum zirconate powder for thermal barrier coating application and its coating by plasma spray on nickel-based superalloy substrate. Single-phase La2Zr2O7 coating of thickness of the order of 45 µm on the Ni-Cr-Al bond coat coated Ni-based superalloy substrate was deposited by plasma spray process. The layers at the interface did not show spallation and inter diffusion was very less. The microstructure, interface, porosity, and mechanical properties of different layers are investigated. The lanthanum zirconate hardness and modulus were 10.5 and 277 GPa, respectively. The load depth curve for lanthanum zirconate showed good elastic recovery around 74%.

  10. Numerical Study of In-flight Particle Parameters in Low-Pressure Cold Spray Process

    NASA Astrophysics Data System (ADS)

    Ning, Xian-Jin; Wang, Quan-Sheng; Ma, Zhuang; Kim, Hyung-Jun

    2010-12-01

    A 2-D model of the low-pressure cold spray with a radial powder feeding was established using CFD software in this study. The flow field was simulated for both propellant gases of nitrogen and helium. To predict the in-flight particle velocity and temperature, discrete phase model was introduced to simulate the interaction of particle and the supersonic gas jet. The experimental velocity of copper powder with different sizes was used to validate the calculated one for low-pressure cold spray process. The results show that the computational model can provide a satisfactory prediction of the supersonic gas flow, which is consistent with the experimental Schlieren photos. It was found that similar velocity was obtained with the drag coefficient formula of Henderson and with that of Morsi and Alexander. As the shape factor was estimated, the reasonable prediction of velocity for non-spherical particle can be obtained, to compare with the experimental results.

  11. Fabrication of Nanosized Lanthanum Zirconate Powder and Deposition of Thermal Barrier Coating by Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Mishra, S. K.; Jagdeesh, N.; Pathak, L. C.

    2016-05-01

    The present manuscript discusses our findings on fabrication of nanosized lanthanum zirconate powder for thermal barrier coating application and its coating by plasma spray on nickel-based superalloy substrate. Single-phase La2Zr2O7 coating of thickness of the order of 45 µm on the Ni-Cr-Al bond coat coated Ni-based superalloy substrate was deposited by plasma spray process. The layers at the interface did not show spallation and inter diffusion was very less. The microstructure, interface, porosity, and mechanical properties of different layers are investigated. The lanthanum zirconate hardness and modulus were 10.5 and 277 GPa, respectively. The load depth curve for lanthanum zirconate showed good elastic recovery around 74%.

  12. Process-directed self-assembly of multiblock copolymers: Solvent casting vs spray coating

    NASA Astrophysics Data System (ADS)

    Tang, Q.; Tang, J.; Müller, M.

    2016-07-01

    Using computer simulation of a soft, coarse-grained model and self-consistent field theory we investigate how collapsed, globular chain conformations in the initial stages of structure formation, which are produced by spray-coating, affect the single-chain structure and morphology of microphase-separated multiblock copolymers. Comparing spray-coated films with films that start from a disordered state of Gaussian chains, we observe that the collapsed molecular conformations in the initial stage give rise to (1) a smaller fraction of blocks that straddle domains (bridges), (2) a significant reduction of the molecular extension normal to the internal interfaces, and (3) a slightly larger lamellar domain spacing in the final morphology. The relaxation of molecular conformations towards equilibrium is very protracted for both processes - solvent casting and spray coating. These findings illustrate that the process conditions of the copolymer materials may significantly affect materials properties (such as mechanical properties) because the system does not reach thermal equilibrium on the relevant time scales.

  13. Optimization of spray drying process for developing seabuckthorn fruit juice powder using response surface methodology.

    PubMed

    Selvamuthukumaran, Meenakshisundaram; Khanum, Farhath

    2014-12-01

    The response surface methodology was used to optimize the spray drying process for development of seabuckthorn fruit juice powder. The independent variables were different levels of inlet air temperature and maltodextrin concentration. The responses were moisture, solubility, dispersibility, vitamin C and overall color difference value. Statistical analysis revealed that independent variables significantly affected all the responses. The Inlet air temperature showed maximum influence on moisture and vitamin C content, while the maltodextrin concentration showed similar influence on solubility, dispersibility and overall color difference value. Contour plots for each response were used to generate an optimum area by superimposition. The seabuckthorn fruit juice powder was developed using the derived optimum processing conditions to check the validity of the second order polynomial model. The experimental values were found to be in close agreement to the predicted values and were within the acceptable limits indicating the suitability of the model in predicting quality attributes of seabuckthorn fruit juice powder. The recommended optimum spray drying conditions for drying 100 g fruit juice slurry were inlet air temperature and maltodextrin concentration of 162.5 °C and 25 g, respectively. The spray dried juice powder contains higher amounts of antioxidants viz., vitamin C, vitamin E, total carotenoids, total anthocyanins and total phenols when compared to commercial fruit juice powders and they are also found to be free flowing without any physical alterations such as caking, stickiness, collapse and crystallization by exhibiting greater glass transition temperature. PMID:25477639

  14. Process maps for plasma spray: Part 1: Plasma-particle interactions

    SciTech Connect

    GILMORE,DELWYN L.; NEISER JR.,RICHARD A.; WAN,YUEPENG; SAMPATH,SANJAY

    2000-01-26

    This is the first paper of a two part series based on an integrated study carried out at Sandia National Laboratories and the State University of New York at Stony Brook. The aim of the study is to develop a more fundamental understanding of plasma-particle interactions, droplet-substrate interactions, deposit formation dynamics and microstructural development as well as final deposit properties. The purpose is to create models that can be used to link processing to performance. Process maps have been developed for air plasma spray of molybdenum. Experimental work was done to investigate the importance of such spray parameters as gun current, auxiliary gas flow, and powder carrier gas flow. In-flight particle diameters, temperatures, and velocities were measured in various areas of the spray plume. Samples were produced for analysis of microstructures and properties. An empirical model was developed, relating the input parameters to the in-flight particle characteristics. Multi-dimensional numerical simulations of the plasma gas flow field and in-flight particles under different operating conditions were also performed. In addition to the parameters which were experimentally investigated, the effect of particle injection velocity was also considered. The simulation results were found to be in good general agreement with the experimental data.

  15. Elastoplastic analysis of process induced residual stresses in thermally sprayed coatings

    SciTech Connect

    Chen Yongxiong; Liang Xiubing; Liu Yan; Xu Binshi

    2010-07-15

    The residual stresses induced from thermal spraying process have been extensively investigated in previous studies. However, most of such works were focused on the elastic deformation range. In this paper, an elastoplastic model for predicting the residual stresses in thermally sprayed coatings was developed, in which two main contributions were considered, namely the deposition induced stress and that due to differential thermal contraction between the substrate and coating during cooling. The deposition induced stress was analyzed based on the assumption that the coating is formed layer-by-layer, and then a misfit strain is accommodated within the multilayer structure after the addition of each layer (plastic deformation is induced consequently). From a knowledge of specimen dimensions, processing temperatures, and material properties, residual stress distributions within the structure can be determined by implementing the model with a simple computer program. A case study for the plasma sprayed NiCoCrAlY on Inconel 718 system was performed finally. Besides some similar phenomena observed from the present study as compared with previous elastic model reported in literature, the elastoplastic model also provides some interesting features for prediction of the residual stresses.

  16. SOFC system with integrated catalytic fuel processing

    NASA Astrophysics Data System (ADS)

    Finnerty, Caine; Tompsett, Geoff. A.; Kendall, Kevin; Ormerod, R. Mark

    In recent years, there has been much interest in the development of solid oxide fuel cell technology operating directly on hydrocarbon fuels. The development of a catalytic fuel processing system, which is integrated with the solid oxide fuel cell (SOFC) power source is outlined here. The catalytic device utilises a novel three-way catalytic system consisting of an in situ pre-reformer catalyst, the fuel cell anode catalyst and a platinum-based combustion catalyst. The three individual catalytic stages have been tested in a model catalytic microreactor. Both temperature-programmed and isothermal reaction techniques have been applied. Results from these experiments were used to design the demonstration SOFC unit. The apparatus used for catalytic characterisation can also perform in situ electrochemical measurements as described in previous papers [C.M. Finnerty, R.H. Cunningham, K. Kendall, R.M. Ormerod, Chem. Commun. (1998) 915-916; C.M. Finnerty, N.J. Coe, R.H. Cunningham, R.M. Ormerod, Catal. Today 46 (1998) 137-145]. This enabled the performance of the SOFC to be determined at a range of temperatures and reaction conditions, with current output of 290 mA cm -2 at 0.5 V, being recorded. Methane and butane have been evaluated as fuels. Thus, optimisation of the in situ partial oxidation pre-reforming catalyst was essential, with catalysts producing high H 2/CO ratios at reaction temperatures between 873 K and 1173 K being chosen. These included Ru and Ni/Mo-based catalysts. Hydrocarbon fuels were directly injected into the catalytic SOFC system. Microreactor measurements revealed the reaction mechanisms as the fuel was transported through the three-catalyst device. The demonstration system showed that the fuel processing could be successfully integrated with the SOFC stack.

  17. Deposition of solid oxide fuel cell electrodes by solution precursor plasma spray

    NASA Astrophysics Data System (ADS)

    Wang, Youliang

    Porous La1-xSrxMnO3 (LSM) perovskite cathodes and Yttria Stabilized Zirconia (YSZ)-Nickel (Ni) anodes were successfully deposited by direct current arc solution precursor plasma spray (DC-SPPS), in which a solution precursor of the product material was injected into DC plasma jet. The deposition mechanisms, such as the changes in the solution precursor with the increase of temperature and the evolution of the droplet as it moved along the plasma jet, as well as the impact of the synthesized particles onto the substrate, were investigated. The effects of processing parameters on the microstructure and phase composition of the fabricated LSM cathode and Ni-YSZ anode were examined systematically using TGA/TDA, XRD and SEM. Coating deposition efficiencies and porosities as a function of processing parameters were analyzed by statistical experimental design techniques, based on which the deposition processes were optimized. In addition, the hardness and electrical resistance of the fabricated coatings were measured. From the theoretical and experimental analyses conducted, a comprehensive description of the DC-SPPS process was developed. The precursor solution droplets undergo breakup; solvent evaporation and precursor salt precipitation and crystallization; precursor salt melting and decomposition; nucleation and growth of particles of the product phase; agglomeration, sintering, and perhaps melting of these particles; and impact onto the substrate. The breakup of droplets can only occur in the short period of time after the droplets are injected into the plasma jet. Agglomeration of droplets or particles may occur at any point along the plasma plume. This work has clearly established: (a) the critical importance of droplet breakup and the agglomeration of precursors or synthesized particles in-flight in the plasma jet in determining the structure of the deposited coating, and (b) the basis of the low deposition efficiencies obtained in DC-SPPS. The microstructure and

  18. A Design of Experiment approach to predict product and process parameters for a spray dried influenza vaccine.

    PubMed

    Kanojia, Gaurav; Willems, Geert-Jan; Frijlink, Henderik W; Kersten, Gideon F A; Soema, Peter C; Amorij, Jean-Pierre

    2016-09-25

    Spray dried vaccine formulations might be an alternative to traditional lyophilized vaccines. Compared to lyophilization, spray drying is a fast and cheap process extensively used for drying biologicals. The current study provides an approach that utilizes Design of Experiments for spray drying process to stabilize whole inactivated influenza virus (WIV) vaccine. The approach included systematically screening and optimizing the spray drying process variables, determining the desired process parameters and predicting product quality parameters. The process parameters inlet air temperature, nozzle gas flow rate and feed flow rate and their effect on WIV vaccine powder characteristics such as particle size, residual moisture content (RMC) and powder yield were investigated. Vaccine powders with a broad range of physical characteristics (RMC 1.2-4.9%, particle size 2.4-8.5μm and powder yield 42-82%) were obtained. WIV showed no significant loss in antigenicity as revealed by hemagglutination test. Furthermore, descriptive models generated by DoE software could be used to determine and select (set) spray drying process parameter. This was used to generate a dried WIV powder with predefined (predicted) characteristics. Moreover, the spray dried vaccine powders retained their antigenic stability even after storage for 3 months at 60°C. The approach used here enabled the generation of a thermostable, antigenic WIV vaccine powder with desired physical characteristics that could be potentially used for pulmonary administration. PMID:27523619

  19. The Use of Particle/Substrate Material Models in Simulation of Cold-Gas Dynamic-Spray Process

    NASA Astrophysics Data System (ADS)

    Rahmati, Saeed; Ghaei, Abbas

    2014-02-01

    Cold spray is a coating deposition method in which the solid particles are accelerated to the substrate using a low temperature supersonic gas flow. Many numerical studies have been carried out in the literature in order to study this process in more depth. Despite the inability of Johnson-Cook plasticity model in prediction of material behavior at high strain rates, it is the model that has been frequently used in simulation of cold spray. Therefore, this research was devoted to compare the performance of different material models in the simulation of cold spray process. Six different material models, appropriate for high strain-rate plasticity, were employed in finite element simulation of cold spray process for copper. The results showed that the material model had a considerable effect on the predicted deformed shapes.

  20. The effect of spraying parameters on micro-structural properties of WC-12%Co coating deposited on copper substrate by HVOF process

    NASA Astrophysics Data System (ADS)

    Sathwara, Nishit; Jariwala, C.; Chauhan, N.; Raole, P. M.; Basa, D. K.

    2015-08-01

    High Velocity Oxy-Fuel (HVOF) thermal sprayed coatingmade from Tungsten Carbide (WC) isconsidered as one of the most durable materials as wear resistance for industrial applications at room temperature. WC coating offers high wear resistance due to its high hardness and tough matrix imparts. The coating properties strongly depend on thermal spray processing parameters, surface preparation and surface finish. In this investigation, the effect of variousHVOF process parameters was studied on WC coating properties. The WC-12%Co coating was produced on Copper substrate. Prior to coating, theCopper substrate surface was prepared by grit blasting. WC-12%Co coatings were deposited on Coppersubstrates with varying process parameters such as Oxygen gas pressure, Air pressure, and spraying distance. Microstructure of coating was examined using Scanning Electron Microscope (SEM) and characterization of phasespresentin the coating was examined by X-Ray Diffraction (XRD). Microhardness of all coatingswas measured by VickerMicrohardness tester. At low Oxygen Pressure(10.00 bar), high Air pressure (7bar) and short nozzle to substrate distance of 170mm, best coating adhesion and porosity less structure isachieved on Coppersubstrate.

  1. The effect of spraying parameters on micro-structural properties of WC-12%Co coating deposited on copper substrate by HVOF process

    SciTech Connect

    Sathwara, Nishit; Jariwala, C. Chauhan, N.; Raole, P. M.; Basa, D. K.

    2015-08-28

    High Velocity Oxy-Fuel (HVOF) thermal sprayed coatingmade from Tungsten Carbide (WC) isconsidered as one of the most durable materials as wear resistance for industrial applications at room temperature. WC coating offers high wear resistance due to its high hardness and tough matrix imparts. The coating properties strongly depend on thermal spray processing parameters, surface preparation and surface finish. In this investigation, the effect of variousHVOF process parameters was studied on WC coating properties. The WC-12%Co coating was produced on Copper substrate. Prior to coating, theCopper substrate surface was prepared by grit blasting. WC-12%Co coatings were deposited on Coppersubstrates with varying process parameters such as Oxygen gas pressure, Air pressure, and spraying distance. Microstructure of coating was examined using Scanning Electron Microscope (SEM) and characterization of phasespresentin the coating was examined by X-Ray Diffraction (XRD). Microhardness of all coatingswas measured by VickerMicrohardness tester. At low Oxygen Pressure(10.00 bar), high Air pressure (7bar) and short nozzle to substrate distance of 170mm, best coating adhesion and porosity less structure isachieved on Coppersubstrate.

  2. Study of the laser marking process of cold sprayed titanium coatings on aluminium substrates

    NASA Astrophysics Data System (ADS)

    Astarita, A.; Genna, S.; Leone, C.; Memola Capece Minutolo, F.; Squillace, A.; Velotti, C.

    2016-09-01

    This paper deals with the study of the laser marking process of titanium cold sprayed coatings on aluminium substrates. Despite several studies regarding the laser marking process are available in literature very few attention have been paid to the marking of cold sprayed coatings and there are no previous papers in literature. Also the phenomena occurring during the marking of a porous coating are to date not fully understood and will be discussed in this paper. The experimental campaign was also repeated on grade 2 titanium rolled sheets with a thickness of 2 mm. The marking tests were carried out under different experimental conditions varying the main process parameters (i.e. laser pulse power and laser scan speed), after that the mark sections were observed by optical microscope and SEM. Both the maximum penetration depth and width of the marks were acquired and also internal damages induced by the process were studied. A correlation between the process parameters and the mark's geometry was found. The results show the effectiveness of the laser process to produce high quality marks on both the titanium layer and the titanium sheet. Moreover, a higher mark penetration on Ti coating was observed compared to the Ti sheet. However, the results show also the possibility to introduce severe and hidden damages in both materials if the process parameters are not properly set.

  3. Fabrication of gas turbine water-cooled composite nozzle and bucket hardware employing plasma spray process

    DOEpatents

    Schilke, Peter W.; Muth, Myron C.; Schilling, William F.; Rairden, III, John R.

    1983-01-01

    In the method for fabrication of water-cooled composite nozzle and bucket hardware for high temperature gas turbines, a high thermal conductivity copper alloy is applied, employing a high velocity/low pressure (HV/LP) plasma arc spraying process, to an assembly comprising a structural framework of copper alloy or a nickel-based super alloy, or combination of the two, and overlying cooling tubes. The copper alloy is plamsa sprayed to a coating thickness sufficient to completely cover the cooling tubes, and to allow for machining back of the copper alloy to create a smooth surface having a thickness of from 0.010 inch (0.254 mm) to 0.150 inch (3.18 mm) or more. The layer of copper applied by the plasma spraying has no continuous porosity, and advantageously may readily be employed to sustain a pressure differential during hot isostatic pressing (HIP) bonding of the overall structure to enhance bonding by solid state diffusion between the component parts of the structure.

  4. Chemical compatibility and properties of suspension plasma-sprayed SrTiO3-based anodes for intermediate-temperature solid oxide fuel cells

    NASA Astrophysics Data System (ADS)

    Zhang, Shan-Lin; Li, Cheng-Xin; Li, Chang-Jiu

    2014-10-01

    La-doped strontium titanate (LST) is a promising, redox-stable perovskite material for direct hydrocarbon oxidation anodes in intermediate-temperature solid oxide fuel cells (IT-SOFCs). In this study, nano-sized LST and Sm-doped ceria (SDC) powders are produced by the sol-gel and glycine-nitrate processes, respectively. The chemical compatibility between LST and electrolyte materials is studied. A LST-SDC composite anode is prepared by suspension plasma spraying (SPS). The effects of annealing conditions on the phase structure, microstructure, and chemical stability of the LST-SDC composite anode are investigated. The results indicate that the suspension plasma-sprayed LST-SDC anode has the same phase structure as the original powders. LST exhibits a good chemical compatibility with SDC and Mg/Sr-doped lanthanum gallate (LSGM). The anode has a porosity of ∼40% with a finely porous structure that provides high gas permeability and a long three-phase boundary for the anode reaction. Single cells assembled with the LST-SDC anode, La0.8Sr0.2Ga0.8Mg0.2O3 electrolyte, and La0.8Sr0.2CoO3-SDC cathode show a good performance at 650-800 °C. The annealing reduces the impedances due to the enhancement in the bonding between the particles in the anode and interface of anode and LSGM electrolyte, thus improving the output performance of the cell.

  5. Evaluation of models for predicting spray mist diameter for scaling-up of the fluidized bed granulation process.

    PubMed

    Fujiwara, Maya; Dohi, Masafumi; Otsuka, Tomoko; Yamashita, Kazunari; Sako, Kazuhiro

    2012-01-01

    We evaluated models for predicting spray mist diameter suitable for scaling-up the fluidized bed granulation process. By precise selection of experimental conditions, we were able to identify a suitable prediction model that considers changes in binder solution, nozzle dimension, and spray conditions. We used hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), or polyvinylpyrrolidone (PVP) binder solutions, which are commonly employed by the pharmaceutical industry. Nozzle dimension and spray conditions for oral dosing were carefully selected to reflect manufacturing and small (1/10) scale process conditions. We were able to demonstrate that the prediction model proposed by Mulhem optimally estimated spray mist diameter when each coefficient was modified. Moreover, we developed a simple scale-up rule to produce the same spray mist diameter at different process scales. We confirmed that the Rosin-Rammler distribution could be applied to this process, and that its distribution coefficient was 1.43-1.72 regardless of binder solution, spray condition, or nozzle dimension. PMID:23124561

  6. Effect of Spray Particle Velocity on Cavitation Erosion Resistance Characteristics of HVOF and HVAF Processed 86WC-10Co4Cr Hydro Turbine Coatings

    NASA Astrophysics Data System (ADS)

    Kumar, R. K.; Kamaraj, M.; Seetharamu, S.; Pramod, T.; Sampathkumaran, P.

    2016-06-01

    The hydro plants utilizing silt-laden water for power generation suffer from severe metal wastage due to particle-induced erosion and cavitation. High-velocity oxy-fuel process (HVOF)-based coatings is widely applied to improve the erosion life. The process parameters such as particle velocity, size, powder feed rate, temperature, affect their mechanical properties. The high-velocity air fuel (HVAF) technology, with higher particle velocities and lower spray temperatures, gives dense and substantially nonoxidized coating. In the present study, the cavitation resistance of 86WC-10Co4Cr-type HVOF coating processed at 680 m/s spray particle velocity was compared with HVAF coatings made at 895, 960, and 1010 m/s. The properties such as porosity, hardness, indentation toughness, and cavitation resistance were investigated. The surface damage morphology has been analyzed in SEM. The cohesion between different layers has been examined qualitatively through scratch depth measurements across the cross section. The HVAF coatings have shown a lower porosity, higher hardness, and superior cavitation resistance. Delamination, extensive cracking of the matrix interface, and detachment of the WC grains were observed in HVOF coating. The rate of metal loss is low in HVAF coatings implying that process parameters play a vital role in achieving improved cavitation resistance.

  7. Effect of Spray Particle Velocity on Cavitation Erosion Resistance Characteristics of HVOF and HVAF Processed 86WC-10Co4Cr Hydro Turbine Coatings

    NASA Astrophysics Data System (ADS)

    Kumar, R. K.; Kamaraj, M.; Seetharamu, S.; Pramod, T.; Sampathkumaran, P.

    2016-08-01

    The hydro plants utilizing silt-laden water for power generation suffer from severe metal wastage due to particle-induced erosion and cavitation. High-velocity oxy-fuel process (HVOF)-based coatings is widely applied to improve the erosion life. The process parameters such as particle velocity, size, powder feed rate, temperature, affect their mechanical properties. The high-velocity air fuel (HVAF) technology, with higher particle velocities and lower spray temperatures, gives dense and substantially nonoxidized coating. In the present study, the cavitation resistance of 86WC-10Co4Cr-type HVOF coating processed at 680 m/s spray particle velocity was compared with HVAF coatings made at 895, 960, and 1010 m/s. The properties such as porosity, hardness, indentation toughness, and cavitation resistance were investigated. The surface damage morphology has been analyzed in SEM. The cohesion between different layers has been examined qualitatively through scratch depth measurements across the cross section. The HVAF coatings have shown a lower porosity, higher hardness, and superior cavitation resistance. Delamination, extensive cracking of the matrix interface, and detachment of the WC grains were observed in HVOF coating. The rate of metal loss is low in HVAF coatings implying that process parameters play a vital role in achieving improved cavitation resistance.

  8. The N.A.C.A. Photographic Apparatus for Studying Fuel Sprays from Oil Engine Injection Valves and Test Results from Several Researches

    NASA Technical Reports Server (NTRS)

    Beardsley, Edward G

    1928-01-01

    Apparatus for recording photographically the start, growth, and cut-off of oil sprays from injection valves has been developed at the Langley Memorial Aeronautical Laboratory. The apparatus consists of a high-tension transformer by means of which a bank of condensers is charged to a high voltage. The controlled discharge of these condensers in sequence, at a rate of several thousand per second, produces electric sparks of sufficient intensity to illuminate the moving spray for photographing. The sprays are injected from various types of valves into a chamber containing gases at pressures up to 600 pounds per square inch. Several series of pictures are shown. The results give the effects of injection pressure, chamber pressure, specific gravity of the fuel oil used, and injection-valve design, upon spray characteristics.

  9. Continuous synthesis of graphene sheets by spray pyrolysis and their use as catalysts for fuel cells.

    PubMed

    Zou, Biao; Wang, Xiao Xia; Huang, Xin Xin; Wang, Jian Nong

    2015-01-14

    Graphene sheets (GNS) were synthesized continuously by spray pyrolysis of iron carbonyl and pyridine. The Pt catalyst supported on GNS exhibited excellent durability for oxygen reduction reaction (ORR). The GNS, when used as a metal-free catalyst for ORR, showed performance even better than the commercial Pt/C catalyst. PMID:25421428

  10. Vacuum Plasma Spray of Cu-8Cr-4Nb for Advanced Liquid-Fuel Combustion Chambers

    NASA Technical Reports Server (NTRS)

    Zimmerman, F.; Elam, S.; Ellis, D.; Miller, H.; McKechnie, T.; Hickman, R.

    2001-01-01

    Vacuum plasma spray (VPS) formed Cu-8Cr-4Nb alloy, with low oxygen, exhibits higher strength at room and elevated temperature than material formed by extrusion. The VPS formed material exhibits slightly lower ductility than the extruded material. VPS forming of Cu-8Cr-4Nb can be used to produce near net structures with mechanical properties comparable to current extruded material.

  11. Alternative Fuel for Portland Cement Processing

    SciTech Connect

    Schindler, Anton K; Duke, Steve R; Burch, Thomas E; Davis, Edward W; Zee, Ralph H; Bransby, David I; Hopkins, Carla; Thompson, Rutherford L; Duan, Jingran; Venkatasubramanian, Vignesh; Stephen, Giles

    2012-06-30

    The production of cement involves a combination of numerous raw materials, strictly monitored system processes, and temperatures on the order of 1500 °C. Immense quantities of fuel are required for the production of cement. Traditionally, energy from fossil fuels was solely relied upon for the production of cement. The overarching project objective is to evaluate the use of alternative fuels to lessen the dependence on non-renewable resources to produce portland cement. The key objective of using alternative fuels is to continue to produce high-quality cement while decreasing the use of non-renewable fuels and minimizing the impact on the environment. Burn characteristics and thermodynamic parameters were evaluated with a laboratory burn simulator under conditions that mimic those in the preheater where the fuels are brought into a cement plant. A drop-tube furnace and visualization method were developed that show potential for evaluating time- and space-resolved temperature distributions for fuel solid particles and liquid droplets undergoing combustion in various combustion atmospheres. Downdraft gasification has been explored as a means to extract chemical energy from poultry litter while limiting the throughput of potentially deleterious components with regards to use in firing a cement kiln. Results have shown that the clinkering is temperature independent, at least within the controllable temperature range. Limestone also had only a slight effect on the fusion when used to coat the pellets. However, limestone addition did display some promise in regards to chlorine capture, as ash analyses showed chlorine concentrations of more than four times greater in the limestone infused ash as compared to raw poultry litter. A reliable and convenient sampling procedure was developed to estimate the combustion quality of broiler litter that is the best compromise between convenience and reliability by means of statistical analysis. Multi-day trial burns were conducted

  12. The effect of process parameters on the Liquid Flame Spray generated titania nanoparticles.

    PubMed

    Aromaa, Mikko; Keskinen, Helmi; Mäkelä, Jyrki M

    2007-11-01

    Nanoparticles have become important in many applications. It is essential to be able to control the particle size because the properties of nanoparticles change dramatically with particle size. An efficient way to generate nanoparticles is via aerosol processes. In this study we used Liquid Flame Spray consisting of liquid precursor droplets sprayed into a high-speed hydrogen/oxygen flame where they evaporate, vapours react and nucleate to form titania nanoparticles. Using flame methods, also dopants and sensitizers can easily be introduced in order to, e.g. improve the photocatalytic activity of the nanomaterial. To obtain a practical guideline in order to tailor the final nanoparticle size in the process, we have systematically studied the effects of different process parameters on the particle size of titania. Titania is used, e.g. as a photocatalyst, and then both particle size and crystal structure are important when looking at the efficiency. In this work, the generated nanoparticle size has been measured by aerosol instrumentation and the particle morphology has been verified with transmission electron microscopy. In Liquid Flame Spray method, there are several adjustable parameters such as precursor feed rate into the flame; concentration of the precursor; precursor material itself as well as solvent used in the precursor; mass flow of combustion gases and also the mechanical design of the torch used. We used metal organic based titanium precursors in alcohol solvents, predominantly ethanol and 2-propanol. Large differences in particle production between the precursors were found. Differences could also be seen for various solvents. As for precursor feed in the flame, the more mass is introduced the larger the nanoparticles are, i.e. precursor concentration and precursor feed rate have an impact on particle size. A similar phenomenon can be discovered for the combustion gas flow rates. Torch design also plays an important role in controlling the particle

  13. Fracture toughness of plasma-sprayed thermal barrier ceramics: Influence of processing, microstructure, and thermal aging

    SciTech Connect

    Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay; Shyam, Amit; Lara-Curzio, Edgar

    2014-06-09

    Fracture toughness has become one of the dominant design parameters that dictates the selection of materials and their microstructure to obtain durable thermal barrier coatings (TBCs). Much progress has been made in characterizing the fracture toughness of relevant TBC compositions in bulk form, and it has become apparent that this property is significantly affected by process-induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma sprayed (APS) TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different spray process conditions inducing different levels of porosity and interfacial defects. Fracture toughness was measured on free standing coatings in as-processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative TBC composition, Gd2Zr2O7 (GDZ), which as anticipated shows significantly lower fracture toughness compared to YSZ. Furthermore, the results from these studies not only point towards a need for process and microstructure optimization for enhanced TBC performance but also a framework for establishing performance metrics for promising new TBC compositions.

