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Sample records for vacuum plasma spraying

  1. 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.

  2. Vacuum Plasma Spraying Replaces Electrodeposition

    NASA Technical Reports Server (NTRS)

    Holmes, Richard R.; Power, Chris; Burns, David H.; Daniel, Ron; Mckechnie, Timothy N.

    1992-01-01

    Vacuum plasma spraying used to fabricate large parts with complicated contours and inner structures, without uninspectable welds. Reduces time, and expense of fabrication. Wall of combustion chamber built up inside of outer nickel-alloy jacket by plasma spraying. Particles of metal sprayed partially melted in plasma gun and thrown at supersonic speed toward deposition surface. Vacuum plasma-spray produces stronger bond between the grooves and covering layer completing channels and wall of combustion chamber. In tests, bond withstood pressure of 20 kpsi, three times allowable limit by old method.

  3. Vacuum plasma spraying of tantalum and niobium

    SciTech Connect

    Lugscheider, E.; Eschnauer, H.; Haeuser, B.; Jaeger, D.

    1985-11-01

    Vacuum plasma spraying is a suitable process for producing high quality coatings of reactive metals such as tantalum and niobium. Ta and Nb coatings used for corrosion protection must be extremely dense, homogeneous, and of high purity and adhesion. Hence, the process parameters have to be carefully optimized even with regard to the spraying powder, its grain size and morphology. Spraying equipment with vacuum systems which allow for a final pressure of 10/sup -3/ mbar, which have heated and evacuated powder feeder units, and heated substrates, as well as the use of powders with high purity and low gas content, are required for producing high quality Ta and Nb coatings. Corrosion tests in sulfuric acid and aqua regia at different concentrations show that Ta and Nb coatings sprayed under optimized conditions have high resistance to both general and localized corrosion.

  4. Rugged Preheaters For Vacuum Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Woodford, William H.; Mckechnie, Timothy N.; Sander, Lewis D.; Power, Christopher A.; Sander, Heather L.; Nguyen, Dalton D.

    1994-01-01

    Electric preheater units built to ensure large workpieces to be coated with metals by vacuum plasma spraying heated uniformly to requisite high temperatures by time plasma torch arrives. Units similar to electrical-resistance ribbon heaters in toasters and in some small portable electric "space" heaters. Nichrome resistance-heating ribbons wrapped around ceramic insulating spools on rings and on plates. Round workpiece placed in middle of ring preheater. Plate preheaters stacked as needed near workpiece.

  5. Heavy-Workpiece Handler For Vacuum Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Myers, William N.

    1991-01-01

    Handling device manipulates heavy, hollow workpiece for plasma spraying in vacuum chamber. Rotates and tilts workpiece, keeping it approximately perpendicular to plasma-spray nozzle, so nozzle deposits uniform layer on interior surface of workpiece. Accommodates workpieces as heavy as 1,000 pounds and compatible with heat and vacuum of spraying process.

  6. 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.

  7. 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.

  8. Alignment Fixtures For Vacuum-Plasma-Spray Gun

    NASA Technical Reports Server (NTRS)

    Woodford, William H.; Mckechnie, Timothy N.; Power, Christopher A.; Daniel, Ronald L., Jr.

    1993-01-01

    Fixtures for alignment of vacuum-plasma-spray guns built. Each fixture designed to fit specific gun and holds small, battery-powered laser on centerline of gun. Laser beam projects small red dot where centerline intersects surface of workpiece to be sprayed. After laser beam positioned on surface of workpiece, fixture removed from gun and spraying proceeds.

  9. Thermal Expansion of Vacuum Plasma Sprayed Coatings

    NASA Technical Reports Server (NTRS)

    Raj, S V.; Palczer, A. R.

    2010-01-01

    Metallic Cu-8%Cr, Cu-26%Cr, Cu-8%Cr-1%Al, NiAl and NiCrAlY monolithic coatings were fabricated by vacuum plasma spray deposition processes for thermal expansion property measurements between 293 and 1223 K. The corrected thermal expansion, (DL/L(sub 0) varies with the absolute temperature, T, as (DL/L(sub 0) = A(T - 293)(sup 3) + BIT - 293)(sup 2) + C(T - 293) + D, where, A, B, C and D are thermal, regression constants. Excellent reproducibility was observed for all of the coatings except for data obtained on the Cu-8%Cr and Cu-26%Cr coatings in the first heat-up cycle, which deviated from those determined in the subsequent cycles. This deviation is attributed to the presence of residual stresses developed during the spraying of the coatings, which are relieved after the first heat-up cycle. In the cases of Cu-8%Cr and NiAl, the thermal expansion data were observed to be reproducible for three specimens. The linear expansion data for Cu-8% Cr and Cu-26%Cr agree extremely well with rule of mixture (ROM) predictions. Comparison of the data for the Cu-8%Cr coating with literature data for Cr and Cu revealed that the thermal expansion behavior of this alloy is determined by the Cu-rich matrix. The data for NiAl and NiCrAlY are in excellent agreement with published results irrespective of composition and the methods used for processing the materials. The implications of these results on coating GRCop-84 copper alloy combustor liners for reusable launch vehicles are discussed.