  14. Fracture toughness of plasma-sprayed thermal barrier ceramics: Influence of processing, microstructure, and thermal aging

    DOE PAGESBeta

    Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay; Shyam, Amit; Lara-Curzio, Edgar

    2014-06-09

    Fracture toughness has become one of the dominant design parameters that dictates the selection of materials and their microstructure to obtain durable thermal barrier coatings (TBCs). Much progress has been made in characterizing the fracture toughness of relevant TBC compositions in bulk form, and it has become apparent that this property is significantly affected by process-induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma sprayed (APS) TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different spray process conditions inducing different levelsmore » of porosity and interfacial defects. Fracture toughness was measured on free standing coatings in as-processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative TBC composition, Gd2Zr2O7 (GDZ), which as anticipated shows significantly lower fracture toughness compared to YSZ. Furthermore, the results from these studies not only point towards a need for process and microstructure optimization for enhanced TBC performance but also a framework for establishing performance metrics for promising new TBC compositions.« less

  15. Numerical analysis of partially molten splat during thermal spray process using the finite element method

    NASA Astrophysics Data System (ADS)

    Zirari, M.; Abdellah El-Hadj, A.; Bacha, N.

    2010-03-01

    A finite element method is used to simulate the deposition of the thermal spray coating process. A set of governing equations is solving by a volume of fluid method. For the solidification phenomenon, we use the specific heat method (SHM). We begin by comparing the present model with experimental and numerical model available in the literature. In this study, completely molten or semi-molten aluminum particle impacts a H13 tool steel substrate is considered. Next we investigate the effect of inclination of impact of a partially molten particle on flat substrate. It was found that the melting state of the particle has great effects on the morphologies of the splat.

  16. Focused analyte spray emission apparatus and process for mass spectrometric analysis

    DOEpatents

    Roach, Patrick J.; Laskin, Julia; Laskin, Alexander

    2012-01-17

    An apparatus and process are disclosed that deliver an analyte deposited on a substrate to a mass spectrometer that provides for trace analysis of complex organic analytes. Analytes are probed using a small droplet of solvent that is formed at the junction between two capillaries. A supply capillary maintains the droplet of solvent on the substrate; a collection capillary collects analyte desorbed from the surface and emits analyte ions as a focused spray to the inlet of a mass spectrometer for analysis. The invention enables efficient separation of desorption and ionization events, providing enhanced control over transport and ionization of the analyte.

  17. A hybrid approach to determine critical and erosion velocities in the cold spray process

    NASA Astrophysics Data System (ADS)

    Moridi, A.; Hassani-Gangaraj, S. M.; Guagliano, M.

    2013-05-01

    Cold spray is a coating process in which bonding is obtained when the impact velocity of small particles exceeds a critical value called critical velocity (CV) but it is less than an upper limit beyond which erosion happens. The success of the cold spray process mainly depends on the correct choice of the process velocity which should be set to be between CV and erosion velocity (EV), that are influenced by many parameters. This justifies the interest of many researchers to define models for the CV assessments. In the present work, we propose a new model, combination of numerical and analytical solutions, to calculate not only the CV but also EV. Compared with previous works, porosity of particles and adherence phenomena between particle and the substrate have been taken into account as a novelty. Results of the proposed approach have been compared with experimental data and good agreement was found. Finally, based on the procedure results, a representative equation was established for calculating critical and erosion velocities as a function of particle porosity, diameter and temperature for Cu and stainless steel 316L particles.

  18. Deposition Mechanisms and Oxidation Behaviors of Ti-Ni Coatings Deposited in Low-Temperature HVOF Spraying Process

    NASA Astrophysics Data System (ADS)

    Lin, Q. S.; Zhou, K. S.; Deng, C. M.; Liu, M.; Xu, L. P.; Deng, C. G.

    2014-08-01

    Three kinds of Ti-Ni powders were deposited on 316L stainless steel by low-temperature high-velocity oxygen fuel (LT-HVOF) spraying process, respectively. Deposition mechanisms and oxidation behaviors of the coatings were researched in this paper. The coating deposited from TiNi intermetallic powder had obvious laminar structure and the oxygen content was the highest among the three kinds of coatings. The oxygen content of the coating deposited from small-sized Ni-clad Ti powder was still high due to the melting of parts of particles. However, most of the coarse Ni-clad Ti powder was deposited in solid states without changes of chemical compositions and phase compositions. The oxygen content of the coating deposited from coarse Ni-clad Ti powder was the lowest among the three kinds of coatings. It indicated that the deposition behavior of the coating could effectively preserve the inner titanium from oxidation. The results of the present research demonstrated that it is entirely feasible to deposit active metal materials such as titanium and titanium alloy through the optimizing selection of powder in the LT-HVOF process.

  19. Properties of heat-treated calcium phosphate coatings deposited by high-velocity oxy-fuel (HVOF) spray.

    PubMed

    Li, H; Khor, K A; Cheang, P

    2002-05-01

    The influence of crystallization, upon heat treatment, on the properties of high-velocity oxy-fuel (HVOF) sprayed hydroxyapatite (HA) coatings was investigated. The characterization of the HA coating was performed by X-ray diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FTIR). Differential Scanning Calorimeter (DSC) was employed to determine the crystallization temperature of the amorphous phase in an as-sprayed HA coating. The study demonstrated the effect of crystallization on the coating properties by considering the changes in materials chemistry, crystallinity level, and mechanical performance. Results showed that complete crystallization of the amorphous phase occurred at approximately 700 degrees C and the crystallization temperature was dependent on sample heating rate in the DSC test. The changes of ion groups were detected by FTIR, before and after the phase transformation. The crystallization of the coating after annealing at 750 degrees C resulted in a significant increase of the coatings' adhesive strength and shear strength, which attained maximum values 34 +/- 3 and 14.1 -/+ 0.8 MPa, respectively. Young's modulus increased from 21 +/- 1 to 25 +/- 2 GPa. Microhardness measurements confirmed the changes in coating properties. It is also found that the transformation from the amorphous phase has crystalline HA as the only resultant phase detected by XRD. PMID:11962650

  20. Effect of Spray Parameters on the Corrosion Behavior of HVOF Sprayed WC-Co-Cr Coatings

    NASA Astrophysics Data System (ADS)

    Hong, Sheng; Wu, Yuping; Zheng, Yugui; Wang, Bo; Gao, Wenwen; Li, Gaiye; Ying, Guobing; Lin, Jinran

    2014-04-01

    WC-10Co-4Cr cermet coatings were deposited on the substrate of AISI 1045 steel by using high-velocity oxygen-fuel (HVOF) thermal spraying process. The Taguchi method including the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) was employed to optimize the porosity and, in turn, the corrosion resistance of the coatings. The spray parameters evaluated in this study were spray distance, oxygen flow, and kerosene flow. The results indicated that the important sequence of spray parameters on the porosity of the coatings was spray distance > oxygen flow > kerosene flow, and the spray distance was the only significant factor. The optimum spraying condition was 300 mm for the spray distance, 1900 scfh for the oxygen flow, and 6.0 gph for the kerosene flow. The results showed the significant influence of the microstructure on the corrosion resistance of the coatings. Potentiodynamic polarization and electrochemical impendence spectroscopy (EIS) results showed that the WC-10Co-4Cr cermet coating obtained by the optimum spraying condition with the lowest porosity exhibits the best corrosion resistance and seems to be an alternative to hard chromium coating.

  1. Heat Transfer Modeling of an Annular On-Line Spray Water Cooling Process for Electric-Resistance-Welded Steel Pipe

    PubMed Central

    Chen, Zejun; Han, Huiquan; Ren, Wei; Huang, Guangjie

    2015-01-01

    On-line spray water cooling (OSWC) of electric-resistance-welded (ERW) steel pipes can replace the conventional off-line heat treatment process and become an important and critical procedure. The OSWC process improves production efficiency, decreases costs, and enhances the mechanical properties of ERW steel pipe, especially the impact properties of the weld joint. In this paper, an annular OSWC process is investigated based on an experimental simulation platform that can obtain precise real-time measurements of the temperature of the pipe, the water pressure and flux, etc. The effects of the modes of annular spray water cooling and related cooling parameters on the mechanical properties of the pipe are investigated. The temperature evolutions of the inner and outer walls of the pipe are measured during the spray water cooling process, and the uniformity of mechanical properties along the circumferential and longitudinal directions is investigated. A heat transfer coefficient model of spray water cooling is developed based on measured temperature data in conjunction with simulation using the finite element method. Industrial tests prove the validity of the heat transfer model of a steel pipe undergoing spray water cooling. The research results can provide a basis for the industrial application of the OSWC process in the production of ERW steel pipes. PMID:26201073

  2. Heat Transfer Modeling of an Annular On-Line Spray Water Cooling Process for Electric-Resistance-Welded Steel Pipe.

    PubMed

    Chen, Zejun; Han, Huiquan; Ren, Wei; Huang, Guangjie

    2015-01-01

    On-line spray water cooling (OSWC) of electric-resistance-welded (ERW) steel pipes can replace the conventional off-line heat treatment process and become an important and critical procedure. The OSWC process improves production efficiency, decreases costs, and enhances the mechanical properties of ERW steel pipe, especially the impact properties of the weld joint. In this paper, an annular OSWC process is investigated based on an experimental simulation platform that can obtain precise real-time measurements of the temperature of the pipe, the water pressure and flux, etc. The effects of the modes of annular spray water cooling and related cooling parameters on the mechanical properties of the pipe are investigated. The temperature evolutions of the inner and outer walls of the pipe are measured during the spray water cooling process, and the uniformity of mechanical properties along the circumferential and longitudinal directions is investigated. A heat transfer coefficient model of spray water cooling is developed based on measured temperature data in conjunction with simulation using the finite element method. Industrial tests prove the validity of the heat transfer model of a steel pipe undergoing spray water cooling. The research results can provide a basis for the industrial application of the OSWC process in the production of ERW steel pipes. PMID:26201073

  3. Comparison of the Mechanical and Electrochemical Properties of WC-25Co Coatings Obtained by High Velocity Oxy-Fuel and Cold Gas Spraying

    NASA Astrophysics Data System (ADS)

    Couto, M.; Dosta, S.; Fernández, J.; Guilemany, J. M.

    2014-12-01

    Cold gas spray (CGS) coatings were previously produced by spraying WC-25Co cermet powders onto Al7075-T6 and low-carbon steel substrates. Unlike conventional flame spray techniques (e.g., high-velocity oxy-fuel; HVOF), no melting of the powder occurs; the particles are deformed and bond together after being sprayed by a supersonic jet of compressed gas, thereby building up several layers and forming a coating. WC-Co cermets are used in wear-resistant parts, because of their combination of mechanical, physical, and chemical properties. XRD tests were previously run on the initial powder and the coatings to determine possible phase changes during spraying. The bonding strength of the coatings was measured by adhesion tests. Here, WC-25Co coatings were also deposited on the same substrates by HVOF spraying. The wear resistance and fracture toughness of the coatings obtained previously by CGS and the HVOF coatings obtained here were studied. Their corrosion resistance was determined by electrochemical measurements. It was possible to achieve thick, dense, and hard CGS coatings on Al7075-T6 and low-carbon steel substrates, with better or the same mechanical and electrochemical properties as those of the HVOF coatings; making the former a highly competitive method for producing WC-25Co coatings.

  4. Finite Element Modeling and Analysis of Powder Stream in Low Pressure Cold Spray Process

    NASA Astrophysics Data System (ADS)

    Goyal, Tarun; Walia, Ravinderjit Singh; Sharma, Prince; Sidhu, Tejinder Singh

    2016-07-01

    Low pressure cold gas dynamic spray (LPCGDS) is a coating process that utilize low pressure gas (5-10 bars instead of 25-30 bars) and the radial injection of powder instead of axial injection with the particle range (1-50 μm). In the LPCGDS process, pressurized compressed gas is accelerated to the critical velocity, which depends on length of the divergent section of nozzle, the propellant gas and particle characteristics, and the diameters ratio of the inlet and outer diameters. This paper presents finite element modeling (FEM) of powder stream in supersonic nozzle wherein adiabatic gas flow and expansion of gas occurs in uniform manner and the same is used to evaluate the resultant temperature and velocity contours during coating process. FEM analyses were performed using commercial finite volume package, ANSYS CFD FLUENT. The results are helpful to predict the characteristics of powder stream at the exit of the supersonic nozzle.

  5. Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

    NASA Astrophysics Data System (ADS)

    Xu, Jia; Zhou, Zhen-yu; Piao, Zhong-yu

    2016-07-01

    The accumulated damage process of rolling contact fatigue (RCF) of plasma-sprayed coatings was investigated. The influences of surface roughness, loading condition, and stress cycle frequency on the accumulated damage status of the coatings were discussed. A ball-ondisc machine was employed to conduct RCF experiments. Acoustic emission (AE) technique was introduced to monitor the RCF process of the coatings. AE signal characteristics were investigated to reveal the accumulated damage process. Result showed that the polished coating would resist the asperity contact and remit accumulated damage. The RCF lifetime would then extend. Heavy load would aggravate the accumulated damage status and induce surface fracture. Wear became the main failure mode that reduced the RCF lifetime. Frequent stress cycle would aggravate the accumulated damage status and induce interface fracture. Fatigue then became the main failure mode that also reduced the RCF lifetime.

  6. Finite Element Modeling and Analysis of Powder Stream in Low Pressure Cold Spray Process

    NASA Astrophysics Data System (ADS)

    Goyal, Tarun; Walia, Ravinderjit Singh; Sharma, Prince; Sidhu, Tejinder Singh

    2016-05-01

    Low pressure cold gas dynamic spray (LPCGDS) is a coating process that utilize low pressure gas (5-10 bars instead of 25-30 bars) and the radial injection of powder instead of axial injection with the particle range (1-50 μm). In the LPCGDS process, pressurized compressed gas is accelerated to the critical velocity, which depends on length of the divergent section of nozzle, the propellant gas and particle characteristics, and the diameters ratio of the inlet and outer diameters. This paper presents finite element modeling (FEM) of powder stream in supersonic nozzle wherein adiabatic gas flow and expansion of gas occurs in uniform manner and the same is used to evaluate the resultant temperature and velocity contours during coating process. FEM analyses were performed using commercial finite volume package, ANSYS CFD FLUENT. The results are helpful to predict the characteristics of powder stream at the exit of the supersonic nozzle.

  7. Distributed generation - the fuel processing example

    SciTech Connect

    Victor, R.A.; Farris, P.J.; Maston, V.

    1996-12-31

    The increased costs of transportation and distribution are leading many commercial and industrial firms to consider the on-site generation for energy and other commodities used in their facilities. This trend has been accelerated by the development of compact, efficient processes for converting basic raw materials into finished services at the distributed sites. Distributed generation with the PC25{trademark} fuel cell power plant is providing a new cost effective technology to meet building electric and thermal needs. Small compact on-site separator systems are providing nitrogen and oxygen to many industrial users of these gases. The adaptation of the fuel processing section of the PC25 power plant for on-site hydrogen generation at industrial sites extends distributed generation benefits to the users of industrial hydrogen.

  8. Prediction of soot and thermal radiation in a model gas turbine combustor burning kerosene fuel spray at different swirl levels

    NASA Astrophysics Data System (ADS)

    Ghose, Prakash; Patra, Jitendra; Datta, Amitava; Mukhopadhyay, Achintya

    2016-05-01

    Combustion of kerosene fuel spray has been numerically simulated in a laboratory scale combustor geometry to predict soot and the effects of thermal radiation at different swirl levels of primary air flow. The two-phase motion in the combustor is simulated using an Eulerian-Lagragian formulation considering the stochastic separated flow model. The Favre-averaged governing equations are solved for the gas phase with the turbulent quantities simulated by realisable k-ɛ model. The injection of the fuel is considered through a pressure swirl atomiser and the combustion is simulated by a laminar flamelet model with detailed kinetics of kerosene combustion. Soot formation in the flame is predicted using an empirical model with the model parameters adjusted for kerosene fuel. Contributions of gas phase and soot towards thermal radiation have been considered to predict the incident heat flux on the combustor wall and fuel injector. Swirl in the primary flow significantly influences the flow and flame structures in the combustor. The stronger recirculation at high swirl draws more air into the flame region, reduces the flame length and peak flame temperature and also brings the soot laden zone closer to the inlet plane. As a result, the radiative heat flux on the peripheral wall decreases at high swirl and also shifts closer to the inlet plane. However, increased swirl increases the combustor wall temperature due to radial spreading of the flame. The high incident radiative heat flux and the high surface temperature make the fuel injector a critical item in the combustor. The injector peak temperature increases with the increase in swirl flow mainly because the flame is located closer to the inlet plane. On the other hand, a more uniform temperature distribution in the exhaust gas can be attained at the combustor exit at high swirl condition.

  9. Experimental investigation of synfuel spray characteristics and combustion dynamics. Quarterly technical progress report, January 1-March 31, 1981

    SciTech Connect

    1981-04-01

    Objective is to study both petroleum-based oils and synthetic fuels in spray combustion, by using advanced optical diagnostic techniques to study the processes of fuel injection and atomization, droplet ignition, and spray flame combustion. During this period, efforts were focused on the completion of the cold spray test facility, the design of the monodisperse droplet combustor, and the construction of an oil burner with the gathering of preliminary holography data. (DLC)

  10. Vacuum plasma spray coating

    NASA Technical Reports Server (NTRS)

    Holmes, Richard R.; Mckechnie, Timothy N.

    1989-01-01

    Currently, protective plasma spray coatings are applied to space shuttle main engine turbine blades of high-performance nickel alloys by an air plasma spray process. Originally, a ceramic coating of yttria-stabilized zirconia (ZrO2.12Y2O3) was applied for thermal protection, but was removed because of severe spalling. In vacuum plasma spray coating, plasma coatings of nickel-chromium-aluminum-yttrium (NiCrAlY) are applied in a reduced atmosphere of argon/helium. These enhanced coatings showed no spalling after 40 MSFC burner rig thermal shock cycles between 927 C (1700 F) and -253 C (-423 F), while current coatings spalled during 5 to 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2.8Y2O3 to the turbine blades of first-stage high-pressure fuel turbopumps utilizing the enhanced NiCrAlY bond-coating process. NiCrAlY bond coating is applied first, with ZrO2.8Y2O3 added sequentially in increasing amounts until a thermal barrier coating is obtained. The enchanced thermal barrier coating has successfully passed 40 burner rig thermal shock cycles.

  11. A discrete element based simulation framework to investigate particulate spray deposition processes

    SciTech Connect

    Mukherjee, Debanjan Zohdi, Tarek I.

    2015-06-01

    This work presents a computer simulation framework based on discrete element method to analyze manufacturing processes that comprise a loosely flowing stream of particles in a carrier fluid being deposited on a target surface. The individual particulate dynamics under the combined action of particle collisions, fluid–particle interactions, particle–surface contact and adhesive interactions is simulated, and aggregated to obtain global system behavior. A model for deposition which incorporates the effect of surface energy, impact velocity and particle size, is developed. The fluid–particle interaction is modeled using appropriate spray nozzle gas velocity distributions and a one-way coupling between the phases. It is found that the particle response times and the release velocity distribution of particles have a combined effect on inter-particle collisions during the flow along the spray. It is also found that resolution of the particulate collisions close to the target surface plays an important role in characterizing the trends in the deposit pattern. Analysis of the deposit pattern using metrics defined from the particle distribution on the target surface is provided to characterize the deposition efficiency, deposit size, and scatter due to collisions.

  12. A discrete element based simulation framework to investigate particulate spray deposition processes

    NASA Astrophysics Data System (ADS)

    Mukherjee, Debanjan; Zohdi, Tarek I.

    2015-06-01

    This work presents a computer simulation framework based on discrete element method to analyze manufacturing processes that comprise a loosely flowing stream of particles in a carrier fluid being deposited on a target surface. The individual particulate dynamics under the combined action of particle collisions, fluid-particle interactions, particle-surface contact and adhesive interactions is simulated, and aggregated to obtain global system behavior. A model for deposition which incorporates the effect of surface energy, impact velocity and particle size, is developed. The fluid-particle interaction is modeled using appropriate spray nozzle gas velocity distributions and a one-way coupling between the phases. It is found that the particle response times and the release velocity distribution of particles have a combined effect on inter-particle collisions during the flow along the spray. It is also found that resolution of the particulate collisions close to the target surface plays an important role in characterizing the trends in the deposit pattern. Analysis of the deposit pattern using metrics defined from the particle distribution on the target surface is provided to characterize the deposition efficiency, deposit size, and scatter due to collisions.

  13. Fabrication and Microstructure of Hydroxyapatite Coatings on Zirconia by Room Temperature Spray Process.

    PubMed

    Seo, Dong Seok; Chae, Hak Cheol; Lee, Jong Kook

    2015-08-01

    Hydroxyapatite coatings were fabricated on zirconia substrates by a room temperature spray process and were investigated with regards to their microstructure, composition and dissolution in water. An initial hydroxyapatite powder was prepared by heat treatment of bovine-bone derived powder at 1100 °C for 2 h, while dense zirconia substrates were fabricated by pressing 3Y-TZP powder and sintering it at 1350 °C for 2 h. Room temperature spray coating was performed using a slit nozzle in a low pressure-chamber with a controlled coating time. The phase composition of the resultant hydroxyapatite coatings was similar to that of the starting powder, however, the grain size of the hydroxyapatite particles was reduced to about 100 nm due to their formation by particle impaction and fracture. All areas of the coating had a similar morphology, consisting of reticulated structure with a high surface roughness. The hydroxyapatite coating layer exhibited biostability in a stimulated body fluid, with no severe dissolution being observed during in vitro experimentation. PMID:26369194

  14. Quantitative fuel vapor/air mixing imaging in droplet/gas regions of an evaporating spray flow using filtered Rayleigh scattering.

    PubMed

    Allison, Patton M; McManus, Thomas A; Sutton, Jeffrey A

    2016-03-15

    This Letter demonstrates the application of filtered Rayleigh scattering (FRS) for quantitative two-dimensional fuel vapor/air mixing measurements in an evaporating hydrocarbon fuel spray flow. Using the FRS approach, gas-phase measurements are made in the presence of liquid-phase droplets without interference. Effective suppression of the liquid-phase droplet scattering using FRS is enabled by the high spectral purity of the current Nd:YAG laser system. Simultaneous Mie-scattering imaging is used to visualize the droplet field and illustrate the droplet loading under which the FRS imaging is applied in the current spray flows. The initial quantification of the FRS imaging is based on calibration measurements from a flow cell of known fuel vapor/air mixtures, while future work targets the utilization of a Rayleigh-Brillouin spectral model for quantification of the FRS signals. PMID:26977637

  15. A particle temperature sensor for monitoring and control of the thermal spray process

    SciTech Connect

    Swank, W.D.; Fincke, J.R.; Haggard, D.C.

    1995-12-01

    The temperature and velocity of thermally sprayed particles prior to their impact on the substrate are two of the predominant determinants of coating quality and characteristics. This paper describes an instrument developed for real time monitoring of in-flight particle temperature in an industrial environment. The instrument is designed to operate as a stand alone device for verifying that a desired particle temperature is attained or for developing process settings to yield a particular temperature. The device is also suitable for incorporation into a closed loop process controller. Data showing the relationship between torch parameters and average particle temperature are presented. There is good agreement between previous measurements using laboratory instrumentation and the simpler, industrially hardened technique described here. The assumption of gray body behavior is evaluated and for known emissivities corrections are developed.

  16. Tungsten Coating on Low Activation Vanadium Alloy by Plasma Spray Process

    SciTech Connect

    Nagasaka, Takuya; Muroga, Takeo; Noda, Nobuaki; Kawamura, Masashi; Ise, Hideo; Kurishita, Hiroaki

    2005-05-15

    Tungsten (W) coating on fusion candidate V-4Cr-4Ti (NIFS-HEAT-2) substrate was demonstrated with plasma spray process for the purpose of applying to protection of the plasma facing surface of a fusion blanket. Increase in plasma input power and temperature of the substrate was effective to reduce porosity of the coating, but resulted in hardening of the substrate and degradation of impact property at 77 K. The hardening seemed to be due to contamination with gaseous impurities and deformation by thermal stress during the coating process. Since all the samples showed good ductility at room temperature, further heating seems to be acceptable for the vanadium substrate. The fracture stress of the W coating was estimated from bending tests as at least 313 MPa, which well exceeds the design stress for the vanadium structure in fusion blanket.

  17. External characteristics of unsteady spray atomization from a nasal spray device.

    PubMed

    Fung, Man Chiu; Inthavong, Kiao; Yang, William; Lappas, Petros; Tu, Jiyuan

    2013-03-01

    The nasal route presents an enormous opportunity to exploit the highly vascularized respiratory airway for systemic drug delivery to provide more rapid onset of therapy and reduced drug degradation compared with conventional oral routes. The dynamics of atomization at low injection pressure is less known as typical spray atomization studies have focused on industrial applications such as fuel injection that are performed at much higher pressure. An experimental test station was designed in house and an alternative method to characterize the external spray is presented. This involved the use of high-speed camera to capture the temporal development of the spray as it is atomized through actuation of the spray device. An image-processing technique based on edge detection was developed to automate processing through the large number of images captured. The results showed that there are three main phases of spray development (prestable, stable, and poststable) that can be correlated by examining the spray width. A comparison with a human nasal cavity is made to put into perspective the dimensions and geometry that the spray atomization produces. This study aimed to extend the current existing set of data to contribute toward a better understanding in nasal spray drug delivery. PMID:23303644

  18. Spray momentum measuring system

    NASA Technical Reports Server (NTRS)

    Sheffield, E. W.

    1971-01-01

    Technique enables accurate prediction of erosion and cavitation produced by fluid spray. Method measures high velocity sprays produced by small orifices. Originally designed to determine oxidizer-injection patterns of liquid fueled rocket engines, technique is used with other liquids, or, with appropriate modification, with gases.

  19. Pyroprocess for processing spent nuclear fuel

    DOEpatents

    Miller, William E.; Tomczuk, Zygmunt

    2002-01-01

    This is a pyroprocess for processing spent nuclear fuel. The spent nuclear fuel is chopped into pieces and placed in a basket which is lowered in to a liquid salt solution. The salt is rich in ZrF.sub.4 and containing alkali or alkaline earth fluorides, and in particular, the salt chosen was LiF-50 mol % ZrF.sub.4 with a eutectic melting point of 500.degree. C. Prior to lowering the basket, the salt is heated to a temperature of between 550.degree. C. and 700.degree. C. in order to obtain a molten solution. After dissolution the oxides of U, Th, rare earth and other like oxides, the salt bath solution is subject to hydro-fluorination to remove the oxygen and then to a fluorination step to remove U as gaseous UF.sub.6. In addition, after dissolution, the basket contains PuO.sub.2 and undissolved parts of the fuel rods, and the basket and its contents are processed to remove the Pu.

  20. Development of Advanced LED Phosphors by Spray-based Processes for Solid State Lighting

    SciTech Connect

    Cabot Corporation

    2007-09-30

    The overarching goal of the project was to develop luminescent materials using aerosol processes for making improved LED devices for solid state lighting. In essence this means improving white light emitting phosphor based LEDs by improvement of the phosphor and phosphor layer. The structure of these types of light sources, displayed in Figure 1, comprises of a blue or UV LED under a phosphor layer that converts the blue or UV light to a broad visible (white) light. Traditionally, this is done with a blue emitting diode combined with a blue absorbing, broadly yellow emitting phosphor such as Y{sub 3}Al{sub 5}O{sub 12}:Ce (YAG). A similar result may be achieved by combining a UV emitting diode and at least three different UV absorbing phosphors: red, green, and blue emitting. These emitted colors mix to make white light. The efficiency of these LEDs is based on the combined efficiency of the LED, phosphor, and the interaction between the two. The Cabot SSL project attempted to improve the over all efficiency of the LED light source be improving the efficiency of the phosphor and the interaction between the LED light and the phosphor. Cabot's spray based process for producing phosphor powders is able to improve the brightness of the powder itself by increasing the activator (the species that emits the light) concentration without adverse quenching effects compared to conventional synthesis. This will allow less phosphor powder to be used, and will decrease the cost of the light source; thus lowering the barrier of entry to the lighting market. Cabot's process also allows for chemical flexibility of the phosphor particles, which may result in tunable emission spectra and so light sources with improved color rendering. Another benefit of Cabot's process is the resulting spherical morphology of the particles. Less light scattering results when spherical particles are used in the phosphor layer (Figure 1) compared to when conventional, irregular shaped phosphor particles

  1. A new high-velocity oxygen fuel process for making finely structured and highly bonded inconel alloy layers from liquid feedstock

    NASA Astrophysics Data System (ADS)

    Ma, X. Q.; Roth, J.; Gandy, D. W.; Frederick, G. J.

    2006-12-01

    High-velocity oxygen fuel (HVOF) thermal spray processes are used in applications requiring the highest density and adhesion strength, which are not achievable in most other thermal spray processes. Similar to other thermal spray processes, however, a normal HVOF process is unable to apply fine powders less than 10 µm via a powder feeder. The advantages of using smaller and even nanosized particles in a HVOF process include uniform microstructure, higher cohesion and adhesion, full density, lower internal stress, and higher deposition efficiency. In this work, a new process has been developed for HVOF forming of fine-grained Inconel 625 alloy layers using a liquid feedstock containing small alloy particles. Process investigations have shown the benefits of making single and duplex layered coatings with full density and high bond strength, which are attributed to the very high kinetic energy of particles striking on the substrates and the better melting of the small particles.

  2. Computational fluid dynamic modeling of gas flow characteristics in a high-velocity oxy-fuel thermal spray system

    NASA Astrophysics Data System (ADS)

    Gu, S.; Eastwick, C. N.; Simmons, K. A.; McCartney, D. G.

    2001-09-01

    A computational fluid dynamics (CFD) model is developed to predict gas dynamic behavior in a high-velocity oxy-fuel (HVOF) thermal spray gun in which premixed oxygen and propylene are burnt in a 12 mm combustion chamber linked to a parallel-sided nozzle. The CFD analysis is applied to investigate axisymmetric, steady-state, turbulent, compressible, and chemically combusting flow both within the gun and in a free jet region between the gun and the substrate to be coated. The combustion of oxygen and propylene is modeled using a single-step, finite-rate chemistry model that also allows for dissociation of the reaction products. Results are presented to show the effect of (1) fuel-to-oxygen gas ratio and (2) total gas flow rate on the gas dynamic behavior. Along the centerline, the maximum temperature reached is insensitive to the gas ratio but depends on the total flow. However, the value attained (˜2500 K) is significantly lower than the maximum temperature (˜3200 K) of the annular flame in the combustion chamber. By contrast, the centerline gas velocity depends on both total flow and gas ratio, the highest axial gas velocity being attained with the higher flow and most fuel-rich mixture. The gas Mach number increases through the gun and reaches a maximum value of approximately 1.6 around 5 mm downstream from the nozzle exit. The numerical calculations also show that the residual oxygen level is principally dependent on the fuel-to-oxygen ratio and decreases by approximately fivefold as the ratio is varied from 90 to 69% of the stoichiometric requirement. The CFD model is also used to investigate the effect of changes in combustion chamber size and geometry on gas dynamics, and the results are compared with the nominal 12 mm chamber baseline calculations.

  3. Critical processing parameters of carbon dioxide spray drying for the production of dried protein formulations: A study with myoglobin.

    PubMed

    Nuchuchua, O; Every, H A; Jiskoot, W

    2016-06-01

    The aim of this study was to gain fundamental insight into protein destabilization induced by supercritical CO2 spray drying processing parameters. Myoglobin was used as a model protein (5mg/ml with 50mg/ml trehalose in 10mM phosphate buffer, pH 6.2). The solution was exposed to sub- and supercritical CO2 conditions (65-130bar and 25-50°C), and CO2 spray drying under those conditions. The heme binding of myoglobin was determined by UV/Vis, fluorescence, and circular dichroism spectroscopy, while myoglobin aggregation was studied by using size-exclusion chromatography and flow imaging microscopy. It was found that pressure and temperature alone did not influence myoglobin's integrity. However, when pressurized CO2 was introduced into myoglobin solutions at any condition, the pH of the myoglobin formulation shifted to about 5 (measured after depressurization), resulting in heme binding destabilization and aggregation of myoglobin. When exposed to CO2, these degradation processes were enhanced by increasing temperature. Heme binding destabilization and myoglobin aggregation were also seen after CO2 spray drying, and to a greater extent. Moreover, the CO2 spray drying induced the partial loss of heme. In conclusion, pressurized CO2 destabilizes the myoglobin, leading to heme loss and protein aggregation upon spray drying. PMID:27080205

  4. Influence of NH4Cl Powder Addition for Fabrication of Aluminum Nitride Coating in Reactive Atmospheric Plasma Spray Process

    NASA Astrophysics Data System (ADS)

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

    2011-01-01

    Reactive plasma spray is the key to fabricating aluminum nitride (AlN) thermally sprayed coatings. It was possible to fabricate AlN/Al composite coatings using atmospheric plasma spray process through plasma nitriding of Al powders (Al 30 μm). The nitriding reaction and the AlN content could be improved by controlling the spray distance and the feedstock powder particle size. Increasing the spray distance and/or using smaller particle size of Al powders improved the in-flight nitriding reaction. However, it was difficult to fabricate thick and dense AlN coatings with an increase in the spray distance and/or when using fine particles. Thus, the coatings thickness was suppressed because of the complete nitriding of some particles (formation of AlN particles) during flight, which prevents the particle deposition. Furthermore, the excessive vaporization of Al fine particles (due to increased particle temperature) decreased the deposition efficiency. To fabricate thick AlN coatings in the reactive plasma spray process, improving the nitriding reaction of the large Al particles at short spray distance is required to decrease the vaporization of Al particles during flight. This study investigated the influence of adding ammonium chloride (NH4Cl) powders on the nitriding process of large Al powders and on the microstructure of the fabricated coatings. It was possible to fabricate thick AlN coatings at 100 mm spray distance with small addition of NH4Cl powders to the Al feedstock powders (30 μm). Addition of NH4Cl to the starting Al powders promoted the formation of AlN through changing the reaction path to vapor-phase nitridation chlorination-nitridation sequences as confirmed by the thermodynamic analysis of possible intermediate reactions. This changes the nitriding reaction to a mild way, so it is more controlled with no explosive mode and with relatively low heating rates. Thus, NH4Cl acts as a catalyst, nitrogen source, and diluent agent. Furthermore, the evolved

  5. A Novel Hybrid Axial-Radial Atmospheric Plasma Spraying Technique for the Fabrication of Solid Oxide Fuel Cell Anodes Containing Cu, Co, Ni, and Samaria-Doped Ceria

    NASA Astrophysics Data System (ADS)

    Cuglietta, Mark; Kuhn, Joel; Kesler, Olivera

    2013-06-01

    Composite coatings containing Cu, Co, Ni, and samaria-doped ceria (SDC) have been fabricated using a novel hybrid atmospheric plasma spraying technique, in which a multi-component aqueous suspension of CuO, Co3O4, and NiO was injected axially simultaneously with SDC injected radially in a dry powder form. Coatings were characterized for their microstructure, permeability, porosity, and composition over a range of plasma spray conditions. Deposition efficiency of the metal oxides and SDC was also estimated. Depending on the conditions, coatings displayed either layering or high levels of mixing between the SDC and metal phases. The deposition efficiencies of both feedstock types were strongly dependent on the nozzle diameter. Plasma-sprayed metal-supported solid oxide fuel cells utilizing anodes fabricated with this technique demonstrated power densities at 0.7 V as high as 366 and 113 mW/cm2 in humidified hydrogen and methane, respectively, at 800 °C.

  6. Formulation Development, Process Optimization, and In Vitro Characterization of Spray-Dried Lansoprazole Enteric Microparticles

    PubMed Central

    Vora, Chintan; Patadia, Riddhish; Mittal, Karan; Mashru, Rajashree

    2016-01-01

    This research focuses on the development of enteric microparticles of lansoprazole in a single step by employing the spray drying technique and studies the effects of variegated formulation/process variables on entrapment efficiency and in vitro gastric resistance. Preliminary trials were undertaken to optimize the type of Eudragit and its various levels. Further trials included the incorporation of plasticizer triethyl citrate and combinations of other polymers with Eudragit S 100. Finally, various process parameters were varied to investigate their effects on microparticle properties. The results revealed Eudragit S 100 as the paramount polymer giving the highest gastric resistance in comparison to Eudragit L 100-55 and L 100 due to its higher pH threshold and its polymeric backbone. Incorporation of plasticizer not only influenced entrapment efficiency, but diminished gastric resistance severely. On the contrary, polymeric combinations reduced entrapment efficiency for both sodium alginate and glyceryl behenate, but significantly influenced gastric resistance for only sodium alginate and not for glyceryl behenate. The optimized process parameters were comprised of an inlet temperature of 150°C, atomizing air pressure of 2 kg/cm2, feed solution concentration of 6% w/w, feed solution spray rate of 3 ml/min, and aspirator volume of 90%. The SEM analysis revealed smooth and spherical shape morphologies. The DSC and PXRD study divulged the amorphous nature of the drug. Regarding stability, the product was found to be stable under 3 months of accelerated and long-term stability conditions as per ICH Q1A(R2) guidelines. Thus, the technique offers a simple means to generate polymeric enteric microparticles that are ready to formulate and can be directly filled into hard gelatin capsules. PMID:27222612

  7. Formulation Development, Process Optimization, and In Vitro Characterization of Spray-Dried Lansoprazole Enteric Microparticles.

    PubMed

    Vora, Chintan; Patadia, Riddhish; Mittal, Karan; Mashru, Rajashree

    2016-01-01

    This research focuses on the development of enteric microparticles of lansoprazole in a single step by employing the spray drying technique and studies the effects of variegated formulation/process variables on entrapment efficiency and in vitro gastric resistance. Preliminary trials were undertaken to optimize the type of Eudragit and its various levels. Further trials included the incorporation of plasticizer triethyl citrate and combinations of other polymers with Eudragit S 100. Finally, various process parameters were varied to investigate their effects on microparticle properties. The results revealed Eudragit S 100 as the paramount polymer giving the highest gastric resistance in comparison to Eudragit L 100-55 and L 100 due to its higher pH threshold and its polymeric backbone. Incorporation of plasticizer not only influenced entrapment efficiency, but diminished gastric resistance severely. On the contrary, polymeric combinations reduced entrapment efficiency for both sodium alginate and glyceryl behenate, but significantly influenced gastric resistance for only sodium alginate and not for glyceryl behenate. The optimized process parameters were comprised of an inlet temperature of 150°C, atomizing air pressure of 2 kg/cm(2), feed solution concentration of 6% w/w, feed solution spray rate of 3 ml/min, and aspirator volume of 90%. The SEM analysis revealed smooth and spherical shape morphologies. The DSC and PXRD study divulged the amorphous nature of the drug. Regarding stability, the product was found to be stable under 3 months of accelerated and long-term stability conditions as per ICH Q1A(R2) guidelines. Thus, the technique offers a simple means to generate polymeric enteric microparticles that are ready to formulate and can be directly filled into hard gelatin capsules. PMID:27222612

  8. Low platinum loading for high temperature proton exchange membrane fuel cell developed by ultrasonic spray coating technique

    NASA Astrophysics Data System (ADS)

    Su, Huaneng; Jao, Ting-Chu; Barron, Olivia; Pollet, Bruno G.; Pasupathi, Sivakumar

    2014-12-01

    This paper reports use of an ultrasonic-spray for producing low Pt loadings membrane electrode assemblies (MEAs) with the catalyst coated substrate (CCS) fabrication technique. The main MEA sub-components (catalyst, membrane and gas diffusion layer (GDL)) are supplied from commercial manufacturers. In this study, high temperature (HT) MEAs with phosphoric acid (PA)-doped poly(2,5-benzimidazole) (AB-PBI) membrane are fabricated and tested under 160 °C, hydrogen and air feed 100 and 250 cc min-1 and ambient pressure conditions. Four different Pt loadings (from 0.138 to 1.208 mg cm-2) are investigated in this study. The experiment data are determined by in-situ electrochemical methods such as polarization curve, electrochemical impedance spectroscopy (EIS) and cyclic voltammetry (CV). The high Pt loading MEA exhibits higher performance at high voltage operating conditions but lower performances at peak power due to the poor mass transfer. The Pt loading 0.350 mg cm-2 GDE performs the peak power density and peak cathode mass power to 0.339 W cm-2 and 0.967 W mgPt-1, respectively. This work presents impressive cathode mass power and high fuel cell performance for high temperature proton exchange membrane fuel cells (HT-PEMFCs) with low Pt loadings.

  9. Thermal interaction between WC-Co coating and steel substrate in process of HVOF spraying

    SciTech Connect

    Guilemany, J.M.; Sobolev, V.V.; Nutting, J.; Dong, Z.; Calero, J.A. . Metalurgia Fisica-Ciencia de Materials)

    1994-10-01

    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.

  10. Influence of plasma spraying deposition process on optical properties of hydroxyapatite

    NASA Astrophysics Data System (ADS)

    Belka, Radosław; Kowalski, Szymon; Żórawski, Wojciech; Suchańska, Małgorzata

    2015-09-01

    Hydroxyapatite (HAp) is a well-known bioceramic, nonorganic material of the bones of the vertebrate responsible for their mechanical durability. In human bones it occupies 60-80 % of the volume depending on a number of factors. Synthetic HAp is valued in bone endoprosthetic to its high biocompatibility. It is widely used to fill cavities of bone and as the coating of bone implants to increase their biocompatibility and adhesion to bone surface. In this paper a diffuse reflectance spectra of plasma-spraying deposited hydroxyapatite were presented and compared with pure powder samples. Optical band gap were estimated basing on Kubelka-Munk functions and Tauc plot extrapolation. We found that deposition process affects the value of band gap.

  11. Improvement on droplet production rate of ultrasonic - nebulizer in spray pyrolysis process

    NASA Astrophysics Data System (ADS)

    Panatarani, Camellia; Demen, Tuti Aryati; Men, Liu Kin; Maulana, Dwindra Wilham; Hidayat, Darmawan; Joni, I. Made

    2013-09-01

    Atomization is an important part in Spray Pyrolysis (SP) process which is applied to synthesize submicron or nano sized particles or to deposit thin film. Ultrasonic Nebulizer (UN) is usually use in SP due to its homogeneous droplets production with size between 1-5 μm. The drawback of the UN is low droplets production rate. In this research, we successfully developed a Digital Ultrasonic Nebulizer (DUN) with high droplets production rate using two ultrasonic traducers with applied frequency of 2.4 MHz. The result of DUN atomization was improved 4-6 fold compare to the conventional UN. The DUN also has an additional digital features such as pushbutton, LCD and microcontroller which is allow to set duration and applied voltage.

  12. A deep look into the spray coating process in real-time-the crucial role of x-rays.

    PubMed

    Roth, Stephan V

    2016-10-12

    Tailoring functional thin films and coating by rapid solvent-based processes is the basis for the fabrication of large scale high-end applications in nanotechnology. Due to solvent loss of the solution or dispersion inherent in the installation of functional thin films and multilayers the spraying and drying processes are strongly governed by non-equilibrium kinetics, often passing through transient states, until the final structure is installed. Therefore, the challenge is to observe the structural build-up during these coating processes in a spatially and time-resolved manner on multiple time and length scales, from the nanostructure to macroscopic length scales. During installation, the interaction of solid-fluid interfaces and between the different layers, the flow and evaporation themselves determine the structure of the coating. Advanced x-ray scattering methods open a powerful pathway for observing the involved processes in situ, from the spray to the coating, and allow for gaining deep insight in the nanostructuring processes. This review first provides an overview over these rapidly evolving methods, with main focus on functional coatings, organic photovoltaics and organic electronics. Secondly the role and decisive advantage of x-rays is outlined. Thirdly, focusing on spray deposition as a rapidly emerging method, recent advances in investigations of spray deposition of functional materials and devices via advanced x-ray scattering methods are presented. PMID:27537198

  13. Beneficial effects of laser irradiation on the deposition process of diamond/Ni60 composite coating with cold spray

    NASA Astrophysics Data System (ADS)

    Yao, Jianhua; Yang, Lijing; Li, Bo; Li, Zhihong

    2015-03-01

    Although cold spray process has many unique advantages over other coating techniques, it has difficulties in depositing hard materials. This article presents a study in the beneficial effects of laser irradiation on the fabrication process of diamond/Ni60 composite coating using cold spray. The focus of this research is on the comparison between the composite coatings produced with laser cladding (LC) and with supersonic laser deposition (SLD), with respect to diamond graphitization and tribological properties, thus to demonstrate the beneficial effects of laser irradiation on the cold spray process. The influence of deposition temperature on the coating characteristics, such as deposition efficiency, diamond volume fraction, microstructure and phase is also investigated. The tribological properties of the diamond/Ni60 composite coating produced with SLD are determined using a pin-on-disc tribometer, along with the diamond/Ni60 coating produced using LC with the optimal process parameters for comparison. The experimental results show that with the assistance of laser irradiation, diamond/Ni60 composite coating can be successfully deposited using cold spray; the obtained coating is superior to that processed with LC, because SLD can suppress the graphitization of the diamond particles. The diamond/Ni60 composite coating fabricated with SLD has much better tribological properties than the LC coating.

  14. Situ process for making multifunctional fuel additives

    SciTech Connect

    Carrier, R.C.; Allen, B.R.

    1984-02-28

    Disclosed is an in situ or ''one pot'' process for making a fuel additive comprising reacting an excess of at least one N-primary alkylalkylene diamine with maleic anhydride in the presence of from 20 to 36 weight percent of a mineral oil reaction diluent at a temperature ranging from ambient to about 225/sup 0/ F. and recovering a product containing a primary aliphatic hydrocarbon amino alkylene substituted asparagine, an N-primary alkylalkylene diamine in the reaction oil with the product having a by-product succinimide content not in excess of 1.0 weight percent, based on the weight of asparagine present.

  15. Microstructural Characterization and Wear Behavior of Nano-Boride Dispersed Coating on AISI 304 Stainless Steel by Hybrid High Velocity Oxy-Fuel Spraying Laser Surface Melting

    NASA Astrophysics Data System (ADS)

    Sharma, Prashant; Majumdar, Jyotsna Dutta

    2015-07-01

    The current study concerns the detailed microstructural characterization and investigation of wear behavior of nano-boride dispersed coating developed on AISI 304 stainless steel by high velocity oxy-fuel spray deposition of nickel-based alloy and subsequent laser melting. There is a significant refinement and homogenization of microstructure with improvement in microhardness due to laser surface melting (1200 VHN as compared to 945 VHN of as-sprayed and 250 VHN of as-received substrate). The high temperature phase stability of the as-coated and laser melted surface has been studied by differential scanning calorimeter followed by detailed phase analysis at room and elevated temperature. There is a significant improvement in wear resistance of laser melted surface as compared to as-sprayed and the as-received one due to increased hardness and reduced coefficient of friction. The mechanism of wear has been investigated in details. Corrosion resistance of the coating in a 3.56 wt pct NaCl solution is significantly improved (4.43 E-2 mm/year as compared to 5 E-1 mm/year of as-sprayed and 1.66 mm/year of as-received substrate) due to laser surface melting as compared to as-sprayed surface.

  16. Nanostructured bioactive glass-ceramic coatings deposited by the liquid precursor plasma spraying process

    NASA Astrophysics Data System (ADS)

    Xiao, Yanfeng; Song, Lei; Liu, Xiaoguang; Huang, Yi; Huang, Tao; Wu, Yao; Chen, Jiyong; Wu, Fang

    2011-01-01

    Bioactive glass-ceramic coatings have great potential in dental and orthopedic medical implant applications, due to its excellent bioactivity, biocompatibility and osteoinductivity. However, most of the coating preparation techniques either produce only thin thickness coatings or require tedious preparation steps. In this study, a new attempt was made to deposit bioactive glass-ceramic coatings on titanium substrates by the liquid precursor plasma spraying (LPPS) process. Tetraethyl orthosilicate, triethyl phosphate, calcium nitrate and sodium nitrate solutions were mixed together to form a suspension after hydrolysis, and the liquid suspension was used as the feedstock for plasma spraying of P 2O 5-Na 2O-CaO-SiO 2 bioactive glass-ceramic coatings. The in vitro bioactivities of the as-deposited coatings were evaluated by soaking the samples in simulated body fluid (SBF) for 4 h, 1, 2, 4, 7, 14, and 21 days, respectively. The as-deposited coating and its microstructure evolution behavior under SBF soaking were systematically analyzed by scanning electron microscopy (SEM), X-ray diffraction (XRD), inductively coupled plasma (ICP), and Fourier transform infrared (FTIR) spectroscopy. The results showed that P 2O 5-Na 2O-CaO-SiO 2 bioactive glass-ceramic coatings with nanostructure had been successfully synthesized by the LPPS technique and the synthesized coatings showed quick formation of a nanostructured HCA layer after being soaked in SBF. Overall, our results indicate that the LPPS process is an effective and simple method to synthesize nanostructured bioactive glass-ceramic coatings with good in vitro bioactivity.

  17. Superomniphobic and easily repairable coatings on copper substrates based on simple immersion or spray processes.

    PubMed

    Rangel, Thomaz C; Michels, Alexandre F; Horowitz, Flávio; Weibel, Daniel E

    2015-03-24

    Textures that resemble typical fern or bracken plant species (dendrite structures) were fabricated for liquid repellency by dipping copper substrates in a single-step process in solutions containing AgNO3 or by a simple spray liquid application. Superhydrophobic surfaces were produced using a solution containing AgNO3 and trimethoxypropylsilane (TMPSi), and superomniphobic surfaces were produced by a two-step procedure, immersing the copper substrate in a AgNO3 solution and, after that, in a solution containing 1H,1H,2H,2H-perfluorodecyltriethoxysilane (PFDTES). The simple functionalization processes can also be used when the superomniphobic surfaces were destroyed by mechanical stress. By immersion of the wrecked surfaces in the above solutions or by the spray method and soft heating, the copper substrates could be easily repaired, regenerating the surfaces' superrepellency to liquids. The micro- and nanoroughness structures generated on copper surfaces by the deposition of silver dendrites functionalized with TMPSi presented apparent contact angles greater than 150° with a contact angle hysteresis lower than 10° when water was used as the test liquid. To avoid total wettability with very low surface tension liquids, such as rapeseed oil and hexadecane, a thin perfluorinated coating of poly(tetrafluoroethylene) (PTFE), produced by physical vapor deposition, was used. A more efficient perfluorinated coating was obtained when PFDTES was used. The superomniphobic surfaces produced apparent contact angles above 150° with all of the tested liquids, including hexadecane, although the contact angle hysteresis with this liquid was above 10°. The coupling of dendritic structures with TMPSi/PTFE or directly by PFDTES coatings was responsible for the superrepellency of the as-prepared surfaces. These simple, fast, and reliable procedures allow the large area, and cost-effective scale fabrication of superrepellent surfaces on copper substrates for various industrial

  18. In Situ fuel processing in a microbial fuel cell.

    PubMed

    Bahartan, Karnit; Amir, Liron; Israel, Alvaro; Lichtenstein, Rachel G; Alfonta, Lital

    2012-09-01

    A microbial fuel cell (MFC) was designed in which fuel is generated in the cell by the enzyme glucoamylase, which is displayed on the surface of yeast. The enzyme digests starch specifically into monomeric glucose units and as a consequence enables further glucose oxidation by microorganisms present in the MFC anode. The oxidative enzyme glucose oxidase was coupled to the glucoamylase digestive enzyme. When both enzymes were displayed on the surface of yeast cells in a mixed culture, superior fuel-cell performance was observed in comparison with other combinations of yeast cells, unmodified yeast, or pure enzymes. The feasibility of the use of the green macroalgae Ulva lactuca in such a genetically modified MFC was also demonstrated. Herein, we report the performance of such fuel cells as a proof of concept for the enzymatic digestion of complex organic fuels in the anode of MFCs to render the fuel more available to microorganisms. PMID:22833422

  19. Significance of chamber pressure to complex multi-phase physics in jet engine fuel injection processes

    NASA Astrophysics Data System (ADS)

    Dahms, Rainer; Oefelein, Joseph

    2014-11-01

    Injection processes in jet engines at chamber pressures in excess of the thermodynamic critical pressure of the liquid fuel are not well understood. Under some conditions, a distinct two-phase interface may not exist anymore which eliminates the presence of classical spray atomization phenomena. A comprehensive model for jet engine fuel injections is derived to quantify the conditions under which the interfacial dynamics transition to diffusion-dominated mixing processes without surface tension. At certain conditions, the model shows two-phase interfaces with substantially increased thicknesses and distinctively reduced mean free paths in comparison to ambient pressure conditions. Then, the underlying assumptions of a distinct two-phase interface do not apply anymore and the interface along with its surface tension is shown to deteriorate as it broadens substantially. As a consequence of this physical complexity, the conceptual view of spray atomization and evaporation as an appropriate model for jet engine injection processes is, contrary to conventional wisdom, questionable at certain operating conditions. Instead, a Large Eddy Simulation using a dense-fluid approximation is applied which takes the complex thermo-physics of real-fluid behavior into account.

  20. Towards a reliable laser spray powder deposition system through process characterization

    SciTech Connect

    Keicher, D.M.; Jellison, J.L.; Schanwald, L.P.; Romero, J.A.; Abbott, D.H.

    1995-07-01

    A series of experiments have been performed to characterize the laser spray powder deposition tea-one (HAZ) in the process. Goal of these experiments was to minimize the heat affected base substrate while obtaining a maximum build-up rate of the deposited material. Response surface models have been developed to achieve this goal. These models indicate that laser irradiance and component travel speed are both important factors to be considered in optimization of this process. These models suggest that a minimum HAZ can be obtained with a maximum material build-up height by maintaining with a slow travel speed. Although these models are useful in identifying significant factor and process trends, further refinement is required for practical use in industrial applications. Weighting of the response variables used in generating the models is being considered to improve the model robustness. High speed imaging of the deposition process suggests that the powder particle size and/or size distribution affects the stability of this process.

  1. First in-situ SAXS studies of the mesostructuration of spherical silica and titania particles during spray-drying process.

    PubMed

    Boissiere, C; Grosso, D; Amenitsch, H; Gibaud, A; Coupé, A; Baccile, N; Sanchez, C

    2003-11-21

    Meso-organisation of SiO2 and TiO2 particles prepared by spray drying have been for the first time analysed through in-situ SAXS. Both processing and chemical parameters are critical to obtain meso-organised spheres. PMID:14651110

  2. Alternative fuels utilization and the automotive emission certification process

    SciTech Connect

    Not Available

    1980-03-01

    The Clean Air Act of 1977 requires that commercially offered automotive fuels and fuel additives be substantially similar to fuels used in certifying model year 1975 and later vehicles. Procedures for certifying that vehicles perform with emissions that meet the Clean Air Act specifications and the impact of this emissions certification process on the use of alternative fuels, such as alcohols, alcohol-gasoline blends and synthetic fuels, in highway vehicles is discussed. (LCL)

  3. Chromium coatings by HVOF thermal spraying: Simulation and practical results

    SciTech Connect

    Knotek, O.; Lugscheider, E.; Jokiel, P.; Schnaut, U.; Wiemers, A.

    1994-12-31

    Within recent years High Velocity Oxygen-Fuel (HVOF) thermal spraying has been considered an asset to the family of thermal spraying processes. Especially for spray materials with melting points below 3,000 K it has proven successful, since it shows advantages when compared to coating processes that produce similar qualities. In order to enlarge the fields of thermal spraying applications into regions with rather low thickness, e.g. about 50--100 {micro}m, especially HVOF thermally sprayed coatings seem to be advantageous. The usual evaluation of optimized spraying parameters, including spray distance, traverse speed, gas flow rates etc. is, however, based on numerous and extensive experiments laid out by trial-and-error or statistical experimental design and thus being expensive: man-power and material is required, spray systems are occupied for experimental works and the optimal solution is questioned, for instance, when a new powder fraction or nozzle is used. In this paper the possibility of reducing such experimental efforts by using modeling and simulation is exemplified for producing thin chromium coatings with a CDS{trademark}-HVOF system. The aim is the production of thermally sprayed chromium coatings competing with galvanic hard chromium platings, which are applied to reduce friction and corrosion but are environmentally disadvantageous during their production.

  4. Current Status and Future Prospects of Warm Spray Technology

    NASA Astrophysics Data System (ADS)

    Kuroda, Seiji; Watanabe, Makoto; Kim, Keehyun; Katanoda, Hiroshi

    2011-06-01

    A modification of high-velocity oxy-fuel (HVOF) thermal spray process named as warm spray (WS) has been developed. By injecting room temperature inert gas into the combustion gas jet of HVOF, the temperature of the propellant gas can be controlled in a range approximately from 2300 to 1000 K so that many powder materials can be deposited in thermally softened state at high impact velocity. In this review, the characteristics of WS process were analyzed by using gas dynamic simulation of the flow field and heating/acceleration of powder particles in comparison with HVOF, cold spray (CS), and high-velocity air-fuel (HVAF) spray. Transmission electron microscopy of WS and CS titanium splats revealed marked differences in the microstructures stemming from the different impact temperatures. Mechanical properties of several metallic coatings formed under different WS and CS conditions were compared. Characteristics of WC-Co coatings made by WS were demonstrated for wear resistant applications.

  5. Connecting section and associated systems concept for the spray calciner/in-can melter process

    SciTech Connect

    Petkus, L.L.; Gorton, P.S.; Blair, H.T.

    1981-06-01

    For a number of years, researchers at the Pacific Northwest Laboratory have been developing processes and equipment for converting high-level liquid wastes to solid forms. One of these processes is the Spray Calciner/In-Can Melter system. To immobilize high-level liquid wastes, this system must be operated remotely, and the calcine must be reliably conveyed from the calciner to the melting furnace. A concept for such a remote conveyance system was developed at the Pacific Northwest Laboratory, and equipment was tested under full-scale, nonradioactive conditions. This concept and the design of demonstration equipment are described, and the results of equipment operation during experimental runs of 7 d are presented. The design includes a connecting section and its associated systems - a canister sypport and alignment concept and a weight-monitoring system for the melting furnace. Overall, the runs demonstrated that the concept design is an acceptable method of connecting the two pieces of process equipment together. Although the connecting section has not been optimized in all areas of concern, it provides a first-generation design of a production-oriented system.

  6. Characterization and performance assessment of solid dispersions prepared by hot melt extrusion and spray drying process.

    PubMed

    Agrawal, Anjali M; Dudhedia, Mayur S; Patel, Ashwinkumar D; Raikes, Michelle S

    2013-11-30

    The present study investigated effect of manufacturing methods such as hot melt extrusion (HME) and spray drying (SD) on physicochemical properties, manufacturability, physical stability and product performance of solid dispersion. Solid dispersions of compound X and PVP VA64 (1:2) when prepared by SD and HME process were amorphous by polarized light microscopy, powder X-ray diffractometry, and modulated differential scanning calorimetry analyses with a single glass transition temperature. Fourier transform infrared (FT-IR) and Raman spectroscopic analyses revealed similar molecular level interactions between compound X and PVP VA64 as evident by overlapping FT-IR and FT Raman spectra in SD and HME solid dispersions. The compactibility, tabletability, disintegration and dissolution performance were similar for solid dispersions prepared by both processing techniques. Differences in material properties such as surface area, morphological structure, powder densities, and flow characteristics were observed between SD and HME solid dispersion. The SD solid dispersion was physically less stable compared to HME solid dispersion under accelerated stability conditions. Findings from this study suggest that similar product performance could be obtained if the molecular properties of the solid dispersion processed by two different techniques are similar. However differences in material properties might affect the physical stability of the solid dispersions. PMID:24013161

  7. MONOLITHIC FUEL FABRICATION PROCESS DEVELOPMENT AT THE IDAHO NATIONAL LABORATORY_

    SciTech Connect

    G. A. Moore; F. J. Rice; N. E. Woolstenhulme; J-F. Jue; B. H. Park; S. E. Steffler; N. P. Hallinan; M. D. Chapple; M. C. Marshall; B. L. Mackowiak; C. R. Clark; B. H. Rabin

    2009-11-01

    Full-size/prototypic U10Mo monolithic fuel-foils and aluminum clad fuel plates are being developed at the Idaho National Laboratory’s (INL) Materials and Fuels Complex (MFC). These efforts are focused on realizing Low Enriched Uranium (LEU) high density monolithic fuel plates for use in High Performance Research and Test Reactors. The U10Mo fuel foils under development afford a fuel meat density of ~16 gU/cc and thus have the potential to facilitate LEU conversions without any significant reactor-performance penalty. An overview is provided of the ongoing monolithic UMo fuel development effort, including application of a zirconium barrier layer on fuel foils, fabrication scale-up efforts, and development of complex/graded fuel foils. Fuel plate clad bonding processes to be discussed include: Hot Isostatic Pressing (HIP) and Friction Bonding (FB).