  10. Removable Mandrels For Vacuum-Plasma-Spray Forming

    NASA Technical Reports Server (NTRS)

    Krotz, Phillip D.; Davis, William M.; Power, Christopher A.; Woodford, William H.; Todd, Douglas M.; Liaw, Yoon K.; Holmes, Richard R.; Zimmerman, Frank R.; Mckechnie, Timothy N.

    1995-01-01

    Improved mandrels developed for use in vacuum-plasma-spray (VPS) forming of refractory metal and ceramic furnace cartridge tubes. Designed so after tubes formed on them by VPS, mandrels shrink away from tubes upon cooling back to room temperature and simply slip out of tube.

  11. Preventing Clogging In A Vacuum Plasma Spray Gun

    NASA Technical Reports Server (NTRS)

    Krotz, Phillip D.; Daniel, Ronald L., Jr.; Davis, William M.

    1994-01-01

    Modification of powder-injection ports enables lengthy, high-temperature deposition operations. Graphite inserts prevent clogging of ports through which copper powder injected into vacuum plasma spray (VPS) gun. Graphite liners eliminate need to spend production time refurbishing VPS gun, reducing cost of production and increasing productivity. Concept also applied to other material systems used for net-shape fabrication via VPS.

  12. 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.

  13. 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.

  14. Vacuum Plasma Spray Forming of Tungsten Lorentz Force Accelerator Components

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank R.

    2001-01-01

    The Vacuum Plasma Spray (VPS) Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using the VPS process to form anode sections for a Lorentz force accelerator from tungsten. Lorentz force accelerators are an attractive form of electric propulsion that provides continuous, high-efficiency propulsion at useful power levels for such applications as orbit transfers or deep space missions. The VPS process is used to deposit refractory metals such as tungsten onto a graphite mandrel of the desired shape. Because tungsten is reactive at high temperatures, it is thermally sprayed in an inert environment where the plasma gun melts and accelerates the metal powder onto the mandrel. A three-axis robot inside the chamber controls the motion of the plasma spray torch. A graphite mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the anode. This paper describes the processing techniques, design considerations, and process development associated with the VPS forming of the Lorentz force accelerator.

  15. Vacuum Plasma Spray Forming of Tungsten Lorentz Force Accelerator Components

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank R.

    2004-01-01

    The Vacuum Plasma Spray (VPS) Laboratory at NASA's Marshall Space Flight Center, working with the Jet Propulsion Laboratory, has developed and demonstrated a fabrication technique using the VPS process to form anode and cathode sections for a Lorentz force accelerator made from tungsten. Lorentz force accelerators are an attractive form of electric propulsion that provides continuous, high-efficiency propulsion at useful power levels for such applications as orbit transfers or deep space missions. The VPS process is used to deposit refractory metals such as tungsten onto a graphite mandrel of the desired shape. Because tungsten is reactive at high temperatures, it is thermally sprayed in an inert environment where the plasma gun melts and deposits the molten metal powder onto a mandrel. A three-axis robot inside the chamber controls the motion of the plasma spray torch. A graphite mandrel acts as a male mold, forming the required contour and dimensions for the inside surface of the anode or cathode of the accelerator. This paper describes the processing techniques, design considerations, and process development associated with the VPS forming of Lorentz force accelerator components.

  16. Young's Moduli of Cold and Vacuum Plasma Sprayed Metallic Coatings

    NASA Technical Reports Server (NTRS)

    Raj, S. V.; Pawlik, R.; Loewenthal, W.

    2009-01-01

    Monolithic metallic copper alloy and NiCrAlY coatings were fabricated by either the cold spray (CS) or the vacuum plasma spray (VPS) deposition processes. Dynamic elastic modulus property measurements were conducted on these monolithic coating specimens between 300 K and 1273 K using the impulse excitation technique. The Young's moduli decreased almost linearly with increasing temperature at all temperatures except in the case of the CS Cu-23%Cr-5%Al and VPS NiCrAlY, where deviations from linearity were observed above a critical temperature. It was observed that the Young's moduli for VPS Cu-8%Cr were larger than literature data compiled for Cu. The addition of 1%Al to Cu- 8%Cr significantly increased its Young's modulus by 12 to 17% presumably due to a solid solution effect. Comparisons of the Young s moduli data between two different measurements on the same CS Cu- 23%Cr-5%Al specimen revealed that the values measured in the first run were about 10% higher than those in the second run. It is suggested that this observation is due to annealing of the initial cold work microstructure resulting form the cold spray deposition process.