  8. Structurally Integrated, Damage Tolerant Thermal Spray Coatings: Processing Effects on Surface and System Functionalities

    NASA Astrophysics Data System (ADS)

    Vackel, Andrew

    Thermal Spray (TS) coatings have seen extensive application as protective surfaces to enhance the service life of substrates prone to damage in their operating environment (wear, corrosion, heat etc.). With the advent of high velocity TS processes, the ability to deposit highly dense (>99%) metallic and cermet coatings has further enhanced the protective ability of these coatings. In addition to surface functionality, the influence of the coating application on the mechanical performance of a coated component is of great concern when such a component will experience either static or cyclic loading during service. Using a process mapping methodology, the processing-property interplay between coating materials meant to provide damage tolerant surface or for structural restoration are explored in terms of relevant mechanical properties. Most importantly, the residual stresses inherent in TS deposited coatings are shown to play a significant role in the integrated mechanical performance of these coatings. Unique to high velocity TS processes is the ability to produce compressive stresses within the deposit from the cold working induced by the high kinetic energy particles upon impact. The extent of these formation stresses are explored with different coating materials, as well as processing influence. The ability of dense TS coatings to carry significant structural load and synergistically strengthen coated tensile specimens is demonstrated as a function of coating material, processing, and thickness. The sharing of load between the substrate and otherwise brittle coating enables higher loads before yield for the bi-material specimens, offering a methodology to improve the tensile performance of coated components for structural repair or multi-functionality (surface and structure). The concern of cyclic fatigue damage in coated components is explored, since the majority of service application are designed for loading to be well below the yield point. The role of

  9. Flexible and Conducting Metal-Fabric Composites Using the Flame Spray Process for the Production of Li-Ion Batteries

    NASA Astrophysics Data System (ADS)

    Voyer, Joel

    2013-06-01

    The wire flame spray process was used to produce electrically conductive and flexible Al coatings onto diverse textile fabrics. The investigation studied the influence of the spraying parameters and fabric materials on the electrical conductivity of the metal-fabric composites. Furthermore, this study showed that the production of flexible Li-ion batteries having good electrical properties based on the use of such flame-sprayed aluminium cathode current collectors is viable. Results show that a coating quantity threshold of about 20 mg/cm2 exists to obtain a sufficient electrical surface conductivity for a commercial use of the produced metal-fabric composites. An excellent electrical surface conductivity of the composites (about 500 SA) could be achieved through an adequate optimization of the spraying parameters. This conductivity increase enabled a reduction of the coating quantity and thus the flexibility of the fabric materials is better conserved, rendering the use of such composites for flexible batteries even more interesting. This study showed that the production of electrically conductive and flexible metal-fabric composites having sufficient electrical conductivity for the manufacture of flexible Li ions batteries is possible. This new method of producing such batteries represents an alternative to other chemically based processes which are hazardous to the environment because of their chemical nature.

  10. Correlation between Hierarchical Structure and Processing Control of Large-area Spray-coated Polymer Solar Cells toward High Performance

    NASA Astrophysics Data System (ADS)

    Huang, Yu-Ching; Tsao, Cheng-Si; Cha, Hou-Chin; Chuang, Chih-Min; Su, Chun-Jen; Jeng, U.-Ser; Chen, Charn-Ying

    2016-01-01

    The formation mechanism of a spray-coated film is different from that of a spin-coated film. This study employs grazing incidence small- and wide-angle X-ray Scattering (GISAXS and GIWAXS, respectively) quantitatively and systematically to investigate the hierarchical structure and phase-separated behavior of a spray-deposited blend film. The formation of PCBM clusters involves mutual interactions with both the P3HT crystal domains and droplet boundary. The processing control and the formed hierarchical structure of the active layer in the spray-coated polymer/fullerene blend film are compared to those in the spin-coated film. How the different post-treatments, such as thermal and solvent vapor annealing, tailor the hierarchical structure of the spray-coated films is quantitatively studied. Finally, the relationship between the processing control and tailored BHJ structures and the performance of polymer solar cell devices is established here, taking into account the evolution of the device area from 1 × 0.3 and 1 × 1 cm2. The formation and control of the special networks formed by the PCBM cluster and P3HT crystallites, respectively, are related to the droplet boundary. These structures are favorable for the transverse transport of electrons and holes.

  11. Correlation between Hierarchical Structure and Processing Control of Large-area Spray-coated Polymer Solar Cells toward High Performance

    PubMed Central

    Huang, Yu-Ching; Tsao, Cheng-Si; Cha, Hou-Chin; Chuang, Chih-Min; Su, Chun-Jen; Jeng, U-Ser; Chen, Charn-Ying

    2016-01-01

    The formation mechanism of a spray-coated film is different from that of a spin-coated film. This study employs grazing incidence small- and wide-angle X-ray Scattering (GISAXS and GIWAXS, respectively) quantitatively and systematically to investigate the hierarchical structure and phase-separated behavior of a spray-deposited blend film. The formation of PCBM clusters involves mutual interactions with both the P3HT crystal domains and droplet boundary. The processing control and the formed hierarchical structure of the active layer in the spray-coated polymer/fullerene blend film are compared to those in the spin-coated film. How the different post-treatments, such as thermal and solvent vapor annealing, tailor the hierarchical structure of the spray-coated films is quantitatively studied. Finally, the relationship between the processing control and tailored BHJ structures and the performance of polymer solar cell devices is established here, taking into account the evolution of the device area from 1 × 0.3 and 1 × 1 cm2. The formation and control of the special networks formed by the PCBM cluster and P3HT crystallites, respectively, are related to the droplet boundary. These structures are favorable for the transverse transport of electrons and holes. PMID:26817585

  12. Microstructures of Metallic NiCrBSi Coatings Manufactured via Hybrid Plasma Spray and In Situ Laser Remelting Process

    NASA Astrophysics Data System (ADS)

    Serres, Nicolas; Hlawka, Françoise; Costil, Sophie; Langlade, Cécile; Machi, Frédérique

    2011-01-01

    This paper deals with coating alternatives to hard chromium plating. Thermal spraying is already used in industry, but results are not always satisfactory for reasons of porosity and microstructures. In this study, atmospheric plasma spraying (APS) and in situ laser irradiation by diode laser processes were combined to modify the structural characteristics of thick NiCrBSi alloy layers. The microstructure evolution was studied, and results show that in situ laser remelting induced the growth of a dendritic structure, which strongly decreased the porosity of as-sprayed coatings and increased the adhesion on the substrate. Moreover, no phase transition after laser treatment was observed. Lastly, a mechanical investigation demonstrated that the combination between plasma spray and in situ melting with a diode laser could result in very good mechanical properties. The increase of the laser incident power involved an increase of the mean contact pressure, along with coating hardness. The hybrid process appears to be a possible alternative to hard chromium plating, in order to protect mechanical parts, because of the improved mechanical properties of the NiCrBSi layer.

  13. High-pressure flame visualization of autoignition and flashback phenomena with liquid-fuel spray

    NASA Technical Reports Server (NTRS)

    Marek, C. J.; Baker, C. E.

    1983-01-01

    A study was undertaken to determine the effect of boundary layers on autoignition and flashback for premixed Jet-A fuel in a unique high-pressure windowed test facility. A plate was placed in the center of the fuel-air stream to establish a boundary layer. Four experimental configurations were tested: a 24.5-cm-long plate with either a pointed leading edge, a rounded edge or an edge with a 0.317-cm step, or the duct without the plate. Experiments at an equivalence ratio ranging from 0.4 to 0.9 were performed at pressures to 2500 kPa (25 atm.) at temperatures of 600, 645, and 700 K and velocities to 115 meters per second. Flame shapes were observed during flashback and autoignition using high speed cinematography. Flashback and autoignition limits were determined.

  14. An easy and innovative method based on spray-pyrolysis deposition to obtain high efficiency cathodes for Solid Oxide Fuel Cells

    NASA Astrophysics Data System (ADS)

    dos Santos-Gómez, L.; Porras-Vázquez, J. M.; Martín, F.; Ramos-Barrado, J. R.; Losilla, E. R.; Marrero-López, D.

    2016-07-01

    A novel electrode preparation method based on the spray-pyrolysis deposition of metal nitrate solutions onto a porous electrolyte scaffold is proposed. This method has been proved with different cathode materials, usually used in Solid Oxide Fuel Cells, such as La0.8Sr0.2MnO3-δ and La0.6Sr0.4Co1-xFexO3-δ (x = 0, 0.2, 0.8 and 1). The electrode microstructure is composed by two layers; the inner layer is a porous electrolyte scaffold homogeneously coated by cathode nanoparticles, providing an increased number of triple phase boundary sites for oxygen reduction, whereas, the top layer is formed by only cathode nanoparticles and acts mainly as a current collector. Polarization resistance values as low as 0.07 and 1.0 Ω cm2 at 600 and 450 °C, respectively, are obtained at open circuit voltage. This alternative approach has several advantages with respect to the traditional wet infiltration method for large area electrode fabrication, such as higher reproducibility, shorter preparation time in a single thermal deposition step, and easy implementation at industrial scale as a continuous process.

  15. Ultrasonic cavitation erosion of high-velocity oxygen-fuel (HVOF) sprayed near-nanostructured WC-10Co-4Cr coating in NaCl solution.

    PubMed

    Hong, Sheng; Wu, Yuping; Zhang, Jianfeng; Zheng, Yugui; Qin, Yujiao; Lin, Jinran

    2015-09-01

    The high-velocity oxygen-fuel (HVOF) spraying process was used to prepare near-nanostructured WC-10Co-4Cr coating. The cavitation erosion behavior and mechanism of the coating in 3.5 wt.% NaCl solution were analyzed in detail. The results showed that the amorphous phase and WC grain were present in the coating. The cavitation erosion resistance of the coating was about 1.27 times that of the stainless steel 1Cr18Ni9Ti under the same testing conditions. The effects of erosion time on the microstructural evolution were discussed. It was revealed that cracks initiated at the edge of pre-existing pores and propagated along the carbide-binder interface, leading to the pull-out of carbide particle and the formation of pits and craters on the surface. The main failure mechanism of the coating was erosion of the binder phases, brittle detachment of hard phases and formation of pitting corrosion products. PMID:25617967

  16. Bond Strength of Multicomponent White Cast Iron Coatings Applied by HVOF Thermal Spray Process

    NASA Astrophysics Data System (ADS)

    Maranho, Ossimar; Rodrigues, Daniel; Boccalini, Mario; Sinatora, Amilton

    2009-12-01

    Multicomponent white cast iron is a new alloy that belongs to system Fe-C-Cr-W-Mo-V, and because of its excellent wear resistance it is used in the manufacture of hot rolling mills rolls. To date, this alloy has been processed by casting, powder metallurgy, and spray forming. The high-velocity oxyfuel process is now also considered for the manufacture of components with this alloy. The effects of substrate, preheating temperature, and coating thickness on bond strength of coatings have been determined. Substrates of AISI 1020 steel and of cast iron with preheating of 150 °C and at room temperature were used to apply coatings with 200 and 400 μm nominal thickness. The bond strength of coatings was measured with the pull-off test method and the failure mode by scanning electron microscopic analysis. Coatings with thickness of 200 μm and applied on substrates of AISI 1020 steel with preheating presented bond strength of 87 ± 4 MPa.

  17. High Temperature Oxidation Behavior of HVOF-sprayed Coatings for Use in Thixoextrusion Processes

    SciTech Connect

    Picas, J. A.; Punset, M.; Menargues, S.; Campillo, M.; Baile, M. T.; Forn, A.

    2011-05-04

    The dies used for the thixoextrusion of steels have to be capable of withstanding complex thermal and mechanical loads, while giving a sufficient wear resistance against abrasion and adhesion at very high temperatures. In order to improve the wear resistance and reduce the heating of the extrusion die it can be protected with a hard cermet coating. The purpose of this work is to study the high-temperature performance of CrC-CoNiCrAlY coating and explore the potential application of this coating to improve dies used in thixoextrusion processes. A two-layer 75CrC-25CoNiCrAlY coating with a CoNiCrAlY bond-coating was fabricated by the HVOF thermal spray process on a steel substrate. Coatings were heat-treated at a range of temperatures between 900 deg. C and 1100 deg. C. The microstructural characterization of the coatings before and after heat treatment was conducted by scanning electron microscopy (SEM) and an X-ray diffractometer (XRD). The mechanical properties of coatings were determined as a function of the temperature of heat treatment. The bond coat effect on the thermal shock resistance of CrC-CoNiCrAlY coating was analyzed.

  18. High Temperature Oxidation Behavior of HVOF-sprayed Coatings for Use in Thixoextrusion Processes

    NASA Astrophysics Data System (ADS)

    Picas, J. A.; Punset, M.; Menargues, S.; Campillo, M.; Baile, M. T.; Forn, A.

    2011-05-01

    The dies used for the thixoextrusion of steels have to be capable of withstanding complex thermal and mechanical loads, while giving a sufficient wear resistance against abrasion and adhesion at very high temperatures. In order to improve the wear resistance and reduce the heating of the extrusion die it can be protected with a hard cermet coating. The purpose of this work is to study the high-temperature performance of CrC-CoNiCrAlY coating and explore the potential application of this coating to improve dies used in thixoextrusion processes. A two-layer 75CrC-25CoNiCrAlY coating with a CoNiCrAlY bond-coating was fabricated by the HVOF thermal spray process on a steel substrate. Coatings were heat-treated at a range of temperatures between 900 °C and 1100 °C. The microstructural characterization of the coatings before and after heat treatment was conducted by scanning electron microscopy (SEM) and an X-ray diffractometer (XRD). The mechanical properties of coatings were determined as a function of the temperature of heat treatment. The bond coat effect on the thermal shock resistance of CrC-CoNiCrAlY coating was analyzed.

  19. Numerical Studies of the Application of Shock Tube Technology for Cold Gas Dynamic Spray Process

    NASA Astrophysics Data System (ADS)

    Nickel, R.; Bobzin, K.; Lugscheider, E.; Parkot, D.; Varava, W.; Olivier, H.; Luo, X.

    2007-12-01

    A new method for a combustion-free spraying is studied fundamentally by modeling and simulation in comparison with first experiments. The article focuses on the numerical simulation of the gas-particle nozzle flow, which is generated by the shock reflection at the end wall section of a shock tube. To study the physical fundamentals of this process, at present only a single shot operation is considered. The particles are injected downstream of the nozzle throat into a supersonic nozzle flow. The measurements of the particle velocity made by a laser Doppler anemometry (LDA) set up show that the maximum velocity amounts to 1220 m/s for stainless steel particles of 15 μm diameter. The CFD-Code (Fluent) is first verified by a comparison with available numerical and experimental data for gas and gas-particle flow fields in a long Laval-nozzle. The good agreement implied the great potential of the new dynamic process concept for cold-gas coating applications. Then the flow fields in the short Laval nozzle designed and realized by the Shock Wave Laboratory (SWL) are investigated. The gas flow for experimentally obtained stagnation conditions is simulated. The gas-particle flow without and with the influence of the particles on the gas flow is calculated by the Surface Engineering Institute (IOT) and compared with experiments. The influence of the injection parameters on the particle velocities is investigated, as well.

  20. Low Emissions Burner Technology for Metal Processing Industry using Byproducts and Biomass Derived Liquid Fuels

    SciTech Connect

    Agrawal, Ajay; Taylor, Robert

    2013-09-30

    This research and development efforts produced low-emission burner technology capable of operating on natural gas as well as crude glycerin and/or fatty acids generated in biodiesel plants. The research was conducted in three stages (1) Concept definition leading to the design and development of a small laboratory scale burner, (2) Scale-up to prototype burner design and development, and (3) Technology demonstration with field vefiication. The burner design relies upon the Flow Blurring (FB) fuel injection based on aerodynamically creating two-phase flow near the injector exit. The fuel tube and discharge orifice both of inside diameter D are separated by gap H. For H < 0.25D, the atomizing air bubbles into liquid fuel to create a two-phase flow near the tip of the fuel tube. Pressurized two-phase fuel-air mixture exits through the discharge orifice, which results in expansion and breakup of air bubbles yielding a spray with fine droplets. First, low-emission combustion of diesel, biodiesel and straight VO (soybean oil) was achieved by utilizing FB injector to yield fine sprays for these fuels with significantly different physical properties. Visual images for these baseline experiments conducted with heat release rate (HRR) of about 8 kW illustrate clean blue flames indicating premixed combustion for all three fuels. Radial profiles of the product gas temperature at the combustor exit overlap each other signifying that the combustion efficiency is independent of the fuel. At the combustor exit, the NOx emissions are within the measurement uncertainties, while CO emissions are slightly higher for straight VO as compared to diesel and biodiesel. Considering the large variations in physical and chemical properties of fuels considered, the small differences observed in CO and NOx emissions show promise for fuel-flexible, clean combustion systems. FB injector has proven to be very effective in atomizing fuels with very different physical properties, and it offers a

  1. Overview of fuel processing options for polymer electrolyte fuel cell systems

    SciTech Connect

    Kumar, R.

    1995-12-31

    The polymer electrolyte fuel cell (PEFC) is being developed for use in heavy- and light-duty transportation applications. While this fuel cell has been used successfully in buses and vans with compressed hydrogen as the on-board fuel [1,2], the fuel cell system must incorporate fuel processing (reforming) for any other on-board fuel to produce the hydrogen or hydrogen-rich fuel gas to be fed to the fuel cell stack. This is true even for alternative methods of storing hydrogen, such as use of a metal hydride or liquefied hydrogen. The ``fuel processing`` needed to recover the hydrogen includes providing the heat of dissociation of the hydride and cooling the hydrogen to the temperature of the fuel cell stack. Discussed below are some of the options being considered for processing of on-board fuels (other than compressed hydrogen) to generate the fuel cell anode gas, and the effects of fuel processing on system design, efficiency, steady-state and dynamic performance, and other factors.

  2. [Optimization of extraction process of compound Clematidis Radix spray by support vector machine].

    PubMed

    Zhao, Li; Li, Hui; Liu, Yi-fan; Fu, Yan; Liu, Yu-ling; Zhang, Xiao-li

    2015-04-01

    L9 (3(4)) orthogonal experiment was used to design the extraction technology of compound Clematidis Radix spray. Weight coefficients of active ingredients and dry extract rate were solved by information entropy. Support vector machine (SVM) was established and the model parameters were optimized through the genetic algorithm. Grid search algorithm was used for optimization of extraction technology of Clematidis Radix spray. The optimal extraction technology was to extract Clematidis Radix spray in water with 6 times the weight of herbal medicine for 3 times, with 2 h once. Bias of value between real and predicted by SVM was 1.23%. SVM was compared with traditional intuitive analysis of orthogonal design. It indicates that the new method used to optimize the extraction parameters of compound Clematidis Radix spray is more accurate and reliable. PMID:26281549

  3. Effect of nano-crystallization of high velocity oxy-fuel-sprayed amorphous NiCrBSi alloy on properties of the coatings

    NASA Astrophysics Data System (ADS)

    Li, Chang-Jiu; Wang, Yu-Yue; Li, Hua

    2004-09-01

    NiCrBSi self-fluxing alloy coatings were deposited by high velocity oxy-fuel (HVOF) spraying. Annealing treatment was applied to the as-sprayed coatings to develop the microstructure of the Ni-based coating. The microstructure of the coating was characterized using optical microscopy, x-ray diffraction and transmission electron microscopy. The crystallization behavior of the amorphous coating was also characterized by differential scanning calorimetry. The properties of the coating were characterized by microhardness and abrasive wear tests. The results showed that the as-sprayed HVOF coating deposited by well melted spray particles exhibited a dense microstructure of amorphous phase. It was revealed that the crystallization of the amorphous phase in HVOF NiCrBSi coating occurs at a temperature of about 502°C. Annealing at temperature a little higher than recrystallization temperature leads to the formation of the nano-crystalline microstructure. The subsequent nanostructured Ni-based coating presents higher microhardness and excellent wear performance. With the further increase in annealing temperature, the growth of the nano-crystalline grains occurs and, accordingly, the microhardness of the coating and the wear performance decrease. Thereafter, the microstructure and properties of the Ni-based self-fluxing alloy coating can be controlled through postannealing treatment.

  4. The effect of process variables on the degradation and physical properties of spray dried insulin intended for inhalation.

    PubMed

    Ståhl, Kristina; Claesson, Malin; Lilliehorn, Pontus; Lindén, Helena; Bäckström, Kjell

    2002-02-21

    The aim of this study was to investigate the effect of process variables on the degradation and physical properties of spray dried insulin intended for inhalation. A 2(4) full factorial experimentally designed study was performed to investigate the influence of the following independent spray drying variables: feed flow rate, nozzle gas flow rate, inlet air temperature and aspirator capacity (drying gas flow rate). Human insulin (biosynthetic and Ph.Eur. quality) was dissolved in distilled water to concentrations of 5 mg/ml. The solutions were spray dried in a Mini Spray Dryer Büchi and the dry powders produced were characterized by high performance liquid chromatography, size exclusion chromatography, laser diffraction, thermo gravimetric analysis, scanning electron microscopy and weighing. The degradation of insulin was found to be affected mainly by the process variables that determine the outlet air temperature, i.e.: inlet air temperature, aspirator capacity and feed flow rate. The outlet air temperature should be kept below 120 degrees C to avoid degradation. A statistical optimization of the spray drying variables was performed, and found to recommend an experiment with an outlet air temperature of 61+/-4 degrees C. This experiment ought to generate a yield of 54+/-7% by weight of particles with a mass median diameter 2.9+/-0.4 microm, moisture content 3.9+/-0.5% by weight, content of high molecular weight proteins 0.3+/-0.1% by area, A-21 desamido insulin 0.3+/-0.05% by area and other insulin related compounds 0.3+/-0.1% by area. PMID:11897427

  5. Parametric Appraisal of Process Parameters for Adhesion of Plasma Sprayed Nanostructured YSZ Coatings Using Taguchi Experimental Design

    PubMed Central

    Mantry, Sisir; Mishra, Barada K.; Chakraborty, Madhusudan

    2013-01-01

    This paper presents the application of the Taguchi experimental design in developing nanostructured yittria stabilized zirconia (YSZ) coatings by plasma spraying process. This paper depicts dependence of adhesion strength of as-sprayed nanostructured YSZ coatings on various process parameters, and effect of those process parameters on performance output has been studied using Taguchi's L16 orthogonal array design. Particle velocities prior to impacting the substrate, stand-off-distance, and particle temperature are found to be the most significant parameter affecting the bond strength. To achieve retention of nanostructure, molten state of nanoagglomerates (temperature and velocity) has been monitored using particle diagnostics tool. Maximum adhesion strength of 40.56 MPa has been experimentally found out by selecting optimum levels of selected factors. The enhanced bond strength of nano-YSZ coating may be attributed to higher interfacial toughness due to cracks being interrupted by adherent nanozones. PMID:24288490

  6. [Effect of air humidity on traditional Chinese medicine extract of spray drying process and prediction of its powder stability].

    PubMed

    He, Yan; Xie, Yin; Zheng, Long-jin; Liu, Wei; Rao, Xiao-yong; Luo, Xiao-jian

    2015-02-01

    In order to solve the adhesion and the softening problems of traditional Chinese medicine extract during spray drying, a new method of adding dehumidified air into spray drying process was proposed, and the storage stability conditions of extract powder could be predicted. Kouyanqing extract was taken as model drug to investigate on the wet air (RH = 70%) and dry air conditions of spray drying. Under the dry air condition, the influence of the spray drying result with different air compression ratio and the spray-dried powder properties (extract powder recovery rate, adhesion percentage, water content, angle of repose, compression ratio, particle size and distribution) with 100, 110, 120, 130, 140 °C inlet temperature were studied. The hygroscopic investigation and Tg value with different moisture content of ideal powder were determined. The water activity-equilibrium moisture content (aw-EMC) and the equilibrium moisture content-Tg (EMC-Tg) relationships were fitted by GAB equation and Gordon-Taylor model respectively, and the state diagram of kouyanqing powder was obtained to guide the rational storage conditions. The study found that in the condition of dry air, the extract powder water content decreased with the increase of air compression ratio and the spray drying effect with air compression ratio of 100% was the best performance; in the condition of wet air, the extract powder with high water content and low yield, and the value were 4.26% and 16.73 °C, while, in the dry air condition the values were 2.43% and 24.86 °C with the same other instru- ment parameters. From the analysis of kouyanqing powder state diagram, in order to keep the stability, the critical water content of 3.42% and the critical water content of 0.188. As the water decreased Tg value of extract powder is the major problem of causing adhesion and softening during spray drying, it is meaningful to aid dehumidified air during the process. PMID:26084164

  7. Microencapsulation of Bioactive Principles with an Airless Spray-Gun Suitable for Processing High Viscous Solutions

    PubMed Central

    Cocchietto, Moreno; Blasi, Paolo; Lapasin, Romano; Moro, Chiara; Gallo, Davide; Sava, Gianni

    2013-01-01

    Purpose: to design, assemble and test a prototype of a novel production plant, suitable for producing microparticles (MPs) by processing highly viscous feed solutions (FSs). Methods: the prototype has been built using a commercial air compressor, a piston pump, an airless spray-gun, a customized air-treatment section, a timer, a rotating base, and a filtration section. Preliminary prototype parameter setting was carried out to individuate the best performing nozzle’s dimension, the nebulization timing, and the CaCl2 concentration in the gelation fluid. In addition, prototype throughput (1 L to 5 L) and the range of practicable feed solution (FS) viscosities were assayed. A set of four batches was prepared in order to characterize the MPs, in terms of mean particle size and distribution, flow properties, swelling, encapsulation efficiency and release. Results: according to a qualitative scoring, the large nozzle was suitable to nebulize FSs at a higher alginate concentration. Conversely, the small nozzle performed better in the processing of FSs with an alginate concentration up to 2% w/v. Only at the highest degree of viscosity, corresponding to 5% w/v of alginate, the FS processing was not technically possible. Among the CaCl2 concentrations considered, 15% w/v was recognized as the most versatile. The prototype appears to be convenient and suitable to grant a high yield starting from 2 L of FS. The flow behavior of the FSs assayed can be satisfactorily described with the Carreau-Yasuda equation and the throughput begins to slightly decrease for FSs at alginate concentrations exceeding 3% w/v. MP morphology was irregular with crumpled shape. The angle of repose indicates a good flowability and the release studies showed gastro-resistance and potential prolonged release applications. Conclusions: the novel prototype of production plant is suitable to process large amounts (2 L or more) of FSs, characterized by a high viscosity, to produce MPs suitable for

  8. Diagnostics and modeling of yttria-stabilized zirconia formation in solution-precursor plasma-spray process

    NASA Astrophysics Data System (ADS)

    Ozturk, Alper

    Thermal barrier coatings produced by solution-precursor plasma-spray (SPPS) process have been shown to offer superior thermal properties and durability. The microstructure of these coatings combines favorable properties of conventional air plasma spray (APS) and electron beam physical vapor deposition (EB-PVD) coatings by providing evenly spaced, through-thickness vertical cracks and uniformly distributed porosity resulting in good strain tolerance and low thermal conductivity. This experimental and computational study aims at clarifying some of the key aspects of this process through diagnostics of the actual process, modeling of vaporization and precipitation within droplets and through model experiments which utilize a combustion flame instead of a plasma jet. The work also includes characterization of the combustion flame and study of the possibility of coating formation utilizing combustion processes instead of plasmas. Plasma-extracted sample indicate presence of spherical sintered polycrystalline particles of 100 nm to 1 micron. Characterization of the precursor spray show that the mean droplet size is about 40 micron suggesting droplet disintegration in the process. Modeling of the heat and mass transfer around the droplets and solute precipitation predict formation of shell type structures and ceno-spheres supported by the experimental evidence of shell type structures in the single pass plasma experiments. Combustion flame experiments were found to produce sintered polycrystalline tetragonal yttria-stabilized zirconia particles similar to the plasma-extracted samples. The microstructural and compositional evolution of the ceramic particles was characterized as a function of downstream distance in the flame jet.

  9. Process for producing fluid fuel from coal

    DOEpatents

    Hyde, Richard W.; Reber, Stephen A.; Schutte, August H.; Nadkarni, Ravindra M.

    1977-01-01

    Process for producing fluid fuel from coal. Moisture-free coal in particulate form is slurried with a hydrogen-donor solvent and the heated slurry is charged into a drum wherein the pressure is so regulated as to maintain a portion of the solvent in liquid form. During extraction of the hydrocarbons from the coal, additional solvent is added to agitate the drum mass and keep it up to temperature. Subsequently, the pressure is released to vaporize the solvent and at least a portion of the hydrocarbons extracted. The temperature of the mass in the drum is then raised under conditions required to crack the hydrocarbons in the drum and to produce, after subsequent stripping, a solid coke residue. The hydrocarbon products are removed and fractionated into several cuts, one of which is hydrotreated to form the required hydrogen-donor solvent while other fractions can be hydrotreated or hydrocracked to produce a synthetic crude product. The heaviest fraction can be used to produce ash-free coke especially adapted for hydrogen manufacture. The process can be made self-sufficient in hydrogen and furnishes as a by-product a solid carbonaceous material with a useful heating value.

  10. Microstructure and Corrosion Resistance of Fe-Based Coatings Prepared by Twin Wires Arc Spraying Process

    NASA Astrophysics Data System (ADS)

    Lin, Jinran; Wang, Zehua; Lin, Pinghua; Cheng, Jiangbo; Zhang, Jingjing; Zhang, Xin

    2014-02-01

    FeB, FeBSi, and FeNiCrBSiNbW coatings were prepared by twin wires arc spraying process on AISI 1045 steel substrate, and the microstructure and phases were characterized by scanning electron microscope, transmission electron microscope, and x-ray diffraction. The corrosion resistance was investigated by means of electrochemical tests. It was found that FeB coating and FeBSi coating were composed of α-Fe, FeO, and Fe2O3 phases. FeNiCrBSiNbW coating consisted of amorphous phase and α-(Fe, Cr) nanocrystalline phase, with porosity of 1.8%, hardness of 807 Hv0.1 and tensile bonding strength of 52.1 MPa. Three kinds of electrochemical tests were employed to identify the corrosion resistance of the coatings. The results indicated that the FeNiCrBSiNbW coating had a superior corrosion resistance, much better than FeB and FeBSi coatings. It was attributed to the amorphous/nanocrystalline structure and the presence of corrosion-resistant element Cr.

  11. Optimization of process parameters for the production of spray dried Ber (Ziziphus jujube L.) powder.

    PubMed

    Singh, V K; Pandey, Sheela; Pare, Akash; Singh, R B

    2014-12-01

    The study covers effect of operating variables of spray dryer i.e. inlet temperature (170, 180, 190, 200 and 210 °C,), aspirator blower capacity (40, 50, 60, 70 and 80 %) and feed pump capacity (9, 12, 15, 18, and 21 %) and processing parameters of feed i.e. total soluble solid (TSS) of feed (7.5 %) and encapsulating material, maltodextrin (4, 6, 8, 10, and 12 %), aerosil (1.0 %), citric acid (0.25 %) upon the physical properties (colour, packed density and hygroscopicity) of powder were observed. After complete evaluation and analysis of all the attributes for physical properties i.e. colour, packed density (0.45 g/cc) and hygroscopicity (0.17 g/g dry matter), it was concluded that best quality of Ber powder were obtained at inlet air temperature 190 °C, aspirator blower capacity 60 %, feed pump capacity 15 %, encapsulating material 8 %. PMID:25477666

  12. Fabrication of Wollastonite Coatings on Zirconia by Room Temperature Spray Process.

    PubMed

    Lee, Jong Kook; Eum, Sangcheol; Kim, Jaehong; Hwang, Kyu Hong

    2016-02-01

    Wollastonite-based bioceramic powders were synthesized by solid-state reaction between calcite and silica powder. To control the phase and bioactivity of wollastonite, we also prepared four kinds of wollastonite-based bioceramics by adding an enstatite (MgSiO3) powder. After solid state reaction at 1000-1300 degrees C, micron-sized powders were obtained by milling and screening. By using these powders, wollastonite coatings were fabricated on zirconia substrates by a room temperature spray process, and their microstructure and composition under different coating condition were investigated. Wollastonite coatings on zirconia substrates were formed with the homogeneous microstructure and nanoscaled grain size. The phase composition of the resultant wollastonite coatings was similar to that of the starting powders, however, the grain size of the wollastonite particles was reduced to about 100 nm due to their formation by particle impaction and fracture. The wollastonite coating layer exhibited bioactivity in a stimulated body fluid and forming ability of 25 nm sized-hydroxyapatite precipitates of during in vitro test in SBF solution. PMID:27433716

  13. SAFEGUARDS EXPERIENCE ON THE DUPIC FUEL CYCLE PROCESS

    SciTech Connect

    J. HONG; H. KIM; ET AL

    2001-02-01

    Safeguards have been applied to the R and D process for directly fabricating CANDU fuel with PWR spent fuel material. Safeguards issues to be resolved were identified in the areas such as international cooperation on handling foreign origin nuclear material, technology development of operator's measurement system of the bulk handling process of spent fuel material, and a built-in C/S system for independent verification of material flow. The fuel cycle concept (Direct Use of PWR spent fuel in CANDU, DUPIC) was developed in consideration of reutilization of over-flowing spent fuel resources at PWR sites and a reduction of generated high level wastes. All those safeguards issues have been finally resolved, and the first batch of PWR spent fuel material was successfully introduced in the DUPIC lab facility and has been in use for routine process development.

  14. Fuel Cell Stations Automate Processes, Catalyst Testing

    NASA Technical Reports Server (NTRS)

    2010-01-01

    Glenn Research Center looks for ways to improve fuel cells, which are an important source of power for space missions, as well as the equipment used to test fuel cells. With Small Business Innovation Research (SBIR) awards from Glenn, Lynntech Inc., of College Station, Texas, addressed a major limitation of fuel cell testing equipment. Five years later, the company obtained a patent and provided the equipment to the commercial world. Now offered through TesSol Inc., of Battle Ground, Washington, the technology is used for fuel cell work, catalyst testing, sensor testing, gas blending, and other applications. It can be found at universities, national laboratories, and businesses around the world.

  15. Advancement of Shock-wave Induced Spraying Process through the Study of Gas and Particle Flow Fields

    NASA Astrophysics Data System (ADS)

    Karimi Esfahani, Mohammad

    This research advances the knowledge of the working principles of the Shock-wave Induced Spraying Process (SISP), a thermal spray material deposition technique. Pulses created by a fast acting valve pass through a heated line increasing energy content and interacting with metered batches of heated or non-heated powder introduced into the line. The powder is accelerated to high velocities before bonding to the substrate upon impact. Advantages over other cold spray processes include cost savings and a more effective transfer of thermal energy to the powder. The shock-wave occurring near the substrate in other cold spray processes is avoided. The SISP flow field is resolved by using a computational model. The two-dimensional model accounts for the valve, gas heater, a tapered nozzle at the tip of the device, and preheating of the powder. It is implemented with a commercial computational fluid dynamics code. Comparisons are made with one-dimensional predictions, and measurements of pressure and temperature. Particle flow predictions are validated using particle velocity and adhesion measurements. A flow region of both high temperature and velocity gas, favorable to material deposition, forms which is not present in comparable steady-state cold spray processes. Increasing gas pressure increases the gas speed, while increasing temperature increases speed and temperature of this region. Using helium results in greater energy levels but for shorter periods of time. This indicates the need for a powder feeder which places particles in the flow at correct instants and durations of time. The effects of particle flow parameters on system performance are examined. It is found that the device must be operated at very high main heater and powder heater temperatures: 900 °C and 700 °C respectively to achieve a coating with stainless steel using nitrogen as the driving gas. It is also shown that a heater length range of 0.9 m to 1.4 m results in the greatest likelihood of

  16. HVOF and plasma sprayed molybdenum coatings -- microstructure and properties

    SciTech Connect

    Zimmermann, S.; Kreye, H.

    1995-12-31

    High velocity oxy-fuel (HVOF) and plasma spray experiments were carried out to investigate the oxidation mechanism of molybdenum in the spray process and to determine how the various process parameters affect the microstructure and properties of the coatings. HVOF coatings exhibit their highest hardness and wear resistance at an oxygen content of 6 to 8% by weight. Such an oxygen level can be achieved with Mo and Mo-MoO{sub 2} composite powders as well. In the plasma spray process oxidation of molybdenum is less pronounced and Mo-MoO{sub 2} composite powders containing 6 to 8% oxygen have to be used to obtain similar properties as compared to HVOF-coatings. When Mo-Mo{sub 2}C composite powders are used oxidation of molybdenum becomes greatly reduced and highly wear resistant coatings are obtained at a low hardness level in both spray processes.

  17. Renewable hydrogen production for fossil fuel processing

    SciTech Connect

    Greenbaum, E.; Lee, J.W.; Tevault, C.V.

    1995-06-01

    In the fundamental biological process of photosynthesis, atmospheric carbon dioxide is reduced to carbohydrate using water as the source of electrons with simultaneous evolution of molecular oxygen: H{sub 2}O + CO{sub 2} + light {yields} O{sub 2} + (CH{sub 2}O). It is well established that two light reactions, Photosystems I and II (PSI and PSII) working in series, are required to perform oxygenic photosynthesis. Experimental data supporting the two-light reaction model are based on the quantum requirement for complete photosynthesis, spectroscopy, and direct biochemical analysis. Some algae also have the capability to evolve molecular hydrogen in a reaction energized by the light reactions of photosynthesis. This process, now known as biophotolysis, can use water as the electron donor and lead to simultaneous evolution of molecular hydrogen and oxygen. In green algae, hydrogen evolution requires prior incubation under anaerobic conditions. Atmospheric oxygen inhibits hydrogen evolution and also represses the synthesis of hydrogenase enzyme. CO{sub 2} fixation competes with proton reduction for electrons relased from the photosystems. Interest in biophotolysis arises from both the questions that it raises concerning photosynthesis and its potential practical application as a process for converting solar energy to a non-carbon-based fuel. Prior data supported the requirement for both Photosystem I and Photosystem II in spanning the energy gap necessary for biophotolysis of water to oxygen and hydrogen. In this paper we report the at PSII alone is capable of driving sustained simultaneous photoevolution of molecular hydrogen and oxygen in an anaerobically adapted PSI-deficient strain of Chlamydomonas reinhardtii, mutant B4, and that CO{sub 2} competes as an electron acceptor.

  18. Low Thermal Conductivity Yttria-Stabilized Zirconia Thermal Barrier Coatings Using the Solution Precursor Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Jordan, Eric H.; Jiang, Chen; Roth, Jeffrey; Gell, Maurice

    2014-06-01

    The primary function of thermal barrier coatings (TBCs) is to insulate the underlying metal from high temperature gases in gas turbine engines. As a consequence, low thermal conductivity and high durability are the primary properties of interest. In this work, the solution precursor plasma spray (SPPS) process was used to create layered porosity, called inter-pass boundaries, in yttria-stabilized zirconia (YSZ) TBCs. IPBs have been shown to be effective in reducing thermal conductivity. Optimization of the IPB microstructure by the SPPS process produced YSZ TBCs with a thermal conductivity of 0.6 W/mK, an approximately 50% reduction compared to standard air plasma sprayed (APS) coatings. In preliminary tests, SPPS YSZ with IPBs exhibited equal or greater furnace thermal cycles and erosion resistance compared to regular SPPS and commercially made APS YSZ TBCs.

  19. Understanding the effects of process parameters on the properties of cold gas dynamic sprayed pure titanium coatings

    NASA Astrophysics Data System (ADS)

    Wong, Wilson

    The cold gas dynamic spraying of commercially pure titanium coatings was investigated. Specifically, the relationship between several key cold spray parameters on the quality of the resulting coatings was studied in order to gain a more thorough understanding of the cold spray process. To achieve this goal, three distinct investigations were performed. The first part of the investigation focussed on the effect of propelling gas, particularly helium and nitrogen, during the cold spraying of titanium coatings. Coatings were characterised by SEM and were evaluated for their deposition efficiency (DE), microhardness, and porosity. In selected conditions, three particle velocities were investigated such that for each condition, the propelling gasses temperature and pressure were attuned to attain similar particle velocities for each gas. In addition, a thick and fully dense cold sprayed titanium coating was achieved with optimised spray parameters and nozzle using helium. The corresponding average particle velocity was 1173 m/s. The second part of the investigation studied the effect of particle morphology (spherical, sponge, and irregular) and size distributions (mean particle sizes of 20, 29, and 36 mum) of commercially pure titanium on the mechanical properties of the resulting cold sprayed coatings. Numerous powder and coating characterisations were performed. From these data, semi-empirical flow (stress-strain) curves were generated based on the Johnson-Cook plasticity model which could be used as a measure of cold sprayability. Cold sprayability can be defined as the ease with which a powder can be cold sprayed. It was found that the sponge and irregular commercially pure titanium powders had higher oxygen content, poorer powder flowability, higher compression ratio, lower powder packing factor, and higher average particle impact velocities compared to the spherical powders. XRD results showed no new phases present when comparing the various feedstock powders to

  20. Effect on the nasal bioavailability of co-processing drug and bioadhesive carrier via spray-drying.

    PubMed

    Coucke, D; Vervaet, C; Foreman, P; Adriaensens, P; Carleer, R; Remon, J P

    2009-09-01

    A mucoadhesive combination of a maize starch (Amioca, mainly consisting of amylopectine) and a cross-linked acrylic acid-based polymer (Carbopol 974P) was spray-dried with metoprolol tartrate (used as model molecule) in order to develop a powder suitable for nasal drug delivery via a one-step manufacturing process. The bioavailability of metoprolol tartrate after nasal administration of this powder to rabbits was compared with powders manufactured via other procedures: (a) freeze-drying of a dispersion prepared using the co-spray-dried powder, (b) freeze-drying of a dispersion prepared using a physical mixture of drug and mucoadhesive polymers. After co-processing via spray-drying a low bioavailability (BA 10.8+/-2.3%) was obtained, whereas manufacturing procedures based on freeze-drying yielded a higher BA: 37.9+/-12.8% using the co-processed powder and 73.6+/-24.9% using the physical mixture. The higher bioavailability was due to the deprotonation of poly(acrylic acid) during neutralisation of the dispersion prior to freeze-drying. This induced repulsion of the ionised carboxyl groups and a lower interaction between poly(acrylic acid) and starch, creating a less compact matrix upon hydration of the polymer and allowing an easier escape of metoprolol tartrate from the matrix. This study showed that co-processing of a mucoadhesive Amioca/Carbopol 974P formulation with metoprolol tartrate via co-spray-drying did not provide any added value towards the bioavailability of the drug after nasal administration of the mucoadhesive powder. PMID:19539738

  1. Solid oxide fuel cell process and apparatus

    DOEpatents

    Cooper, Matthew Ellis; Bayless, David J.; Trembly, Jason P.

    2011-11-15

    Conveying gas containing sulfur through a sulfur tolerant planar solid oxide fuel cell (PSOFC) stack for sulfur scrubbing, followed by conveying the gas through a non-sulfur tolerant PSOFC stack. The sulfur tolerant PSOFC stack utilizes anode materials, such as LSV, that selectively convert H.sub.2S present in the fuel stream to other non-poisoning sulfur compounds. The remaining balance of gases remaining in the completely or near H.sub.2S-free exhaust fuel stream is then used as the fuel for the conventional PSOFC stack that is downstream of the sulfur-tolerant PSOFC. A broad range of fuels such as gasified coal, natural gas and reformed hydrocarbons are used to produce electricity.

  2. Numerical analysis of particle impacting and bonding processes during high velocity oxygen fuel spraying process

    NASA Astrophysics Data System (ADS)

    Pan, Jiajing; Hu, Shengsun; Niu, Anning; Ding, Kunying; Yang, Lijun

    2016-03-01

    In this paper, the dynamic impact behavior of a particle and a substrate under different particle temperatures and velocities as well as using different materials for the particle and substrate were systematically studied. We found that the highest temperature occurred at the side edge of the particle after the collision, which is consistent with the distribution of equivalent plastic strain. The deformation of the particle and substrate was very severe at the first 40 ns, slowed down after 40 ns and remained almost unchanged after 80 ns. With the increase in the particle velocity, the effective combination area became larger, the equivalent plastic strain of the substrate is increased, and the equivalent plastic strain of the particle is decreased. As the initial temperature of particles increased, the effective combination area between the particle and substrate increased, and higher temperature and larger equivalent plastic strain of the particle could be obtained. With the increase in the substrate strength, the temperature and the equivalent plastic strain of the particle is increased, whereas the plastic deformation of the substrate is decreased.

  3. Friction and wear properties of high-velocity oxygen fuel sprayed WC-17Co coating under rotational fretting conditions

    NASA Astrophysics Data System (ADS)

    Luo, Jun; Cai, Zhenbing; Mo, Jiliang; Peng, Jinfang; Zhu, Minhao

    2016-05-01

    Rotational fretting which exist in many engineering applications has incurred enormous economic loss. Thus, accessible methods are urgently needed to alleviate or eliminate damage by rotational fretting. Surface engineering is an effective approach that is successfully adopted to enhance the ability of components to resist the fretting damage. In this paper, using a high-velocity oxygen fuel sprayed (HVOF) technique WC-17Co coating is deposited on an LZ50 steel surface to study its properties through Vickers hardness testing, scanning electric microscope (SEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffractrometry (XRD). Rotational fretting wear tests are conducted under normal load varied from 10 N to 50 N, and angular displacement amplitudes vary from 0.125° to 1°. Wear scars are examined using SEM, EDX, optical microscopy (OM), and surface topography. The experimental results reveal that the WC-17Co coating adjusted the boundary between the partial slip regime (PSR) and the slip regime (SR) to the direction of smaller amplitude displacement. As a result, the coefficients of friction are consistently lower than the substrate's coefficients of friction both in the PSR and SR. The damage to the coating in the PSR is very slight. In the SR, the coating exhibits higher debris removal efficiency and load-carrying capacity. The bulge is not found for the coating due to the coating's higher hardness to restrain plastic flow. This research could provide experimental bases for promoting industrial application of WC-17Co coating in prevention of rotational fretting wear.

  4. Friction and wear properties of high-velocity oxygen fuel sprayed WC-17Co coating under rotational fretting conditions

    NASA Astrophysics Data System (ADS)

    Luo, Jun; Cai, Zhenbing; Mo, Jiliang; Peng, Jinfang; Zhu, Minhao

    2016-04-01

    Rotational fretting which exist in many engineering applications has incurred enormous economic loss. Thus, accessible methods are urgently needed to alleviate or eliminate damage by rotational fretting. Surface engineering is an effective approach that is successfully adopted to enhance the ability of components to resist the fretting damage. In this paper, using a high-velocity oxygen fuel sprayed (HVOF) technique WC-17Co coating is deposited on an LZ50 steel surface to study its properties through Vickers hardness testing, scanning electric microscope (SEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffractrometry (XRD). Rotational fretting wear tests are conducted under normal load varied from 10 N to 50 N, and angular displacement amplitudes vary from 0.125° to 1°. Wear scars are examined using SEM, EDX, optical microscopy (OM), and surface topography. The experimental results reveal that the WC-17Co coating adjusted the boundary between the partial slip regime (PSR) and the slip regime (SR) to the direction of smaller amplitude displacement. As a result, the coefficients of friction are consistently lower than the substrate's coefficients of friction both in the PSR and SR. The damage to the coating in the PSR is very slight. In the SR, the coating exhibits higher debris removal efficiency and load-carrying capacity. The bulge is not found for the coating due to the coating's higher hardness to restrain plastic flow. This research could provide experimental bases for promoting industrial application of WC-17Co coating in prevention of rotational fretting wear.

  5. Determination of process conditions for the spray nozzle for the DWPF melter off-gas HEME

    SciTech Connect

    Lee, L.

    1991-12-15

    The DWPF melter off-gas systems have High Efficiency Mist Eliminators (HEME) upstream of the High Efficiency Particulates Air filters (HEPA) to remove fine mist and particulates from the off-gas. To have an acceptable filter life and an efficient HEME operation, air atomized water is sprayed into the melter off-gas and onto the HEME surface. The water spray keeps the HEME wet, which dissolves the soluble particulates and enhances the HEME efficiency. DWPF Technical requested SRL to determine the conditions for the DWPF nozzle which will give complete atomization of water so that the HEME will operate efficiently. Since the air pressure and flow rate to generate the desired spray are not known before hand, an experiment was performed in two stages. The first stage involved preliminary tests which mapped out a general operating region for producing the desired spray pattern. Afterward, all the gages and meters were changed to suitable ranges for the conditions which generated an acceptable spray. This report summarizes the results and the conclusions of the second stage experiment.

  6. Portable Spray Booth

    NASA Technical Reports Server (NTRS)

    Hansen, Timothy D.; Bardwell, Micheal J.

    1996-01-01

    Portable spray booth provides for controlled application of coating materials with high solvent contents. Includes contoured shroud and carbon filter bed limiting concentration of fumes in vicinity. Designed to substitute spraying for brush application of solvent-based adhesive prior to installing rubber waterproof seals over joints between segments of solid-fuel rocket motor. With minor adjustments and modifications, used to apply other solvent-based adhesives, paints, and like.

  7. Influence of the process parameters on the spray pyrolysis technique, on the synthesis of gadolinium doped-ceria thin film

    SciTech Connect

    Halmenschlager, C.M.; Neagu, R.; Rose, L.; Malfatti, C.F.

    2013-02-15

    Graphical abstract: Gas-tight CGO made by spray pyrolysis suitable to be used as SOFC electrolyte. Display Omitted Highlights: ► Dense and crystalline CGO films deposited by spray pyrolysis on various substrates. ► Solvent did not have a strong influence on the film microstructure, defect concentration or thickness. ► The substrate did not have a strong influence on the film microstructure, defect concentration or thickness. ► Films with at least 2.5 μm of thickness presented high impermeability. ► The films obtained are suitable to use as a SOFC electrolyte. -- Abstract: This work presents the results of a process of optimization applied to gadolinia-doped ceria (Ce{sub 0.8}Gd{sub 0.2}O{sub 1.9−x}, or CGO) thin films, deposited by spray pyrolysis (SP). Spray pyrolysis is a high thermal deposition method that combines material deposition and heat treatment. This combination is advantageous since the post-deposition heat treatment step is not necessary. However, stresses are solidified in the coating during the deposition, which may lead to the initiation of a crack in the coating. The aim of this work was to achieve thin, dense, and continuous CGO coatings, which may be used as gas separation membranes and as a solid state electrochemical interfaces. Dense, flat, low-defect substrates such as silica slides, silicon mono crystal wafers, and porous substrates were used as substrates in this work. Cerium ammonium nitrate and gadolinium acetylacetonate were dissolved in ethanol and butyl carbitol to form a precursor solution that was sprayed on the heated substrates. Process parameters such as solvent composition, deposition rate and different heating regimes were analyzed. The microstructure was analyzed by secondary electron microscopy (SEM) and was found that thin, dense, and defect-free films could be produced on dense and porous substrates. The results obtained show that it is possible to obtain a CGO dense film deposited by spray pyrolysis. X

  8. Electrocatalytic and fuel processing studies for portable fuel cells

    NASA Astrophysics Data System (ADS)

    Matter, Paul H.

    In the field of catalysis, the development of alternative catalysts for the oxygen reduction reaction (ORR) in Polymer Electrolyte Membrane Fuel Cell (PEMFC) cathodes has been an ongoing task for researchers over the past two decades. PEM fuel cells are considered to be potential replacements for internal combustion engines in automobiles, and their reduced emissions and better efficiency would have huge payoffs for our environment, and in reducing our nation's dependence on foreign oil. To date, PEMFC cathode over-potentials are still significant, and the only materials discovered to be highly active and stable catalysts in an acidic environment are platinum-based. Despite several major advances in recent years in reducing platinum loading in fuel cell electrodes, the high expense and low availability of platinum will hinder the large-scale commercialization of PEM fuel cells. The most hopeful advances being made in replacing platinum are related to pyrolyzed organic macrocycles with transition metal centers (such as Fe or Co porphyrins and phthalocyanines). Encouragingly, it has recently been discovered that active electrodes could be prepared by heat-treating metal and nitrogen precursors (not necessarily organic macrocycles) together in the presence of a carbon support. In the first study of this dissertation, catalysts for the Oxygen Reduction Reaction (ORR) were prepared by the pyrolysis of acetonitrile over various supports. The supports used included Vulcan Carbon, high purity alumina, silica, magnesia, and these same supports impregnated with Fe, Co, or Ni in the form of acetate salt. The catalysts were characterized by BET surface area analysis, BJH Pore Size Distribution (PSD), conductivity testing, Transmission Electron Microscopy (TEM), Temperature Programmed Oxidation (TPO), Thermo-Gravimetric Analysis (TGA), X-Ray Diffraction (XRD), X-ray Photo-electron Spectroscopy (XPS), Mossbauer Spectroscopy, Rotating Disk Electrode (RDE) half cell testing, and

  9. Liquid-feed flame spray pyrolysis synthesis of oxide nanopowders for the processing of ceramic composites

    NASA Astrophysics Data System (ADS)

    Taylor, Nathan John

    In the liquid-feed flame spray pyrolysis (LF-FSP) process, alcohol solutions of metalloorganic precursors are aerosolized by O2 and combusted. The metal oxide combustion products are rapidly quenched (< 10 ms) from flame temperatures of 1500°C to temperatures < 400° C, limiting particle growth. The resulting nanopowders are typically agglomerated but unaggregated. Here, we demonstrate two processing approaches to dense materials: nanopowders with the exact composition, and mixed single metal oxide nanopowders. The effect of the initial degree of phase separation on the final microstructures was determined by sintering studies. Our first studies included the production of yttrium aluminum garnet, Y3Al5O12 (YAG), tubes which we extruded from a thermoplastic/ceramic blend. At equivalent final densities, we found finer grain sizes in the from the mixed Y2O3 and Al2 O3 nanopowders, which was attributed to densification occurring before full transformation to the YAG phase. The enhanced densification in production of pure YAG from the reactive sintering process led us to produce composites in the YAG/alpha-Al 2O3 system. Finally, a third Y2O3 stabilized ZrO2 (YSZ) phase was added to further refine grain sizes using the same two processing approaches. In a separate study, single-phase metastable Al2O3 rich spinels with the composition MO•3Al 2O3 where M = Mg, Ni, and Co were sintered to produce dense MAl2O4/alpha-Al2O3 composites. All of these studies provide a test of the bottom-up approach; that is, how the initial length scale of mixing affects the final composite microstructure. Overall, the length scale of mixing is highly dependent upon the specific oxide composites studied. This work provides a processing framework to be adopted by other researchers to further refine microstructural size. LF-FSP flame temperatures were mapped using different alcohols with different heats of combustion: methanol, ethanol, 1-propanol, and n-butanol. The effect of different

  10. 77 FR 823 - Guidance for Fuel Cycle Facility Change Processes

    Federal Register 2010, 2011, 2012, 2013, 2014

    2012-01-06

    ... Information DG-3037 was published in the Federal Register on July 14, 2011 (76 FR 41527). The public comment... COMMISSION Guidance for Fuel Cycle Facility Change Processes AGENCY: Nuclear Regulatory Commission. ACTION... issuing a new regulatory guide (RG) 3.74, ``Guidance for Fuel Cycle Facility Change Processes.''...

  11. Arc-sprayed Coatings for High Temperature Reactors in Titanium Sponge Process

    NASA Astrophysics Data System (ADS)

    Zhang, Z. L.; Gong, X.; Zhang, N. N.

    2015-07-01

    An arc-sprayed composite coating consisted of an under coat Fe25Cr5Al and a top coat Al5Si was sprayed on the reactor wall surface, which is made of mild steel and used for batch production of titanium sponges. After a trial for 15 production cycles, the morphology of the sprayed coating changed greatly into somewhat like a thermal barrier coating. A large number of composite oxides containing aluminum and chromium had been generated in situ within the protective coatings, especially close to the coating/substrate interface. The oxides generated at the interface could improve the bonding of the coating to the steel substrate together with the surface alumina on the coating surface may provide an effective and long-term protection to the steel substrate of reactor at high temperatures.

  12. Studies of Splat Formation of Copper and Copper Aluminium on Ceramic Substrate in Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Tran, A. T. T.; Hyland, M. M.; Fukumoto, M.; Munroe, P.

    2016-01-01

    Of the substrate-related factors that will influence splat formation, alloying elements has been little studied. In the present work, we have examined the role of alloying elements in controlling the extent of splashing of plasma-sprayed splats. Splats of copper (Cu) and copper alloyed with Al and Zr were deposited by plasma spray or as free-falling droplets. The splat formation and splat-substrate interfaces were characterized using SEM and FIB. It was found that the presence of aluminium in plasma-sprayed Cu-10%Al increased the portion of favorable disk-shaped splats compared to pure copper. It was also found that the disk-shaped splat proportion of Cu-10%Al at room temperature is nearly identical to that of Cu splat at 300 °C, indicating that the addition of Al in the alloy leads to the improvement of splat formation, correlating with the improvement in the interface bonding with the substrate.

  13. Nanocomposite Lanthanum Zirconate Thermal Barrier Coating Deposited by Suspension Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Wang, Chaohui; Wang, You; Wang, Liang; Hao, Guangzhao; Sun, Xiaoguang; Shan, Fan; Zou, Zhiwei

    2014-10-01

    This work seeks to develop an innovative nanocomposite thermal barrier coating (TBC) exhibiting low thermal conductivity and high durability compared with that of current TBCs. To achieve this objective, nanosized lanthanum zirconate particles were selected for the topcoat of the TBC system, and a new process—suspension plasma spray—was employed to produce desirable microstructural features: the nanocomposite lanthanum zirconate TBC contains ultrafine splats and high volume porosity, for lower thermal conductivity, and better durability. The parameters of plasma spray experiment included two main variables: (i) spray distance varying from 40 to 80 mm and (ii) the concentration of suspension 20, 25, and 30 wt.%, respectively. The microstructure of obtained coatings was characterized with scanning electron microscope and x-ray diffraction. The porosity of coatings is in the range of 6-10%, and the single phase in the as-sprayed coatings was pyrochlore lanthanum zirconate.

  14. Sprayed coatings

    NASA Astrophysics Data System (ADS)

    Steffens, H. D.

    1980-03-01

    Thermal spraying is shown to be an efficient means for the protection of surface areas against elevated temperature, wear, corrosion, hot gas corrosion, and erosion in structural aircraft components. Particularly in jet engines, numerous parts are coated by flame, detonation, or plasma spraying techniques. The applied methods of flame, detonation, and plasma spraying are explained, as well as electric arc spraying. Possibilities for spray coatings which meet aircraft service requirements are discussed, as well as methods for quality control, especially nondestructive test methods. In particular, coating characteristics and properties obtained by different spray methods are described, and special attention is paid to low pressure plasma spraying.

  15. Binder Jetting: A Novel Solid Oxide Fuel-Cell Fabrication Process and Evaluation

    NASA Astrophysics Data System (ADS)

    Manogharan, Guha; Kioko, Meshack; Linkous, Clovis

    2015-03-01

    With an ever-growing concern to find a more efficient and less polluting means of producing electricity, fuel cells have constantly been of great interest. Fuel cells electrochemically convert chemical energy directly into electricity and heat without resorting to combustion/mechanical cycling. This article studies the solid oxide fuel cell (SOFC), which is a high-temperature (100°C to 1000°C) ceramic cell made from all solid-state components and can operate under a wide range of fuel sources such as hydrogen, methanol, gasoline, diesel, and gasified coal. Traditionally, SOFCs are fabricated using processes such as tape casting, calendaring, extrusion, and warm pressing for substrate support, followed by screen printing, slurry coating, spray techniques, vapor deposition, and sputter techniques, which have limited control in substrate microstructure. In this article, the feasibility of engineering the porosity and configuration of an SOFC via an additive manufacturing (AM) method known as binder jet printing was explored. The anode, cathode and oxygen ion-conducting electrolyte layers were fabricated through AM sequentially as a complete fuel cell unit. The cell performance was measured in two modes: (I) as an electrolytic oxygen pump and (II) as a galvanic electricity generator using hydrogen gas as the fuel. An analysis on influence of porosity was performed through SEM studies and permeability testing. An additional study on fuel cell material composition was conducted to verify the effects of binder jetting through SEM-EDS. Electrical discharge of the AM fabricated SOFC and nonlinearity of permeability tests show that, with additional work, the porosity of the cell can be modified for optimal performance at operating flow and temperature conditions.

  16. One-step spray-coating process for the fabrication of colorful superhydrophobic coatings with excellent corrosion resistance.

    PubMed

    Li, Jian; Wu, Runni; Jing, Zhijiao; Yan, Long; Zha, Fei; Lei, Ziqiang

    2015-10-01

    A simple method was used to generate colorful hydrophobic stearate particles via chemical reactions between inorganic salts and sodium stearate. Colored self-cleaning superhydrophobic coatings were prepared through a facile one-step spray-coating process by spraying the stearate particle suspensions onto stainless steel substrates. Furthermore, the colorful superhydrophobic coating maintains excellent chemical stability under both harsh acidic and alkaline circumstances. After being immersed in a 3.5 wt % NaCl aqueous solution for 1 month, the as-prepared coatings remained superhydrophobic; however, they lost their self-cleaning property with a sliding angle of about 46 ± 3°. The corrosion behavior of the superhydrophobic coatings on the Al substrate was characterized by the polarization curve and electrochemical impedance spectroscopy (EIS). The electrochemical corrosion test results indicated that the superhydrophobic coatings possessed excellent corrosion resistance, which could supply efficient and long-term preservation for the bare Al substrate. PMID:26365307

  17. The major species of heavy metal aerosol resulting from water cooling systems and spray dryer systems during incineration processes

    PubMed

    Wey; Yang; Wei

    1998-11-01

    Trace toxic metals in municipal solid waste may escape from the incineration process in flue gas, in dry collected ash, in wet scrubbed ash, or as a suspended aerosol. Therefore, understanding the behavior of heavy metals in the flue gas and the best controls in the air pollution control equipment are important and necessary. The control conditions of water cooling and spray dryer systems during incineration processes significantly influence the formation of heavy metal compounds. The formation of chromium (Cr), lead (Pb), and cadmium (Cd) species under various control conditions (water cooling tower and spray dryer reactor) was investigated in this study. The object of the experiment is to understand the effects of water cooling and spray dryer systems individually on the formation of heavy metal species. The operating parameters that are evaluated include different control systems, control temperatures, and chlorine content. A thermodynamic equilibrium model was also used to evaluate experimental data. In order to match real incineration conditions, a two-stage simulation was performed in this experiment. The results showed that the relationship of speciation between the simulation prediction and X-ray diffraction (XRD) analysis is consistent for Cr compounds; both indicated that Cr2O3 is the major species. The relationship is almost the same for Cd compounds, but not for Pb compounds. PMID:9846130

  18. SPH modeling of adhesion in fast dynamics: Application to the Cold Spray process

    NASA Astrophysics Data System (ADS)

    Profizi, Paul; Combescure, Alain; Ogawa, Kahuziro

    2016-04-01

    The objective of this paper is to show, in a specific case, the importance of modeling adhesive forces when simulating the bouncing of very small particles impacting a substrate at high speed. The implementation of this model into a fast-dynamics SPH code is described. Taking the example of an impacted elastic cylinder, we show that the adhesive forces, which are surface forces, play a significant role only if the particles are sufficiently small. The effect of the choice of the type of interaction law in the cohesive zone is studied and some conclusions on the relevance of the modeling of the adhesive forces for fast-dynamics impacts are drawn. Then, the adhesion model is used to simulate the Cold Spray process. An aluminum particle is projected against a substrate made of the same material at a velocity ranging from 200 to 1000 m ṡs-1. We study the effects of the various modeling assumptions on the final result: bouncing or sticking. Increasingly complex models are considered. At a 200 m ṡs-1 impact velocity, elastic behavior is assumed, the substrate being simply supported at its base and supplied with absorbing boundaries. The same absorbing boundaries are also used for all the other simulations. Then, plasticity is introduced and the impact velocity is increased up to 1000 m ṡs-1. At the highest velocities, the resulting strains are very significant. The calculations show that if the adhesion model is appropriately chosen, it is possible to reproduce the experimental observations: the particles stick to the substrate in a range of impact velocities surrounded by two velocity ranges in which the particles bounce.

  19. Fundamental studies of spray combustion

    SciTech Connect

    Li, S.C.; Libby, P.A.; Williams, F.A.

    1997-12-31

    Our research on spray combustion involves both experiment and theory and addresses the characteristics of individual droplets and of sprays in a variety of flows: laminar and turbulent, opposed and impinging. Currently our focus concerns water and fuel sprays in two stage laminar flames, i.e., flames arising, for example from a stream of fuel and oxidizer flowing opposite to an air stream carrying a water spray. Our interest in these flames is motivated by the goals of reducing pollutant emissions and extending the range of stable spray combustion. There remains considerable research to be carried out in order to achieve these goals. Thus far our research on the characteristics of sprays in turbulent flows has been limited to nonreacting jets impinging on a plate but this work will be extended to opposed flows with and without a flame. In the following we discuss details of these studies and our plans for future work.

  20. Fuel quality/processing study. Volume 4: On site processing studies

    NASA Technical Reports Server (NTRS)

    Jones, G. E., Jr.; Cutrone, M.; Doering, H.; Hickey, J.

    1981-01-01

    Fuel treated at the turbine and the turbine exhaust gas processed at the turbine site are studied. Fuel treatments protect the turbine from contaminants or impurities either in the upgrading fuel as produced or picked up by the fuel during normal transportation. Exhaust gas treatments provide for the reduction of NOx and SOx to environmentally acceptable levels. The impact of fuel quality upon turbine maintenance and deterioration is considered. On site costs include not only the fuel treatment costs as such, but also incremental costs incurred by the turbine operator if a turbine fuel of low quality is not acceptably upgraded.

  1. Spray-on polyvinyl alcohol separators and impact on power production in air-cathode microbial fuel cells with different solution conductivities.

    PubMed

    Hoskins, Daniel L; Zhang, Xiaoyuan; Hickner, Michael A; Logan, Bruce E

    2014-11-01

    Separators are used to protect cathodes from biofouling and to avoid electrode short-circuiting, but they can adversely affect microbial fuel cell (MFC) performance. A spray method was used to apply a polyvinyl alcohol (PVA) separator to the cathode. Power densities were unaffected by the PVA separator (339±29mW/m(2)), compared to a control lacking a separator in a low conductivity solution (1mS/cm) similar to wastewater. Power was reduced with separators in solutions typical of laboratory tests (7-13mS/cm), compared to separatorless controls. The PVA separator produced more power in a separator assembly (SEA) configuration (444±8mW/m(2)) in the 1mS/cm solution, but power was reduced if a PVA or wipe separator was used in higher conductivity solutions with either Pt or activated carbon catalysts. Spray and cast PVA separators performed similarly, but the spray method is preferred as it was easier to apply and use. PMID:25260178

  2. Superior Na-ion storage properties of high aspect ratio SnSe nanoplates prepared by a spray pyrolysis process.

    PubMed

    Park, Gi Dae; Lee, Jong-Heun; Kang, Yun Chan

    2016-06-01

    SnSe nanoplates with thin and uniform morphology are prepared by one-pot spray pyrolysis, and are examined as anode materials for Na-ion batteries. During the spray pyrolysis process, metallic Se and Sn are prepared from SeO2 and SnO2, respectively, under a reducing atmosphere. Metallic Sn and metalloid Se, with melting points of 232 and 221 °C, respectively, form a melted Sn-Se mixture, which reacts exothermally to form SnSe nanocrystals. Several of these nanocrystals are grown simultaneously forming a micron-sized powder. Complete elimination of the excess amount of metalloid Se, by forming H2Se gas, results in aggregation-free SnSe nanoplates. The aspect ratio of these nanoplates is as high as 11.3. The discharge capacities for the SnSe nanoplates, prepared from spray solutions containing 100, 400, and 800% of the stoichiometric SeO2 content needed to form SnSe, are 407, 558, and 211 mA h g(-1), respectively, after 50 cycles at a constant current density of 0.3 A g(-1); their capacity retentions calculated from the second cycle onwards are 77, 100, and 60%, respectively. The phase pure SnSe nanoplates with a high aspect ratio show good cycling and rate performances for Na-ion storage. PMID:27240748

  3. Oxidation Behavior of In-Flight Molten Aluminum Droplets in the Twin-Wire Electric Arc Thermal Spray Process

    SciTech Connect

    Donna Post Guillen; Brian G. Williams

    2005-05-01

    This paper examines the in-flight oxidation of molten aluminum sprayed in air using the twin-wire electric arc (TWEA) thermal spray process. The oxidation reaction of aluminum in air is highly exothermic and is represented by a heat generation term in the energy balance. Aerodynamic shear at the droplet surface enhances the amount of in-flight oxidation by: (1) promoting entrainment and mixing of the surface oxides within the droplet, and (2) causing a continuous heat generation effect that increases droplet temperature over that of a droplet without internal circulation. This continual source of heat input keeps the droplets in a liquid state during flight. A linear rate law based on the Mott-Cabrera theory was used to estimate the growth of the surface oxide layer formed during droplet flight. The calculated oxide volume fraction of an average droplet at impact agrees well with the experimentally determined oxide content for a typical TWEA-sprayed aluminum coating, which ranges from 3.3 to 12.7%. An explanation is provided for the elevated, nearly constant surface temperature (~ 2000 oC) of the droplets during flight to the substrate and shows that the majority of oxide content in the coating is produced during flight, rather than after deposition.

  4. Fabrication of Oxidation-Resistant Metal Wire Network-Based Transparent Electrodes by a Spray-Roll Coating Process.

    PubMed

    Kiruthika, S; Gupta, Ritu; Anand, Aman; Kumar, Ankush; Kulkarni, G U

    2015-12-16

    Roll and spray coating methods have been employed for the fabrication of highly oxidation resistant transparent and conducting electrodes (TCEs) by a simple solution process using crackle lithography technique. We have spray-coated a crackle paint-based precursor to produce highly interconnected crackle network on PET roll mounted on a roll coater with web speed of 0.6 m/min. Ag TCE with a transmittance of 78% and sheet resistance of ∼20 Ω/□ was derived by spraying Ag precursor ink over the crackle template followed by lift-off and annealing under ambient conditions. The Ag wire mesh was stable toward bending and sonication tests but prone to oxidation in air. When electrolessly coated with Pd, its robustness toward harsh oxidation conditions was enhanced. A low-cost transparent electrode has also been realized by using only small amounts of Ag as seed layer and growing Cu wire mesh by electroless method. Thus, made Ag/Cu meshes are found to be highly stable for more than a year even under ambient atmosphere. PMID:26580415

  5. Spray Rolling Aluminum Strip

    SciTech Connect

    Lavernia, E.J.; Delplanque, J-P; McHugh, K.M.

    2006-05-10

    Spray forming is a competitive low-cost alternative to ingot metallurgy for manufacturing ferrous and non-ferrous alloy shapes. It produces materials with a reduced number of processing steps, while maintaining materials properties, with the possibility of near-net-shape manufacturing. However, there are several hurdles to large-scale commercial adoption of spray forming: 1) ensuring strip is consistently flat, 2) eliminating porosity, particularly at the deposit/substrate interface, and 3) improving material yield. Through this program, a new strip/sheet casting process, termed spray rolling, has been developed, which is an innovative manufacturing technique to produce aluminum net-shape products. Spray rolling combines the benefits of twin-roll casting and conventional spray forming, showing a promising potential to overcome the above hurdles associated with spray forming. Spray rolling requires less energy and generates less scrap than conventional processes and, consequently, enables the development of materials with lower environmental impacts in both processing and final products. Spray Rolling was developed as a collaborative project between the University of California-Davis, the Colorado School of Mines, the Idaho National Engineering and Environmental Laboratory, and an industry team. The following objectives of this project were achieved: (1) Demonstration of the feasibility of the spray rolling process at the bench-scale level and evaluation of the materials properties of spray rolled aluminum strip alloys; and (2) Demonstration of 2X scalability of the process and documentation of technical hurdles to further scale up and initiate technology transfer to industry for eventual commercialization of the process.

  6. Plasma sprayed ceria-containing interlayer

    DOEpatents

    Schmidt, Douglas S.; Folser, George R.

    2006-01-10

    A plasma sprayed ceria-containing interlayer is provided. The interlayer has particular application in connection with a solid oxide fuel cell used within a power generation system. The fuel cell advantageously comprises an air electrode, a plasma sprayed interlayer disposed on at least a portion of the air electrode, a plasma sprayed electrolyte disposed on at least a portion of the interlayer, and a fuel electrode applied on at least a portion of the electrolyte.

  7. Estimation and control of droplet size and frequency in projected spray mode of a gas metal arc welding (GMAW) process.

    PubMed

    Anzehaee, Mohammad Mousavi; Haeri, Mohammad

    2011-07-01

    New estimators are designed based on the modified force balance model to estimate the detaching droplet size, detached droplet size, and mean value of droplet detachment frequency in a gas metal arc welding process. The proper droplet size for the process to be in the projected spray transfer mode is determined based on the modified force balance model and the designed estimators. Finally, the droplet size and the melting rate are controlled using two proportional-integral (PI) controllers to achieve high weld quality by retaining the transfer mode and generating appropriate signals as inputs of the weld geometry control loop. PMID:21444083

  8. Simulation of primary fuel atomization processes at subcritical pressures.

    SciTech Connect

    Arienti, Marco

    2013-06-01

    This report documents results from an LDRD project for the first-principles simulation of the early stages of spray formation (primary atomization). The first part describes a Cartesian embedded-wall method for the calculation of flow internal to a real injector in a fully coupled primary calculation. The second part describes the extension to an all-velocity formulation by introducing a momentum-conservative semi-Lagrangian advection and by adding a compressible term in the Poisson's equation. Accompanying the description of the new algorithms are verification tests for simple two-phase problems in the presence of a solid interface; a validation study for a scaled-up multi-hole Diesel injector; and demonstration calculations for the closing and opening transients of a single-hole injector and for the high-pressure injection of liquid fuel at supersonic velocity.

  9. Fuel quality-processing study. Volume 2: Literature survey

    NASA Technical Reports Server (NTRS)

    Jones, G. E., Jr.; Amero, R.; Murthy, B.; Cutrone, M.

    1981-01-01

    The validity of initial assumptions about raw materials choices and relevant upgrading processing options was confirmed. The literature survey also served to define the on-site (at the turbine location) options for fuel treatment and exhaust gas treatment. The literature survey also contains a substantial compilation of specification and physical property information about liquid fuel products relevant to industrial gas turbines.

  10. Treatment of oxide spent fuel using the lithium reduction process

    SciTech Connect

    Karell, E.J.; Pierce, R.D.; Mulcahey, T.P.

    1996-05-01

    The wide variety in the composition of DOE spent nuclear fuel complicates its long-term disposition because of the potential requirement to individually qualify each type of fuel for repository disposal. Argonne National Laboratory (ANL) has developed the electrometallurgical treatment technique to convert all of these spent fuel types into a single set of disposal forms, simplifying the qualification process. While metallic fuels can be directly processed using the electrometallurgical treatment technique, oxide fuels must first be reduced to the metallic form. The lithium reduction process accomplishes this pretreatment. In the lithium process the oxide components of the fuel are reduced using lithium at 650 C in the presence of molten LiCl, yielding the corresponding metals and Li{sub 2}O. The reduced metal components are then separated from the LiCl salt phase and become the feed material for electrometallurgical treatment. A demonstration test of the lithium reduction process was successfully conducted using a 10-kg batch of simulated oxide spent fuel and engineering-scale equipment specifically constructed for that purpose. This paper describes the lithium process, the equipment used in the demonstration test, and the results of the demonstration test.

  11. Commercial Demonstration of the Manufactured Aggregate Processing Technology Utilizing Spray Dryer Ash

    SciTech Connect

    Milton Wu; Paul Yuran

    2006-12-31

    Universal Aggregates LLC (UA) was awarded a cost sharing Co-operative Agreement from the Department of Energy (DOE) through the Power Plant Improvement Initiative Program (PPII) to design, construct and operate a lightweight aggregate manufacturing plant at the Birchwood Power Facility in King George, Virginia in October 2001. The Agreement was signed in November 2002. The installation and start-up expenses for the Birchwood Aggregate Facility are $19.5 million. The DOE share is $7.2 million (37%) and the UA share is $12.3 million (63%). The original project team consists of UA, SynAggs, LLC, CONSOL Energy Inc. and P. J. Dick, Inc. Using 115,000 ton per year of spray dryer ash (SDA), a dry FGD by-product from the power station, UA will produce 167,000 tons of manufactured lightweight aggregate for use in production of concrete masonry units (CMU). Manufacturing aggregate from FGD by-products can provide an economical high-volume use and substantially expand market for FGD by-products. Most of the FGD by-products are currently disposed of in landfills. Construction of the Birchwood Aggregate Facility was completed in March 2004. Operation startup was begun in April 2004. Plant Integration was initiated in December 2004. Integration includes mixing, extrusion, curing, crushing and screening. Lightweight aggregates with proper size gradation and bulk density were produced from the manufacturing aggregate plant and loaded on a stockpile for shipment. The shipped aggregates were used in a commercial block plant for CMU production. However, most of the production was made at low capacity factors and for a relatively short time in 2005. Several areas were identified as important factors to improve plant capacity and availability. Equipment and process control modifications and curing vessel clean up were made to improve plant operation in the first half of 2006. About 3,000 tons of crushed aggregate was produced in August 2006. UA is continuing to work to improve plant

  12. Environmentally compatible spray cement

    SciTech Connect

    Loeschnig, P.

    1995-12-31

    Within the framework of a European research project, Heidelberger Zement developed a quickly setting and hardening binder for shotcrete, called Chronolith S, which avoids the application of setting accelerators. Density and strength of the shotcrete produced with this spray cement correspond to those of an unaccelerated shotcrete. An increased hazard for the heading team and for the environment, which may occur when applying setting accelerators, can be excluded here. Owing to the special setting properties of a spray cement, the process engineering for its manufacturing is of great importance. The treatment of a spray cement as a dry concrete with kiln-dried aggregates is possible without any problems. The use of a naturally damp pre-batched mixture is possible with Chronolith S but requires special process engineering; spray cement and damp aggregate are mixed with one another immediately before entering the spraying machinery.

  13. Fe-Al Weld Overlay and High Velocity Oxy-Fuel Thermal Spray Coatings for Corrosion Protection of Waterwalls in Fossil Fired Plants with Low NOx Burners

    SciTech Connect

    Regina, J.R.

    2002-02-08

    Iron-aluminum-chromium coatings were investigated to determine the best candidates for coatings of boiler tubes in Low NOx fossil fueled power plants. Ten iron-aluminum-chromium weld claddings with aluminum concentrations up to 10wt% were tested in a variety of environments to evaluate their high temperature corrosion resistance. The weld overlay claddings also contained titanium additions to investigate any beneficial effects from these ternary and quaternary alloying additions. Several High-Velocity Oxy-Fuel (HVOF) thermal spray coatings with higher aluminum concentrations were investigated as well. Gaseous corrosion testing revealed that at least 10wt%Al is required for protection in the range of environments examined. Chromium additions were beneficial in all of the environments, but additions of titanium were beneficial only in sulfur rich atmospheres. Similar results were observed when weld claddings were in contact with corrosive slag while simultaneously, exposed to the corrosive environments. An aluminum concentration of 10wt% was required to prevent large amounts of corrosion to take place. Again chromium additions were beneficial with the greatest corrosion protection occurring for welds containing both 10wt%Al and 5wt%Cr. The exposed thermal spray coatings showed either significant cracking within the coating, considerable thickness loss, or corrosion products at the coating substrate interface. Therefore, the thermal spray coatings provided the substrate very little protection. Overall, it was concluded that of the coatings studied weld overlay coatings provide superior protection in these Low NOx environments; specifically, the ternary weld composition of 10wt%Al and 5wt%Cr provided the best corrosion protection in all of the environments tested.

  14. Development of Oxidation Resistant Coatings on GRCop-84 Substrates by Cold Spray Process

    NASA Technical Reports Server (NTRS)

    Karthikeyan, J.

    2007-01-01

    GRCop-84, a Cu-CR-Nb alloy, has been developed for rocket engine liner applications. For maximum life additional oxidation protection is required to prevent blanching. NiCrAlY was identified as a suitable coating, and efforts were initiated to develop suitable coating techniques. Cold spray is one technique under consideration. Efforts at ASB Industries to produce dense, adherent coatings are detailed. The work culminated in the production of samples for testing at NASA Glenn Research Center.

  15. Optimization of the laser remelting process for HVOF-sprayed Stellite 6 wear resistant coatings

    NASA Astrophysics Data System (ADS)

    Ciubotariu, Costel-Relu; Frunzăverde, Doina; Mărginean, Gabriela; Șerban, Viorel-Aurel; Bîrdeanu, Aurel-Valentin

    2016-03-01

    Cobalt base alloys are used in all industrial areas due to their excellent wear resistance. Several studies have shown that Stellite 6 coatings are suitable not only for protection against sliding wear, but also in case of exposure to impact loading. In this respect, a possible application is the protection of hydropower plant components affected by cavitation. The main problem in connection with Stellite 6 is the deposition procedure of the protective layers, both welding and thermal spraying techniques requesting special measures in order to prevent the brittleness of the coating. In this study, Stellite 6 layers were HVOF thermally sprayed on a martensitic 13-4 stainless steel substrate, as usually used for hydraulic machinery components. In order to improve the microstructure of the HVOF-sprayed coatings and their adhesion to the substrate, laser remelting was applied, using a TRUMPF Laser type HL 124P LCU and different working parameters. The microstructure of the coatings, obtained for various remelting conditions, was evaluated by light microscopy, showing the optimal value of the pulse power, which provided a homogenous Stellite 6 layer with good adhesion to the substrate.

  16. Properties of NiO thin films deposited by intermittent spray pyrolysis process

    NASA Astrophysics Data System (ADS)

    Reguig, B. A.; Khelil, A.; Cattin, L.; Morsli, M.; Bernède, J. C.

    2007-02-01

    NiO thin films have been grown on glass substrates by intermittent spray pyrolysis deposition of NiCl 2·6H 2O diluted in distilled water, using a simple "perfume atomizer". The effect of the solution molarity on their properties was studied and compared to those of NiO thin films deposited with a classical spray system. It is shown that NiO thin films crystallized in the NiO structure are achieved after deposition. Whatever the precursor molarity, the grain size is around 25-30 nm. The crystallites are preferentially oriented along the (1 1 1) direction. All the films are p-type. However, the thickness and the conductivity of the NiO films depend on the precursor contraction. By comparison with the properties of films deposited by classical spray technique, it is shown that the critical precursor concentration, which induces strong thin films properties perturbations, is higher when a perfume atomizer is used. This broader stability domain can be attributed to better chlorides decomposition during the rest time used in the perfume atomizer technique.

  17. Mechanization of the Grit Blasting Process for Thermal Spray Coating Applications: A Parameter Study

    NASA Astrophysics Data System (ADS)

    Begg, Henry; Riley, Melissa; de Villiers Lovelock, Heidi

    2016-01-01

    The bond strength between a thermal spray coating and substrate is critical for many applications and is dependent on good substrate surface preparation and optimized spray parameters. While spray parameters are usually carefully monitored and controlled, most surface preparation is carried out by manual grit blasting, with little or no calibration of blast parameters. Blasting is currently highly dependent on operator skill and often surface finish is only assessed visually, meaning a consistent, reproducible surface profile cannot be guaranteed. This paper presents investigations on the effect of blast parameters (including blast pressure, standoff distance, media feed rate, blast angle, traverse speed, and media size) on surface profile for seven different metallic substrates using a mechanized, robotic blasting system and employing a brown fused alumina blast medium. Substrates were characterized using non-contact focus variation microscopy. Average surface roughness was found to be most affected by blast pressure, media size, and traverse speed, while changes to media feed rate and standoff distance had a limited effect on surface profile. Changes to blast angle resulted in limited change to average roughness, but microscopy examinations suggested a change in the mechanism of material removal.

  18. Integrated coke, asphalt and jet fuel production process and apparatus

    DOEpatents

    Shang, Jer Y.

    1991-01-01

    A process and apparatus for the production of coke, asphalt and jet fuel m a feed of fossil fuels containing volatile carbon compounds therein is disclosed. The process includes the steps of pyrolyzing the feed in an entrained bed pyrolyzing means, separating the volatile pyrolysis products from the solid pyrolysis products removing at least one coke from the solid pyrolysis products, fractionating the volatile pyrolysis products to produce an overhead stream and a bottom stream which is useful as asphalt for road pavement, condensing the overhead stream to produce a condensed liquid fraction and a noncondensable, gaseous fraction, and removing water from the condensed liquid fraction to produce a jet fuel-containing product. The disclosed apparatus is useful for practicing the foregoing process. the process provides a useful method of mass producing and jet fuels from materials such as coal, oil shale and tar sands.

  19. Convective Evaporation Of Sprayed Liquid

    NASA Technical Reports Server (NTRS)

    Bellan, Josette; Harstad, Kenneth G.

    1987-01-01

    Theoretical model developed to analyze behavior of both dense and dilute clusters of evaporating liquid drops in gas flows. Particularly useful in search for methods of controlling evaporation, ignition, and combustion of fuel sprays.

  20. Electrochemical fluorination for processing of used nuclear fuel

    DOEpatents

    Garcia-Diaz, Brenda L.; Martinez-Rodriguez, Michael J.; Gray, Joshua R.; Olson, Luke C.

    2016-07-05

    A galvanic cell and methods of using the galvanic cell is described for the recovery of uranium from used nuclear fuel according to an electrofluorination process. The galvanic cell requires no input energy and can utilize relatively benign gaseous fluorinating agents. Uranium can be recovered from used nuclear fuel in the form of gaseous uranium compound such as uranium hexafluoride, which can then be converted to metallic uranium or UO.sub.2 and processed according to known methodology to form a useful product, e.g., fuel pellets for use in a commercial energy production system.

  1. Synergize fuel and petrochemical processing plans with catalytic reforming

    SciTech Connect

    1997-03-01

    Depending on the market, refiner`s plans to produce clean fuels and higher value petrochemicals will weigh heavily on the catalytic reformer`s flexibility. It seems that as soon as a timely article related to catalytic reforming operations is published, a new {open_quotes}boutique{close_quotes} gasoline fuel specification is slapped on to existing fuel standards, affecting reformer operations and processing objectives. Just as importantly, the petrochemical market (such as aromatics) that refiners are targeting, can be very fickle. That`s why process engineers have endeavored to maintain an awareness of the flexibility that technology suppliers are building into modern catalytic reformers.

  2. Comparison of the photocatalytic behavior of TiO2 coatings elaborated by different thermal spraying processes

    NASA Astrophysics Data System (ADS)

    Toma, Filofteia-Laura; Sokolov, Dmitry; Bertrand, Ghislaine; Klein, Didier; Coddet, Christian; Meunier, Cathy

    2006-12-01

    This paper proposes a comparative study on the microstructure and photocatalytic performances of titanium dioxide coatings elaborated by various thermal spraying methods (plasma spraying in atmospheric conditions, suspension plasma spraying, and high-velocity oxyfuel spraying). Agglomerated spray dried anatase TiO2 powder was used as feedstock material for spraying. Morphology and microstructural characteristics of the coatings were studied mainly by scanning electron microscopy and x-ray diffraction. The photocatalytic behavior of the TiO2-base surfaces was evaluated from the conversion rate of gaseous nitrogen oxides (NOx). It was found that the crystalline structure depended strongly on the technique of thermal spraying deposition. Moreover, a high amount of anatase was suitable for the photocatalytic degradation of the pollutants. Suspension plasma spraying has allowed retention of the original anatase phase and for very reactive TiO2 surfaces to be obtained for the removal of nitrogen oxides.

  3. Investigation of processing parameters of spray freezing into liquid to prepare polyethylene glycol polymeric particles for drug delivery.

    PubMed

    Barron, Melisa K; Young, Timothy J; Johnston, Keith P; Williams, Robert O

    2003-01-01

    The objective of this study was to investigate the influence of processing parameters on the morphology, porosity, and crystallinity of polymeric polyethylene glycol (PEG) microparticles by spray freezing into liquid (SFL), a new particle engineering technology. Processing parameters investigated were the viscosity and flow rate of the polymer solution, nozzle diameter, spray time, pressure, temperature, and flow rate of the cryogenic liquid. By varying the processing parameters and feed composition, atomization and heat transfer mechanisms were modified resulting in particles of different size distribution, shape, morphology, density, porosity, and crystallinity. Median particle diameter (M50) varied from 25 microm to 600 microm. Particle shape was spherical or elongated with highly irregular surfaces. Granule density was between 0.5 and 1.5 g/mL. In addition to producing particles of pure polymer, drug particles were encapsulated in polymeric microparticles. The encapsulation efficiency of albuterol sulfate was 96.0% with a drug loading of 2.4%, indicating that SFL is useful for producing polymeric microparticles for drug delivery applications. It was determined that the physicochemical characteristics of model polymeric microparticles composed of PEG could be modified for use as a drug delivery carrier. PMID:12916894

  4. High Power Diode Laser-Treated HP-HVOF and Twin Wire Arc-Sprayed Coatings for Fossil Fuel Power Plants

    NASA Astrophysics Data System (ADS)

    Mann, B. S.

    2013-08-01

    This article deals with high power diode laser (HPDL) surface modification of twin wire arc-sprayed (TWAS) and high pressure high velocity oxy-fuel (HP-HVOF) coatings to combat solid particle erosion occurring in fossil fuel power plants. To overcome solid particle impact wear above 673 K, Cr3C2-NiCr-, Cr3C2-CoNiCrAlY-, and WC-CrC-Ni-based HVOF coatings are used. WC-CoCr-based HVOF coatings are generally used below 673 K. Twin wire arc (TWA) spraying of Tafa 140 MXC and SHS 7170 cored wires is used for a wide range of applications for a temperature up to 1073 K. Laser surface modification of high chromium stainless steels for steam valve components and LPST blades is carried out regularly. TWA spraying using SHS 7170 cored wire, HP-HVOF coating using WC-CoCr powder, Ti6Al4V alloy, and high chromium stainless steels (X20Cr13, AISI 410, X10CrNiMoV1222, 13Cr4Ni, 17Cr4Ni) were selected in the present study. Using robotically controlled parameters, HPDL surface treatments of TWAS-coated high strength X10CrNiMoV1222 stainless steel and HP-HVOF-coated AISI 410 stainless steel samples were carried out and these were compared with HPDL-treated high chromium stainless steels and titanium alloy for high energy particle impact wear (HEPIW) resistance. The HPDL surface treatment of the coatings has improved the HEPIW resistance manifold. The improvement in HPDL-treated stainless steels and titanium alloys is marginal and it is not comparable with that of HPDL-treated coatings. These coatings were also compared with "as-sprayed" coatings for fracture toughness, microhardness, microstructure, and phase analyses. The HEPIW resistance has a strong relationship with the product of fracture toughness and microhardness of the HPDL-treated HP-HVOF and TWAS SHS 7170 coatings. This development opens up a possibility of using HPDL surface treatments in specialized areas where the problem of HEPIW is very severe. The HEPIW resistance of HPDL-treated high chromium stainless steels and

  5. High Fidelity Simulation of Primary Atomization in Diesel Engine Sprays

    NASA Astrophysics Data System (ADS)

    Ivey, Christopher; Bravo, Luis; Kim, Dokyun

    2014-11-01

    A high-fidelity numerical simulation of jet breakup and spray formation from a complex diesel fuel injector at ambient conditions has been performed. A full understanding of the primary atomization process in fuel injection of diesel has not been achieved for several reasons including the difficulties accessing the optically dense region. Due to the recent advances in numerical methods and computing resources, high fidelity simulations of atomizing flows are becoming available to provide new insights of the process. In the present study, an unstructured un-split Volume-of-Fluid (VoF) method coupled to a stochastic Lagrangian spray model is employed to simulate the atomization process. A common rail fuel injector is simulated by using a nozzle geometry available through the Engine Combustion Network. The working conditions correspond to a single orifice (90 μm) JP-8 fueled injector operating at an injection pressure of 90 bar, ambient condition at 29 bar, 300 K filled with 100% nitrogen with Rel = 16,071, Wel = 75,334 setting the spray in the full atomization mode. The experimental dataset from Army Research Lab is used for validation in terms of spray global parameters and local droplet distributions. The quantitative comparison will be presented and discussed. Supported by Oak Ridge Associated Universities and the Army Research Laboratory.

  6. COMMERCIAL DEMONSTRATION OF THE MANUFACTURED AGGREGATE PROCESSING TECHNOLOGY UTILIZING SPRAY DRYER ASH

    SciTech Connect

    Roy Scandrol

    2003-04-01

    Universal Aggregates, LLC proposes to design, construct and operate a lightweight aggregate manufacturing plant at the Birchwood Power Facility in King George, Virginia. The installation and start-up expenses for the Birchwood Aggregate Facility are $19.5 million. The DOE share is $7.2 million (37%) and the Universal Aggregates share is $12.3 (63%). The project team consists of CONSOL Energy Inc., P.J. Dick, Inc., SynAggs, LLC, and Universal Aggregates, LLC. The Birchwood Facility will transform 115,000 tons per year of spray dryer by-products that are currently being disposed of in an offsite landfill into 167,000 tons of a useful product, lightweight aggregates that can be used to manufacture lightweight aggregates that can be used to manufacture lightweight and medium weight masonry blocks. In addition to the environmental benefits, the Birchwood Facility will create eight (8) manufacturing jobs plus additional employment in the local trucking industry to deliver the aggregate to customers or reagents to the facility. A successful demonstration would lead to additional lightweight aggregate manufacturing facilities in the United States. There are currently twenty-one (21) spray dryer facilities operating in the United States that produce an adequate amount of spray dryer by-product to economically justify the installation of a lightweight aggregate manufacturing facility. Industry sources believe that as additional scrubbing is required, dry flue gas desulfurization (FGD) technologies will be the technology of choice. Letters from potential lightweight aggregate customers indicate that there is a market for the product once the commercialization barriers are eliminated by this demonstration project.

  7. COMMERCIAL DEMONSTRATION OF THE MANUFACTURED AGGREGATE PROCESSING TECHNOLOGY UTILIZING SPRAY DRYER ASH

    SciTech Connect

    Roy Scandrol

    2003-10-01

    Universal Aggregates, LLC proposes to design, construct and operate a lightweight aggregate manufacturing plant at the Birchwood Power Facility in King George, Virginia. The installation and start-up expenses for the Birchwood Aggregate Facility are $19.5 million. The DOE share is $7.2 million (37%) and the Universal Aggregates share is $12.3 (63%). The project team consists of CONSOL Energy Inc., P.J. Dick, Inc., SynAggs, LLC, and Universal Aggregates, LLC. The Birchwood Facility will transform 115,000 tons per year of spray dryer by-products that are currently being disposed of in an offsite landfill into 167,000 tons of a useful product, lightweight aggregates that can be used to manufacture lightweight aggregates that can be used to manufacture lightweight and medium weight masonry blocks. In addition to the environmental benefits, the Birchwood Facility will create nine (9) manufacturing jobs plus additional employment in the local trucking industry to deliver the aggregate to customers or reagents to the facility. A successful demonstration would lead to additional lightweight aggregate manufacturing facilities in the United States. There are currently twenty-one (21) spray dryer facilities operating in the United States that produce an adequate amount of spray dryer by-product to economically justify the installation of a lightweight aggregate manufacturing facility. Industry sources believe that as additional scrubbing is required, dry FGD technologies will be the technology of choice. Letters from potential lightweight aggregate customers indicate that there is a market for the product once the commercialization barriers are eliminated by this demonstration project.

  8. Kilogram-scale production of SnO(2) yolk-shell powders by a spray-drying process using dextrin as carbon source and drying additive.

    PubMed

    Choi, Seung Ho; Kang, Yun Chan

    2014-05-01

    A simple and general method for the large-scale production of yolk-shell powders with various compositions by a spray-drying process is reported. Metal salt/dextrin composite powders with a spherical and dense structure were obtained by spray drying and transformed into yolk-shell powders by simple combustion in air. Dextrin plays a key role in the preparation of precursor powders for fabricating yolk-shell powders by spray drying. Droplets containing metal salts and dextrin show good drying characteristics even in a severe environment of high humidity. Sucrose, glucose, and polyvinylpyrrolidone are widely used as carbon sources in the preparation of metal oxide/carbon composite powders; however, they are not appropriate for large-scale spray-drying processes because of their caramelization properties and adherence to the surface of the spray dryer. SnO2 yolk-shell powders were studied as the first target material in the spray-drying process. Combustion of tin oxalate/dextrin composite powders at 600 °C in air produced single-shelled SnO2 yolk-shell powders with the configuration SnO2 @void@SnO2 . The SnO2 yolk-shell powders prepared by the simple spray-drying process showed superior electrochemical properties, even at high current densities. The discharge capacities of the SnO2 yolk-shell powders at a current density of 2000 mA g(-1) were 645 and 570 mA h g(-1) for the second and 100th cycles, respectively; the corresponding capacity retention measured for the second cycle was 88 %. PMID:24665070

  9. Superior Na-ion storage properties of high aspect ratio SnSe nanoplates prepared by a spray pyrolysis process

    NASA Astrophysics Data System (ADS)

    Park, Gi Dae; Lee, Jong-Heun; Kang, Yun Chan

    2016-06-01

    SnSe nanoplates with thin and uniform morphology are prepared by one-pot spray pyrolysis, and are examined as anode materials for Na-ion batteries. During the spray pyrolysis process, metallic Se and Sn are prepared from SeO2 and SnO2, respectively, under a reducing atmosphere. Metallic Sn and metalloid Se, with melting points of 232 and 221 °C, respectively, form a melted Sn-Se mixture, which reacts exothermally to form SnSe nanocrystals. Several of these nanocrystals are grown simultaneously forming a micron-sized powder. Complete elimination of the excess amount of metalloid Se, by forming H2Se gas, results in aggregation-free SnSe nanoplates. The aspect ratio of these nanoplates is as high as 11.3. The discharge capacities for the SnSe nanoplates, prepared from spray solutions containing 100, 400, and 800% of the stoichiometric SeO2 content needed to form SnSe, are 407, 558, and 211 mA h g-1, respectively, after 50 cycles at a constant current density of 0.3 A g-1 their capacity retentions calculated from the second cycle onwards are 77, 100, and 60%, respectively. The phase pure SnSe nanoplates with a high aspect ratio show good cycling and rate performances for Na-ion storage.SnSe nanoplates with thin and uniform morphology are prepared by one-pot spray pyrolysis, and are examined as anode materials for Na-ion batteries. During the spray pyrolysis process, metallic Se and Sn are prepared from SeO2 and SnO2, respectively, under a reducing atmosphere. Metallic Sn and metalloid Se, with melting points of 232 and 221 °C, respectively, form a melted Sn-Se mixture, which reacts exothermally to form SnSe nanocrystals. Several of these nanocrystals are grown simultaneously forming a micron-sized powder. Complete elimination of the excess amount of metalloid Se, by forming H2Se gas, results in aggregation-free SnSe nanoplates. The aspect ratio of these nanoplates is as high as 11.3. The discharge capacities for the SnSe nanoplates, prepared from spray solutions

  10. Automated spray coating process for the fabrication of large-area artificial opals on textured substrates.

    PubMed

    Sprafke, Alexander N; Schneevoigt, Daniela; Seidel, Sophie; Schweizer, Stefan L; Wehrspohn, Ralf B

    2013-05-01

    3D photonic crystals, such as opals, have been shown to have a high potential to increase the efficiency of solar cells by enabling advanced light management concepts. However, methods which comply with the demands of the photovoltaic industry for integration of these structures, i. e. the fabrication in a low-cost, fast, and large-scale manner, are missing up to now. In this work, we present the spray coating of a colloidal suspension on textured substrates and subsequent drying. We fabricated opaline films of much larger lateral dimensions and in much shorter times than what is possible using conventional opal fabrication methods. PMID:24104441

  11. Thermal Arc Spray Overview

    NASA Astrophysics Data System (ADS)

    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.

  12. Distillate fuel-oil processing for phosphoric acid fuel-cell power plants

    SciTech Connect

    Ushiba, K. K.

    1980-02-01

    The current efforts to develop distillate oil-steam reforming processes are reviewed, and the applicability of these processes for integration with the fuel cell are discussed. The development efforts can be grouped into the following processing approaches: high-temperature steam reforming (HTSR); autothermal reforming (ATR); autothermal gasification (AG); and ultra desulfurization followed by steam reforming. Sulfur in the feed is a key problem in the process development. A majority of the developers consider sulfur as an unavoidable contaminant of distillate fuel and are aiming to cope with it by making the process sulfur-tolerant. In the HTSR development, the calcium aluminate catalyst developed by Toyo Engineering represents the state of the art. United Technology (UTC), Engelhard, and Jet Propulsion Laboratory (JPL) are also involved in the HTSR research. The ATR of distillate fuel is investigated by UTC and JPL. The autothermal gasification (AG) of distillate fuel is being investigated by Engelhard and Siemens AG. As in the ATR, the fuel is catalytically gasified utilizing the heat generated by in situ partial combustion of feed, however, the goal of the AG is to accomplish the initial breakdown of the feed into light gases and not to achieve complete conversion to CO and H/sub 2/. For the fuel-cell integration, a secondary reforming of the light gases from the AG step is required. Engelhard is currently testing a system in which the effluent from the AG section enters the steam-reforming section, all housed in a single vessel. (WHK)

  13. Analysis of the ATR fuel element swaging process

    SciTech Connect

    Richins, W.D.; Miller, G.K.

    1995-12-01

    This report documents a detailed evaluation of the swaging process used to connect fuel plates to side plates in Advanced Test Reactor (ATR) fuel elements. The swaging is a mechanical process that begins with fitting a fuel plate into grooves in the side plates. Once a fuel plate is positioned, a lip on each of two side plate grooves is pressed into the fuel plate using swaging wheels to form the joints. Each connection must have a specified strength (measured in terms, of a pullout force capacity) to assure that these joints do not fail during reactor operation. The purpose of this study is to analyze the swaging process and associated procedural controls, and to provide recommendations to assure that the manufacturing process produces swaged connections that meet the minimum strength requirement. The current fuel element manufacturer, Babcock and Wilcox (B&W) of Lynchburg, Virginia, follows established procedures that include quality inspections and process controls in swaging these connections. The procedures have been approved by Lockheed Martin Idaho Technologies and are designed to assure repeatability of the process and structural integrity of each joint. Prior to July 1994, ATR fuel elements were placed in the Hydraulic Test Facility (HTF) at the Idaho National Engineering Laboratory (AGNAIL), Test Reactor Area (TRA) for application of Boehmite (an aluminum oxide) film and for checking structural integrity before placement of the elements into the ATR. The results presented in this report demonstrate that the pullout strength of the swaged connections is assured by the current manufacturing process (with several recommended enhancements) without the need for- testing each element in the HTF.

  14. Process for separating water and solids from fuels

    SciTech Connect

    Filho, J.H.; Bachmann, D.L.

    1987-11-17

    A process for separating water and solid particles from a fuel oil feedstock is described comprising: subjecting the feedstock to a first separation in a scroll type centrifugal separator to form a first recovered fuel stream and an oil cake; subjecting at least the first recovered fuel stream to a second separation in a centrifugal disc separator to form a clean fuel stream, an oil-bearing water stream and a sludge stream; treating the oil-bearing water stream in a separator to recover the oil; treating the oil cake removed from the first separation with a solvent in order to form a suspension; mixing the suspension with the sludge stream to form a mixture; feeding the mixture to a filter press to yield a solid reject and a filtrate; separating the filtrate into a decantate and recovered oil; mixing at least a portion of the recovered oil with first recovered fuel stream to form a semi-cleaned fuel stream; and subjecting the semi-cleaned fuel stream to the second separation in a centrifugal disc separator to form the clean fuel stream.

  15. Al-SiC powder preparation for electronic packaging aluminum composites by plasma spray processing

    NASA Astrophysics Data System (ADS)

    Gui, Manchang; Kang, Suk Bong; Euh, Kwangjun

    2004-06-01

    Powders of pure aluminum (Al) with 55 and 75 vol.% SiC particles were ball milled in a conventional rotating ball mill with stainless steel and ZrO2 balls for 1-10 h. The morphology and microstructure of the milled powders have been observed and analyzed by scanning electron microscopy (SEM) and energy dispersive x-ray (EDX). The milled powders were plasma sprayed onto a graphite substrate to obtain Al matrix composites with high SiC volume fraction. SiC particles in the milled powders existed in two forms; i.e., the combination of Al into composite powder and individual. Plastic Al particles were broken during ball milling, and fine Al particles can be coated onto the surface of SiC particles. Iron contamination in the milled powders occurred when stainless steel balls were used. The iron level can be effectively controlled by using ZrO2 ball media. The milling efficiency by ZrO2 balls is inferior to that by stainless steel balls. Longer milling time was required with ZrO2 balls to achieve the same effect as obtained with stainless steel balls. SiC particles in the sprayed composites from the milled powders exhibited a reasonably uniform distribution and high volume fraction.

  16. Optimum catalytic process for alcohol fuels from syngas

    SciTech Connect

    Not Available

    1990-04-28

    The objectives of this contract are to discover and evaluate the catalytic properties of novel homogeneous, heterogeneous, or combination catalytic systems for the production of alcohol fuel extenders from syngas, to evaluate analytically and on the bench scale novel reactor concepts for use in converting syngas to liquid fuel products, and to develop on the bench scale the best combination of chemistry, reactor, and total process configuration to achieve the minimum product cost for conversion of syngas to liquid fuel products. Methanol production and heterogeneous catalysis utilizing transition elements supported on metal oxides with spinel structure are discussed. 12 figs., 16 tabs.

  17. Process of producing liquid hydrocarbon fuels from biomass

    DOEpatents

    Kuester, James L.

    1987-07-07

    A continuous thermochemical indirect liquefaction process to convert various biomass materials into diesel-type transportation fuels which fuels are compatible with current engine designs and distribution systems comprising feeding said biomass into a circulating solid fluidized bed gasification system to produce a synthesis gas containing olefins, hydrogen and carbon monoxide and thereafter introducing the synthesis gas into a catalytic liquefaction system to convert the synthesis gas into liquid hydrocarbon fuel consisting essentially of C.sub.7 -C.sub.17 paraffinic hydrocarbons having cetane indices of 50+.

  18. Process of producing liquid hydrocarbon fuels from biomass

    DOEpatents

    Kuester, J.L.

    1987-07-07

    A continuous thermochemical indirect liquefaction process is described to convert various biomass materials into diesel-type transportation fuels which fuels are compatible with current engine designs and distribution systems comprising feeding said biomass into a circulating solid fluidized bed gasification system to produce a synthesis gas containing olefins, hydrogen and carbon monoxide and thereafter introducing the synthesis gas into a catalytic liquefaction system to convert the synthesis gas into liquid hydrocarbon fuel consisting essentially of C[sub 7]-C[sub 17] paraffinic hydrocarbons having cetane indices of 50+. 1 fig.

  19. Preferential oxidation of methanol and carbon monoxide for gas cleanup during methanol fuel processing

    SciTech Connect

    Birdsell, S.A.; Vanderborgh, N.E.; Inbody, M.A.

    1993-07-01

    Methanol fuel processing generates hydrogen for low-temperature, PEM fuel cell systems now being considered for transportation and other applications. Although liquid methanol fuel is convenient for this application, existing fuel processing techniques generate contaminants that degrade fuel cell performance. Through mathematical models and laboratory experiments chemical processing is described that removes CO and other contaminants from the anode feed stream.

  20. Microwave Processing of Simulated Advanced Nuclear Fuel Pellets

    SciTech Connect

    D.E. Clark; D.C. Folz

    2010-08-29

    Throughout the three-year project funded by the Department of Energy (DOE) and lead by Virginia Tech (VT), project tasks were modified by consensus to fit the changing needs of the DOE with respect to developing new inert matrix fuel processing techniques. The focus throughout the project was on the use of microwave energy to sinter fully stabilized zirconia pellets using microwave energy and to evaluate the effectiveness of techniques that were developed. Additionally, the research team was to propose fundamental concepts as to processing radioactive fuels based on the effectiveness of the microwave process in sintering the simulated matrix material.

  1. Influence of Heat Treatment on Corrosion Resistance of High-Velocity Oxygen-Fuel Sprayed WC-17Co Coatings on 42CrMo Steel

    NASA Astrophysics Data System (ADS)

    Sun, Wan-chang; Zhang, Pei; Zhang, Feng; Dong, Chu-xu; Zhang, Ju-mei; Cai, Hui

    2015-09-01

    The influence of heat treatment from 500 to 1100 °C on the 5 wt.% H2SO4 solution-induced corrosion resistance of high-velocity oxygen-fuel sprayed WC-17Co coatings on 42CrMo steel was investigated, by using x-ray diffractometer (XRD), scanning electron microscopy (SEM)-energy-dispersive spectrometer (EDS), and polarization curve methods. XRD analysis showed decrease in W2C phase intensity with recrystallization of amorphous Co and generation of new Co3W3C and Co6W6C phases with heat treatment. Porosity distribution did not follow a particular pattern; it initially increased and then decreased with increasing temperature. Corrosion resistance sequence of the as-sprayed and heat-treated coatings in 5 wt.% H2SO4 solution was C-5 > C-9 > C-A > C-7 > C-11. Furthermore, microstructure and phase structure of heat-treated coatings revealed the formation of different discontinuous plate-like oxide films on the surface of the heat-treated coatings which indicated the vital effect of binder structure on the corrosion resistance.

  2. Effect of Particle and Injection Parameters on the Performance of a Dual-Stage High-Velocity Oxygen Fuel Thermal Spray System

    NASA Astrophysics Data System (ADS)

    Khan, Mohammed N.; Shamim, Tariq

    2015-06-01

    For temperature-sensitive material (such as titanium) coatings, recently developed high-velocity oxygen fuel dual-stage thermal spray systems offer better control of particle oxidation and production of various coating structures. These advantages of the dual-stage thermal system are significantly influenced by the state of the coating particles being injected. Hence, the objective of the present study is to investigate the effects of particle size, shape, injection velocity, and injection angle on a dual-stage thermal spray system by employing a comprehensive mathematical model. The results demonstrate that the particle size, shape, injection velocity, and injection angle affect the particle velocity and temperature, which in turn may affect the coating quality. The results show that smaller particles have higher temperatures and velocities owing to decrease in particle thermal and mass inertia. Spherical particles have higher temperature and lower velocity than the non-spherical particles because of lower drag. The particle velocity and temperature also increase with the increase of the injection velocity. Similarly, the particles injection angle also plays an important role. Higher particle temperatures and velocities outside of the barrel are obtained if the particles are injected at oblique angles to the main gaseous flow.

  3. Investigation into the diffusion and oxidation behavior of the interface between a plasma-sprayed anode and a porous steel support for solid oxide fuel cells

    NASA Astrophysics Data System (ADS)

    Zhang, Shan-Lin; Li, Cheng-Xin; Li, Chang-Jiu; Liu, Meilin; Yang, Guan-Jun

    2016-08-01

    Porous metal-supported solid oxide fuel cells (SOFCs) have attracted much attention because their potential to dramatically reduce the cost while enhancing the robustness and manufacturability. In particular, 430 ferritic steel (430L) is one of the popular choice for SOFC support because of its superior performance and low cost. In this study, we investigate the oxidation and diffusion behavior of the interface between a Ni-based anode and porous 430L support exposed to a humidified (3% H2O) hydrogen atmosphere at 700 °C. The Ni-GDC (Ce0.8Gd0.2O2-δ) cermet anodes are deposited on the porous 430L support by atmospheric plasma spraying (APS). The effect of exposure time on the microstructure and phase structure of the anode and the supports is studied and the element diffusion across the support/anode interface is characterized. Results indicate that the main oxidation product of the 430L support is Cr2O3, and that Cr and Fe will diffuse to the anode and the diffusion thickness increases with the exposure time. The diffusion thickness of Cr and Fe reach about 5 and 2 μm, respectively, after 1000 h exposure. However, the element diffusion and oxidation has little influence on the area-specific resistance, indicating that the porous 430L steel and plasma sprayed Ni-GDC anode are promising for durable SOFCs.

  4. Improvement in wear and corrosion resistance of AISI 1020 steel by high velocity oxy-fuel spray coating containing Ni-Cr-B-Si-Fe-C

    NASA Astrophysics Data System (ADS)

    Prince, M.; Thanu, A. Justin; Gopalakrishnan, P.

    2012-04-01

    In this investigation, AISI 1020 low carbon steel has been selected as the base material. The Ni based super alloy powder NiCrBSiFeC was sprayed on the base material using high velocity oxy-fuel spraying (HVOF) technique. The thickness of the coating was approximately 0.5 mm (500 μm). The coating was characterized using optical microscopy, Vickers microhardness testing, X-ray diffraction technique and scanning electron microscopy. Dry sliding wear tests were carried out at 3 m/s sliding speed under the load of 10 N for 1000 m sliding distance at various temperatures i.e., 35° C, 250° C and 350° C. The corrosion test was carried out in 1 M copper chloride in acetic acid solution. The polarization studies were also conducted for both base material and coating. The improvement in microhardness from 1.72 GPa (175 HV0.05) to 10.54 GPa (1075 HV0.05) was observed. The coatings exhibited 3-6 times improved wear resistance as compared with base material. Also, the corrosion rate was reduced by 3.5 times due to the presence of coatings.

  5. Surface characteristic of chemically converted graphene coated low carbon steel by electro spray coating method for polymer electrolyte membrane fuel cell bipolar plate.

    PubMed

    Kim, Jungsoo; Kim, Yang Do; Nam, Dae Geun

    2013-05-01

    Graphene was coated on low carbon steel (SS400) by electro spray coating method to improve its properties of corrosion resistance and contact resistance. Exfoliated graphite was made of the graphite by chemical treatment (Chemically Converted Graphene, CCG). CCG is distributed using dispersing agent, and low carbon steel was coated with diffuse graphene solution by electro spray coating method. The structure of the CCG was analyzed using XRD and the coating layer of surface was analyzed using SEM. Analysis showed that multi-layered graphite structure was destroyed and it was transformed in to fine layers graphene structure. And the result of SEM analysis on the surface and the cross section, graphene layer was uniformly formed with 3-5 microm thickness on the surface of substrate. Corrosion resistance test was applied in the corrosive solution which is similar to the polymer electrolyte membrane fuel cell (PEMFC) stack inside. And interfacial contact resistance (ICR) test was measured to simulate the internal operating conditions of PEMFC stack. As a result of measuring corrosion resistance and contact resistance, it could be confirmed that low carbon steel coated with CCG was revealed to be more effective in terms of its applicability as PEMFC bipolar plate. PMID:23858864

  6. Comparative High-Temperature Corrosion Behavior of Ni-20Cr Coatings on T22 Boiler Steel Produced by HVOF, D-Gun, and Cold Spraying

    NASA Astrophysics Data System (ADS)

    Kaushal, Gagandeep; Bala, Niraj; Kaur, Narinder; Singh, Harpreet; Prakash, Satya

    2014-01-01

    To protect materials from surface degradations such as wear, corrosion, and thermal flux, a wide variety of materials can be deposited on the materials by several spraying processes. This paper examines and compares the microstructure and high-temperature corrosion of Ni-20Cr coatings deposited on T22 boiler steel by high velocity oxy-fuel (HVOF), detonation gun spray, and cold spraying techniques. The coatings' microstructural features were characterized by means of XRD and FE-SEM/EDS analyses. Based upon the results of mass gain, XRD, and FE-SEM/EDS analyses it may be concluded that the Ni-20Cr coating sprayed by all the three techniques was effective in reducing the corrosion rate of the steel. Among the three coatings, D-gun spray coating proved to be better than HVOF-spray and cold-spray coatings.

  7. Process review of lignocellulose biochemical conversion to fuel ethanol

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This review is meant to give a general technical review of the state-of-the-art in process technology for the biochemical conversion of lignocellulose to fuel ethanol. The proceeding details the chemical structure of biomass and basic process steps needed for extracting carbohydrates as sugars and ...

  8. Coating Bores of Light Metal Engine Blocks with a Nanocomposite Material using the Plasma Transferred Wire Arc Thermal Spray Process

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Ernst, F.; Zwick, J.; Schlaefer, T.; Cook, D.; Nassenstein, K.; Schwenk, A.; Schreiber, F.; Wenz, T.; Flores, G.; Hahn, M.

    2008-09-01

    Engine blocks of modern passenger car engines are generally made of light metal alloys, mostly hypoeutectic AlSi-alloys. Due to their low hardness, these alloys do not meet the tribological requirements of the system cylinder running surface—piston rings—lubricating oil. In order to provide a suitable cylinder running surface, nowadays cylinder liners made of gray cast iron are pressed in or cast into the engine block. A newer approach is to apply thermal spray coatings onto the cylinder bore walls. Due to the geometric conditions, the coatings are applied with specifically designed internal diameter thermal spray systems. With these processes a broad variety of feedstock can be applied, whereas mostly low-alloyed carbon steel feedstock is being used for this application. In the context of this work, an iron-based wire feedstock has been developed, which leads to a nanocrystalline coating. The application of this material was carried out with the Plasma Transferred Wire Arc system. AlMgSi0.5 liners were used as substrates. The coating microstructure and the properties of the coatings were analyzed.

  9. Constrained Response Surface Optimisation and Taguchi Methods for Precisely Atomising Spraying Process

    NASA Astrophysics Data System (ADS)

    Luangpaiboon, P.; Suwankham, Y.; Homrossukon, S.

    2010-10-01

    This research presents a development of a design of experiment technique for quality improvement in automotive manufacturing industrial. The quality of interest is the colour shade, one of the key feature and exterior appearance for the vehicles. With low percentage of first time quality, the manufacturer has spent a lot of cost for repaired works as well as the longer production time. To permanently dissolve such problem, the precisely spraying condition should be optimized. Therefore, this work will apply the full factorial design, the multiple regression, the constrained response surface optimization methods or CRSOM, and Taguchi's method to investigate the significant factors and to determine the optimum factor level in order to improve the quality of paint shop. Firstly, 2κ full factorial was employed to study the effect of five factors including the paint flow rate at robot setting, the paint levelling agent, the paint pigment, the additive slow solvent, and non volatile solid at spraying of atomizing spraying machine. The response values of colour shade at 15 and 45 degrees were measured using spectrophotometer. Then the regression models of colour shade at both degrees were developed from the significant factors affecting each response. Consequently, both regression models were placed into the form of linear programming to maximize the colour shade subjected to 3 main factors including the pigment, the additive solvent and the flow rate. Finally, Taguchi's method was applied to determine the proper level of key variable factors to achieve the mean value target of colour shade. The factor of non volatile solid was found to be one more additional factor at this stage. Consequently, the proper level of all factors from both experiment design methods were used to set a confirmation experiment. It was found that the colour shades, both visual at 15 and 45 angel of measurement degrees of spectrophotometer, were nearly closed to the target and the defective at

  10. Gas detonation gun for thermal spraying

    SciTech Connect

    Kadyrov, E.; Kadyrov, V.

    1995-08-01

    High-velocity oxy-fuel and gas detonation are competing spray coating processes well known for providing premium quality coatings with low porosity and high adhesion. They are favored for applications in environments of extreme wear, heat, and aggressive corrosion. Nevertheless, they both have limitations. For the HVOF process, these include excessive gas consumption, high rate of heat transfer to the sprayed substrate, and the short life of the (supersonic) Laval nozzle. On the other hand, the traditional gas detonation gun also has drawbacks, and the purpose of this article is to outline some factors that led to the design of an improved gas detonation coating process called Demeton, produced by Demeton USA Inc., Garden City Park, N.Y.

  11. DEVELOPMENT OF LOW-COST MANUFACTURING PROCESSES FOR PLANAR, MULTILAYER SOLID OXIDE FUEL CELL ELEMENTS

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Harlan Anderson; Tim Armstrong; Michael Cobb; Kirby Meacham; James Stephan; Russell Bennett; Bob Remick; Chuck Sishtla; Scott Barnett; John Lannutti

    2004-06-12

    This report summarizes the results of a four-year project, entitled, ''Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'', jointly funded by the U.S. Department of Energy, the State of Ohio, and by project participants. The project was led by NexTech Materials, Ltd., with subcontracting support provided by University of Missouri-Rolla, Michael A. Cobb & Co., Advanced Materials Technologies, Inc., Edison Materials Technology Center, Gas Technology Institute, Northwestern University, and The Ohio State University. Oak Ridge National Laboratory, though not formally a subcontractor on the program, supported the effort with separate DOE funding. The objective of the program was to develop advanced manufacturing technologies for making solid oxide fuel cell components that are more economical and reliable for a variety of applications. The program was carried out in three phases. In the Phase I effort, several manufacturing approaches were considered and subjected to detailed assessments of manufacturability and development risk. Estimated manufacturing costs for 5-kW stacks were in the range of $139/kW to $179/kW. The risk assessment identified a number of technical issues that would need to be considered during development. Phase II development work focused on development of planar solid oxide fuel cell elements, using a number of ceramic manufacturing methods, including tape casting, colloidal-spray deposition, screen printing, spin-coating, and sintering. Several processes were successfully established for fabrication of anode-supported, thin-film electrolyte cells, with performance levels at or near the state-of-the-art. The work in Phase III involved scale-up of cell manufacturing methods, development of non-destructive evaluation methods, and comprehensive electrical and electrochemical testing of solid oxide fuel cell materials and components.

  12. Plasma Spray System

    NASA Technical Reports Server (NTRS)

    1980-01-01

    Computer aided, fully-automatic TRW system sprays very hot plasma onto a turbine blade. Composed of gas into which metallic and ceramic powders have been injected, the plasma forms a two-layer coating which insulates the blade. Critical part of operation is controlling the thickness of the deposit which is measured in thousandths of an inch. This is accomplished by an optical detector which illuminates spots at various locations on the blade and determines thickness by measuring the light reflections. Optical sensor monitors spraying process until precise thickness is attained, then computer halts the spraying.

  13. Spray combustion stability

    NASA Technical Reports Server (NTRS)

    Liang, Pak-Yan; Jeng, San-Mou; Litchford, Ronald

    1989-01-01

    The central purpose of this project is the improvement of liquid-fueled rocket motor design technology in order to assist the establishment of economical commercial access to space through the development of engines with enhanced performance and reliability. Specific research effort is focused on spray physics and associated combustion instability phenomena. Results concerning high pressure droplet gasification model, droplet turbulent dispersion model, and spray atomization model will contribute to the development of new computational tools for design of stable liquid propellant rocket engines.

  14. Performance of high-velocity oxy-fuel-sprayed chromium carbide-nickel chromium coating in an actual boiler environment of a thermal power plant

    SciTech Connect

    Sidhu, T.S.; Prakash, S.; Agrawal, R.D.

    2007-09-15

    The present study aims to evaluate the performance of a high-velocity oxy-fuel (HVOF)-sprayed Cr{sub 3}C{sub 2}-NiCr (chromium carbide-nickel chromium) coating on a nickel-based super-alloy in an actual industrial environment of a coal-fired boiler, with the objective to protect the boiler super-heater and reheater tubes from hot corrosion. The tests were performed in the platen super heater zone of a coal-fired boiler for 1,000 h at 900 degrees C under cyclic conditions. The Cr{sub 3}C{sub 2}-NiCr coating imparted the necessary protection to the nickel-based super alloy in the given environment. The dense and flat splat structure of the coating, and the formation of oxides of chromium and nickel and their spinels, might have protected the substrate super alloy from the inward permeation of corrosive species.

  15. Effect of ultrasonic cavitation erosion on corrosion behavior of high-velocity oxygen-fuel (HVOF) sprayed near-nanostructured WC-10Co-4Cr coating.

    PubMed

    Hong, Sheng; Wu, Yuping; Zhang, Jianfeng; Zheng, Yugui; Qin, Yujiao; Lin, Jinran

    2015-11-01

    The effect of ultrasonic cavitation erosion on electrochemical corrosion behavior of high-velocity oxygen-fuel (HVOF) sprayed near-nanostructured WC-10Co-4Cr coating in 3.5 wt.% NaCl solution, was investigated using free corrosion potential, potentiodynamic polarization curves and electrochemical impedance spectroscopy (EIS) in comparison with stainless steel 1Cr18Ni9Ti. The results showed that cavitation erosion strongly enhanced the cathodic current density, shifted the free corrosion potential in the anodic direction, and reduced the magnitude of impedance of the coating. The impedance of the coating decreased more slowly under cavitation conditions than that of the stainless steel 1Cr18Ni9Ti, suggesting that corrosion behavior of the coating was less affected by cavitation erosion than that of the stainless steel. PMID:26186856

  16. Electrostatic powder spraying process for the fabrication of stable superhydrophobic surfaces

    NASA Astrophysics Data System (ADS)

    Gu, Guotuan; Tian, Yuping; Li, Zhantie; Lu, Dongfang

    2011-03-01

    Nano-sized Al2O3 particles were modified by heptadecafluorodecyl trimethoxysilane and 2,3-epoxy propoxy propyl trimethoxysilicane to make it both hydrophobic and reactive. The reactive nano-particles were mixed with polyester resin containing curing agents and electrostatic sprayed on stainless steel substrates to obtain stable superhydrophobic coatings after curing. The water contact angle (WCA) on the hybrid coating is influenced by the content of Al2O3 particles in the coating. As the Al2O3 concentration in the coating was increased from 0% to 8%, WCA increased from 68° to 165°. Surface topography of the coatings was examined using scanning electron microscopy (SEM). Nano-particles covered on the coating surface formed continuous film with greatly enhanced roughness, which was found to be responsible for the superhydrophobicity. The method is simple and cost effective and can be used for preparing self-cleaning superhydrophobic coating on large areas.

  17. Indium oxide thin-film transistors processed at low temperature via ultrasonic spray pyrolysis.

    PubMed

    Faber, Hendrik; Lin, Yen-Hung; Thomas, Stuart R; Zhao, Kui; Pliatsikas, Nikos; McLachlan, Martyn A; Amassian, Aram; Patsalas, Panos A; Anthopoulos, Thomas D

    2015-01-14

    The use of ultrasonic spray pyrolysis is demonstrated for the growth of polycrystalline, highly uniform indium oxide films at temperatures in the range of 200-300 °C in air using an aqueous In(NO3)3 precursor solution. Electrical characterization of as-deposited films by field-effect measurements reveals a strong dependence of the electron mobility on deposition temperature. Transistors fabricated at ∼250 °C exhibit optimum performance with maximum electron mobility values in the range of 15-20 cm(2) V (-1) s(-1) and current on/off ratio in excess of 10(6). Structural and compositional analysis of as-grown films by means of X-ray diffraction, diffuse scattering, and X-ray photoelectron spectroscopy reveal that layers deposited at 250 °C are denser and contain a reduced amount of hydroxyl groups as compared to films grown at either lower or higher temperatures. Microstructural analysis of semiconducting films deposited at 250 °C by high resolution cross-sectional transmission electron microscopy reveals that as-grown layers are extremely thin (∼7 nm) and composed of laterally large (30-60 nm) highly crystalline In2O3 domains. These unique characteristics of the In2O3 films are believed to be responsible for the high electron mobilities obtained from transistors fabricated at 250 °C. Our work demonstrates the ability to grow high quality low-dimensional In2O3 films and devices via ultrasonic spray pyrolysis over large area substrates while at the same time it provides guidelines for further material and device improvements. PMID:25490965

  18. Influences of process and formulation parameters on powder flow properties and immunogenicity of spray dried polymer particles entrapping recombinant pneumococcal surface protein A.

    PubMed

    Anish, Chakkumkal; Upadhyay, Arun K; Sehgal, Devinder; Panda, Amulya Kumar

    2014-05-15

    Particle size, antigen load and its release characteristic are the three the main attributes of polymer particles based vaccine delivery systems. The present studies focus on the formulation of spray dried polylactide microparticles entrapping pneumococcal surface protein A (PspA). Influence of process variables during polymer particle formation were optimized by using half-factorial design. Feed rate and atomization pressure during spray drying were found to be the most important parameters for achieving uniform size particles. Spray drying of preformed particles from different stages of solvent evaporation method resulted in formation of particle having different porosity and protein release profile. Presence of polyvinyl alcohol in the external aqueous phase not only contributed towards regulating the size of particles but also influenced the burst release of protein from particles. Polymer particles entrapping PspA elicited robust IgG responses both in mice and in rats. Antigen load in microparticles correlated with the antibody titer indicating the maintenance of protein integrity during particle formation using spray drying. Both, process engineering and formulation parameters during spray drying influenced the particles in terms of size, load and antigen release characteristics. PMID:24631054

  19. CONVERTING PYROLYSIS OILS TO RENEWABLE TRANSPORT FUELS: PROCESSING CHALLENGES & OPPORTUNITIES

    SciTech Connect

    Holmgren, Jennifer; Nair, Prabhakar N.; Elliott, Douglas C.; Bain, Richard; Marinangelli, Richard

    2008-03-11

    To enable a sustained supply of biomass-based transportation fuels, the capability to process feedstocks outside the food chain must be developed. Significant industry efforts are underway to develop these new technologies, such as converting cellulosic wastes to ethanol. UOP, in partnership with U.S. Government labs, NREL and PNNL, is developing an alternate route using cellulosic feedstocks. The waste biomass is first subjected to a fast pyrolysis operation to generate pyrolysis oil (pyoil for short). Current efforts are focused on developing a thermochemical platform to convert pyoils to renewable gasoline, diesel and jet fuel. The fuels produced will be indistinguishable from their fossil fuel counterparts and, therefore, will be compatible with existing transport and distribution infrastructure.

  20. Processing of carbon composite paper as electrode for fuel cell

    NASA Astrophysics Data System (ADS)

    Mathur, R. B.; Maheshwari, Priyanka H.; Dhami, T. L.; Sharma, R. K.; Sharma, C. P.

    The porous carbon electrode in a fuel cell not only acts as an electrolyte and a catalyst support, but also allows the diffusion of hydrogen fuel through its fine porosity and serves as a current-carrying conductor. A suitable carbon paper electrode is developed and possesses the characteristics of high porosity, permeability and strength along with low electrical resistivity so that it can be effectively used in proton-exchange membrane and phosphoric acid fuel cells. The electrode is prepared through a combination of two important techniques, viz., paper-making technology by first forming a porous chopped carbon fibre preform, and composite technology using a thermosetting resin matrix. The study reveals an interdependence of one parameter on another and how judicious choice of the processing conditions are necessary to achieve the desired characteristics. The current-voltage performance of the electrode in a unit fuel cell matches that of a commercially-available material.

  1. Motor fuel alkylation process utilizing low acid

    SciTech Connect

    Kocal, J.A.; Imai, T.

    1987-01-06

    A process is described for the alkylation of an isoparaffin with an olefin acting agent comprising contacting the isoparaffin with the olefin acting agent at alkylation conditions in the presence of a catalyst. The catalyst consists essentially of an anhydrous, nonalcoholic mixture of from about 5 to 15 wt. % methyl tert-butyl ether and from 85 to 95 wt. % hydrofluoric acid. The volumetric ratio of hydrofluoric acid to isoparaffin and olefin acting agent is less than 0.75.

  2. Injector spray characterization of methanol in reciprocating engines

    SciTech Connect

    Dodge, L.; Naegeli, D.

    1994-06-01

    This report covers a study that addressed cold-starting problems in alcohol-fueled, spark-ignition engines by using fine-spray port-fuel injectors to inject fuel directly into the cylinder. This task included development and characterization of some very fine-spray, port-fuel injectors for a methanol-fueled spark-ignition engine. After determining the spray characteristics, a computational study was performed to estimate the evaporation rate of the methanol fuel spray under cold-starting and steady-state conditions.

  3. Nonlinear optical diagnostics of diesel spray. Final report, August 3, 1987--July 31, 1991

    SciTech Connect

    Chang, R.K.

    1991-09-01

    The mechanisms of fuel spray development within engines, particularly processes including atomization, vaporization, and mixing of the fuel and air, are critical in the design and optimization of diesel engines. During the four years of DOE support, significant progress has been made toward furthering the understanding of nonlinear optical effects in fuel sprays and single liquid droplets with radius (a) much larger than the laser wavelength ({lambda}{sub input}), i.e., droplets with with large size parameters x = 2{pi}a/{lambda}{sub input}. The authors have attempted to apply nonlinear optical spectroscopy to determine the chemical composition of the droplet, the droplet morphology (size, shape, and index of refraction), and the physical properties of the droplet (surface tension and bulk viscosity). This research can be divided into two parts: (1) understanding of nonlinear optical effects: and (2) application of nonlinear optical spectroscopy and imaging to fuel droplets and sprays.

  4. Effect of In-Plume Aerosol Processing on the Efficacy of Marine Cloud Albedo Enhancement from Controlled Sea-Spray Injections

    NASA Astrophysics Data System (ADS)

    Stevens, R. G.; Spracklen, D.; Korhonen, H.; Pierce, J. R.

    2010-12-01

    The intentional enhancement of cloud albedo via controlled sea-spray injection from ships has been suggested as a possible means to control anthropogenic global warming (1); however, there remains significant uncertainty in the efficacy of this method due to uncertainties in aerosol and cloud microphysics. Recent analysis showed that more sea-spray may be necessary than previously assumed to reach a desired cooling due to nonlinearities in the aerosol/cloud microphysics (2). A major assumption used in (2) is that all sea-spray was emitted uniformly into some oceanic grid boxes, and thus did not account for sub-grid aerosol microphysics within the sea-spray plumes. However, as a consequnce of the fast sea-spray injection rates which are proposed, in the order of 1x10^17 1/s (1), particle concentrations in these plumes may be quite high and particle coagulation may significantly reduce the number of emitted particles and increase their average size. Therefore, it is possible that the emissions necessary to reach a desired cooling may be even larger than currently assumed. We explore the processing of the freshly emitted sea-spray plumes in the Large-Eddy Simulation (LES)/Cloud Resolving Model (CRM) the System for Atmospheric Modelling (SAM, 3) with the online aerosol microphysics module TOMAS (4). We determine how the final number and size of particles (once well mixed with background air) depends on the emission rate and size distribution of the sea-spray plume and on the pre-existing aerosol concentrations and local atmospheric conditions. Finally, we make suggestions for effective size-resolved emissions for use in climate models. (1) Salter, S. et al., Phil. Trans. R. Soc. A., 2008. (2) Korhonen, H. et al., Atmos. Chem. Phys., 10, 4133-4143, 2010. (3) Khairoutdinov, M., and Randall, D.,. J. Atmos. Sci., 60, 607-625, 2003. (4) Pierce, J. and Adams, P., Atmos. Chem. Phys., 9, 1339-1356, 2009.

  5. Pyrolysis process for producing fuel gas

    NASA Technical Reports Server (NTRS)

    Serio, Michael A. (Inventor); Kroo, Erik (Inventor); Wojtowicz, Marek A. (Inventor); Suuberg, Eric M. (Inventor)

    2007-01-01

    Solid waste resource recovery in space is effected by pyrolysis processing, to produce light gases as the main products (CH.sub.4, H.sub.2, CO.sub.2, CO, H.sub.2O, NH.sub.3) and a reactive carbon-rich char as the main byproduct. Significant amounts of liquid products are formed under less severe pyrolysis conditions, and are cracked almost completely to gases as the temperature is raised. A primary pyrolysis model for the composite mixture is based on an existing model for whole biomass materials, and an artificial neural network models the changes in gas composition with the severity of pyrolysis conditions.

  6. Processing waste fats into a fuel oil substitute

    SciTech Connect

    Pudel, F.; Lengenfeld, P.

    1993-12-31

    Waste fats have a high energy potential. They also contain impurities. For example, fats used for deep-frying contain high contents of solids, water, and chlorides. The process described in this paper removes the impurities by simple processing such as screening, washing, separating, drying, and filtering. The final quality of processed fat allows its use as a fuel oil substitute, and also as a raw material for chemical production.

  7. Oxymetazoline Nasal Spray

    MedlinePlus

    Afrin® Nasal Spray ... Anefrin® Nasal Spray ... Dristan® Nasal Spray ... Mucinex® Nasal Spray ... Nostrilla® Nasal Spray ... Vicks Sinex® Nasal Spray ... Zicam® Nasal Spray ... Oxymetazoline nasal spray is used to relieve nasal discomfort caused by colds, allergies, and hay fever. It is also used to ...

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

    NASA Astrophysics Data System (ADS)

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

    2015-05-01

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

  9. On the combustion of a laminar spray

    NASA Technical Reports Server (NTRS)

    Levy, Yeshayahou; Bulzan, Daniel L.

    1993-01-01

    A spray combustor, with flow velocities in the laminar range, exhibits a unique operating mode where large amplitude, self-induced oscillations of the flame shape occur. The phenomenon, not previously encountered, only occurs when fuel is supplied in the form of fine liquid droplets and does not occur when fuel is supplied in gaseous form. Several flow mechanisms are coupled in such a fashion as to trigger and maintain the oscillatory motion of the flame. These mechanisms include heat transfer and evaporation processes, dynamics of two-phase flows, and effects of gravity (buoyancy forces). An interface volume, lying above the fuel nozzle and below the flame was found to be the most susceptible to gravity effects and postulated to be responsible for inducing the oscillatory motion. Heptane fuel was used in the majority of the tests. Tests performed with iso-octane also showed similar results.

  10. Thermal Shock Resistance of Stabilized Zirconia/Metal Coat on Polymer Matrix Composites by Thermal Spraying Process

    NASA Astrophysics Data System (ADS)

    Zhu, Ling; Huang, Wenzhi; Cheng, Haifeng; Cao, Xueqiang

    2014-09-01

    Stabilized zirconia/metal coating systems were deposited on the polymer matrix composites by a combined thermal spray process. Effects of the thicknesses of metal layers and ceramic layer on thermal shock resistance of the coating systems were investigated. According to the results of thermal shock lifetime, the coating system consisting of 20 μm Zn and 125 μm 8YSZ exhibited the best thermal shock resistance. Based on microstructure evolution, failure modes and failure mechanism of the coating systems were proposed. The main failure modes were the formation of vertical cracks and delamination in the outlayer of substrate, and the appearance of coating spallation. The residual stress, thermal stress and oxidation of substrate near the substrate/metal layer interface were responsible for coating failure, while the oxidation of substrate near the substrate/coating interface was the dominant one.

  11. Thermal Shock Resistance of Stabilized Zirconia/Metal Coat on Polymer Matrix Composites by Thermal Spraying Process

    NASA Astrophysics Data System (ADS)

    Zhu, Ling; Huang, Wenzhi; Cheng, Haifeng; Cao, Xueqiang

    2014-12-01

    Stabilized zirconia/metal coating systems were deposited on the polymer matrix composites by a combined thermal spray process. Effects of the thicknesses of metal layers and ceramic layer on thermal shock resistance of the coating systems were investigated. According to the results of thermal shock lifetime, the coating system consisting of 20 μm Zn and 125 μm 8YSZ exhibited the best thermal shock resistance. Based on microstructure evolution, failure modes and failure mechanism of the coating systems were proposed. The main failure modes were the formation of vertical cracks and delamination in the outlayer of substrate, and the appearance of coating spallation. The residual stress, thermal stress and oxidation of substrate near the substrate/metal layer interface were responsible for coating failure, while the oxidation of substrate near the substrate/coating interface was the dominant one.

  12. Preparation of lithium-rich layered oxide micro-spheres using a slurry spray-drying process

    NASA Astrophysics Data System (ADS)

    Hou, Mengyan; Guo, Shaoshuai; Liu, Jinlong; Yang, Jun; Wang, Yonggang; Wang, Congxiao; Xia, Yongyao

    2015-08-01

    0.5Li2MnO3·0.5LiMn1/3Ni1/3Co1/3O2 microspheres are prepared by a slurry spray-drying process (SD-LLO) with subsequent heat treatment. SEM images show that the SD-LLO microspheres are composed of nano-size primary particles. These particles are quite different from conventional LLO microspheres, which are composed of micron-scale plate-like primary particles prepared by a co-precipitation method (CP-LLO). The SD-LLO material experiences a smaller voltage drop during cycling than CP-LLO when used as cathode material in lithium-ion batteries. High-resolution transmission electron microscopy (HR-TEM) and energy dispersive spectroscopy (EDS) indicate that the smaller voltage drop of SD-LLO can be attributed to a more homogeneous distribution of transition metals.

  13. Application of commercially pure titanium coatings using HVOF thermal spray for machinery component restoration

    SciTech Connect

    McCaw, R.L.; Hays, R.A.; Brenna, R.T.

    1994-12-31

    Alloy 625 has been shown to be susceptible to crevice corrosion under tight metal to nonmetal crevices in both natural and treated seawater. Under similar conditions, commercially pure titanium (CP Ti) has been shown to be immune. Therefore, coating alloy 625 sealing areas with CP Ti is a potentially effective crevice corrosion countermeasure. Specialized thermal spray techniques were developed utilizing the high velocity oxy-fuel (HVOF) process to apply coatings of CP Ti to alloy 625 substrates in atmosphere. Coating quality was similar to plasma sprayed coatings of other less reactive, metals. Crevice corrosion tests were conducted and issues relating to implementation of HVOF thermal spraying on a production basis were considered.

  14. A spray-coating process for highly conductive silver nanowire networks as the transparent top-electrode for small molecule organic photovoltaics.

    PubMed

    Selzer, Franz; Weiss, Nelli; Kneppe, David; Bormann, Ludwig; Sachse, Christoph; Gaponik, Nikolai; Eychmüller, Alexander; Leo, Karl; Müller-Meskamp, Lars

    2015-02-14

    We present a novel top-electrode spray-coating process for the solution-based deposition of silver nanowires (AgNWs) onto vacuum-processed small molecule organic electronic solar cells. The process is compatible with organic light emitting diodes (OLEDs) and organic light emitting thin film transistors (OLETs) as well. By modifying commonly synthesized AgNWs with a perfluorinated methacrylate, we are able to disperse these wires in a highly fluorinated solvent. This solvent does not dissolve most organic materials, enabling a top spray-coating process for sensitive small molecule and polymer-based devices. The optimized preparation of the novel AgNW dispersion and spray-coating at only 30 °C leads to high performance electrodes directly after the deposition, exhibiting a sheet resistance of 10.0 Ω □(-1) at 87.4% transparency (80.0% with substrate). By spraying our novel AgNW dispersion in air onto the vacuum-processed organic p-i-n type solar cells, we obtain working solar cells with a power conversion efficiency (PCE) of 1.23%, compared to the air exposed reference devices employing thermally evaporated thin metal layers as the top-electrode. PMID:25584968

  15. Development of Low-Cost Manufacturing Processes for Planar, Multilayer Solid Oxide Fuel Cell Elements

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Tim Armstrong; Harlan Anderson; John Lannutti

    2001-09-30

    This report summarizes the results of Phase II of this program, 'Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'. The objective of the program is to develop advanced ceramic manufacturing technologies for making planar solid oxide fuel cell (SOFC) components that are more economical and reliable for a variety of applications. Phase II development work focused on three distinct manufacturing approaches (or tracks) for planar solid oxide fuel cell elements. Two development tracks, led by NexTech Materials and Oak Ridge National Laboratory, involved co-sintering of planar SOFC elements of cathode-supported and anode-supported variations. A third development track, led by the University of Missouri-Rolla, focused on a revolutionary approach for reducing operating temperature of SOFCs by using spin-coating to deposit ultra-thin, nano-crystalline YSZ electrolyte films. The work in Phase II was supported by characterization work at Ohio State University. The primary technical accomplishments within each of the three development tracks are summarized. Track 1--NexTech's targeted manufacturing process for planar SOFC elements involves tape casting of porous electrode substrates, colloidal-spray deposition of YSZ electrolyte films, co-sintering of bi-layer elements, and screen printing of opposite electrode coatings. The bulk of NexTech's work focused on making cathode-supported elements, although the processes developed at NexTech also were applied to the fabrication of anode-supported cells. Primary accomplishments within this track are summarized below: (1) Scale up of lanthanum strontium manganite (LSM) cathode powder production process; (2) Development and scale-up of tape casting methods for cathode and anode substrates; (3) Development of automated ultrasonic-spray process for depositing YSZ films; (4) Successful co-sintering of flat bi-layer elements (both cathode and anode supported); (5) Development of anode and cathode screen-printing processes; and (6

  16. One-step spray processing of high power all-solid-state supercapacitors

    PubMed Central

    Huang, Chun; Grant, Patrick S.

    2013-01-01

    Aqueous suspensions of multi-wall carbon nanotubes (MWNTs) in dilute H2SO4 were sprayed onto both sides of a Nafion membrane and dried to fabricate flexible solid-state supercapacitors. A single cell with MWNT-only electrodes had a capacitance of 57 F g−1 per electrode at 2 mV s−1 and 44 F g−1 at 150 mV s−1 but with low H+ mobility. Cells with MWNT + ionomer hybrid electrodes showed higher H+ mobility, and the electric double layer (EDL) capacitance increased to 145 F g−1 at 2 mV s−1 and 91 F g−1 at 150 mV s−1. The energy and power densities of one electrode charged to 1 V at 1 A g−1 were 12.9 Wh kg−1 and 3.3 kW kg−1 respectively. Three solid-state supercapacitor cells connected in series charged to 3 V at 1 and 2 A g−1 provided a device power density of 8.9 kW kg−1 at 1 A g−1 and 9.4 kW kg−1 at 2 A g−1, the highest for all-solid-state EDL supercapacitors. PMID:23928828

  17. One-step spray processing of high power all-solid-state supercapacitors

    NASA Astrophysics Data System (ADS)

    Huang, Chun; Grant, Patrick S.

    2013-08-01

    Aqueous suspensions of multi-wall carbon nanotubes (MWNTs) in dilute H2SO4 were sprayed onto both sides of a Nafion membrane and dried to fabricate flexible solid-state supercapacitors. A single cell with MWNT-only electrodes had a capacitance of 57 F g-1 per electrode at 2 mV s-1 and 44 F g-1 at 150 mV s-1 but with low H+ mobility. Cells with MWNT + ionomer hybrid electrodes showed higher H+ mobility, and the electric double layer (EDL) capacitance increased to 145 F g-1 at 2 mV s-1 and 91 F g-1 at 150 mV s-1. The energy and power densities of one electrode charged to 1 V at 1 A g-1 were 12.9 Wh kg-1 and 3.3 kW kg-1 respectively. Three solid-state supercapacitor cells connected in series charged to 3 V at 1 and 2 A g-1 provided a device power density of 8.9 kW kg-1 at 1 A g-1 and 9.4 kW kg-1 at 2 A g-1, the highest for all-solid-state EDL supercapacitors.

  18. One-step spray processing of high power all-solid-state supercapacitors.

    PubMed

    Huang, Chun; Grant, Patrick S

    2013-01-01

    Aqueous suspensions of multi-wall carbon nanotubes (MWNTs) in dilute H2SO4 were sprayed onto both sides of a Nafion membrane and dried to fabricate flexible solid-state supercapacitors. A single cell with MWNT-only electrodes had a capacitance of 57 F g(-1) per electrode at 2 mV s(-1) and 44 F g(-1) at 150 mV s(-1) but with low H(+) mobility. Cells with MWNT + ionomer hybrid electrodes showed higher H(+) mobility, and the electric double layer (EDL) capacitance increased to 145 F g(-1) at 2 mV s(-1) and 91 F g(-1) at 150 mV s(-1). The energy and power densities of one electrode charged to 1 V at 1 A g(-1) were 12.9 Wh kg(-1) and 3.3 kW kg(-1) respectively. Three solid-state supercapacitor cells connected in series charged to 3 V at 1 and 2 A g(-1) provided a device power density of 8.9 kW kg(-1) at 1 A g(-1) and 9.4 kW kg(-1) at 2 A g(-1), the highest for all-solid-state EDL supercapacitors. PMID:23928828

  19. Fuel ethanol production from crop residues and processing byproducts

    Technology Transfer Automated Retrieval System (TEKTRAN)

    In 2007, the production of fuel ethanol from corn starch reached 6.5 billion gallons in the U.S.A. Various crop residues such as corn stover, wheat straw, and barley straw, and crop processing byproducts such as corn fiber and rice hulls can serve as low-cost lignocellulosic feedstocks for conversi...

  20. 76 FR 44049 - Guidance for Fuel Cycle Facility Change Processes

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-07-22

    ... COMMISSION Guidance for Fuel Cycle Facility Change Processes AGENCY: Nuclear Regulatory Commission. ACTION: Draft regulatory guide; extension of comment period. SUMMARY: On July 14, 2011 (76 FR 41527), the U.S...: Richard.Jervey@nrc.gov . SUPPLEMENTARY INFORMATION: On July 14, 2011 (76 FR 41527), the NRC published...