  17. Vacuum Plasma Spray (VPS) Material Applications for Thruster Components

    NASA Technical Reports Server (NTRS)

    Elam, Sandra; Holmes, Richard; Hickman, Robert

    2006-01-01

    A variety of vacuum plasma spray (VPS) material systems have been successfully applied to injector and thrust chamber components. VPS offers a versatile fabrication process with relatively low costs to produce near net shape parts. The materials available with VPS increase operating margins and improve component life by providing superior thermal and oxidation protection in specific engine environments. Functional gradient materials (FGM) formed with VPS allow thrust chamber liners to be fabricated with GRCop-84 (an alloy of copper, chrome, and niobium) and a protective layer of NiCrAlY on the hot wall. A variety of thrust chamber liner designs have been fabricated to demonstrate the versatility of the process. Hot-fire test results have confirmed the improved durability and high temperature performance of the material systems for thrust chamber liners. Similar FGM s have been applied to provide superior thermal protection on injector faceplates with NiCrAlY and zirconia coatings. The durability of the applied materials has been demonstrated with hot-fire cycle testing on injector faceplates in high temperature environments. The material systems can benefit the components used in booster and main engine propulsion systems. More recent VPS efforts are focused on producing rhenium based material systems for high temperature applications to benefit in-space engines like reaction control system (RCS) thrusters.

  18. Vacuum Plasma Spray (VPS) Material Applications for Thruster Components

    NASA Technical Reports Server (NTRS)

    Elam, Sandra; Holmes, Richard; Hickman, Robert

    2006-01-01

    A variety of vacuum plasma spray (VPS) material systems have been successfully applied to injector and thrust chamber components. VPS offers a versatile fabrication process with relatively low costs to produce near net shape parts. The materials available with VPS increase operating margins and improve component life by providing superior thermal and oxidation protection in specific engine environments. Functional gradient materials (FGM) formed with VPS allow thrust chamber liners to be fabricated with GRCop-84 (an alloy of copper, chrome, and niobium) and a protective layer of NiCrAlY on the hot wall. A variety of thrust chamber liner designs have been fabricated to demonstrate the versatility of the process. Hot-fire test results have confined the improved durability and high temperature performance of the material systems for thrust chamber liners. Similar FGM s have been applied to provide superior thermal protection on injector faceplates with NiCrAlY and zirconia coatings. The durability of the applied materials has been demonstrated with hot-fire cycle testing on injector faceplates in high temperature environments. The material systems can benefit the components used in booster and main engine propulsion systems. More recent VPS efforts are focused on producing rhenium based material systems for high temperature applications to benefit in-space engines like reaction control system (RCS) thrusters.

  19. 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.

  20. Vacuum Plasma Spray Forming of Copper Alloy Liners for Regeneratively Cooled Liquid Rocket Combustion Chambers

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank

    2003-01-01

    Vacuum plasma spray (VPS) has been demonstrated as a method to form combustion chambers from copper alloys NARloy-Z and GRCop-84. Vacuum plasma spray forming is of particular interest in the forming of CuCrNb alloys such as GRCop-84, developed by NASA s Glenn Research Center, because the alloy cannot be formed using conventional casting and forging methods. This limitation is related to the levels of chromium and niobium in the alloy, which exceed the solubility limit in copper. Until recently, the only forming process that maintained the required microstructure of CrNb intermetallics was 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. This paper discusses the techniques used to form combustion chambers from CuCrNb and NARloy-Z, which will be used in regeneratively cooled liquid rocket combustion chambers.

  1. Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank; Gerish, Harold; Davis, William; Hissam, D. Andy

    1998-01-01

    The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorption cavity for a fully-functioning, ground test unit of a solar thermal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (less than 2500 C) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

  2. Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

    NASA Technical Reports Server (NTRS)

    Zimmerman, Frank R.; Hissam, David A.; Gerrish, Harold P.; Davis, William M.

    1999-01-01

    The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorber cavity for a fully-functioning, ground test unit of a solar then-nal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (greater than 25000 C [greater than 4530 F]) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

  3. Thermoelectric properties of magnesium silicide fabricated using vacuum plasma thermal spray

    NASA Astrophysics Data System (ADS)

    Fu, Gaosheng; Zuo, Lei; Longtin, Jon; Nie, Chao; Gambino, Richard

    2013-10-01

    The thermoelectric properties of magnesium silicide samples prepared by Vacuum Plasma Spray (VPS) are compared with those made from the conventional hot press method using the same feedstock powder. Thermal conductivity, electrical conductivity, Seebeck coefficient, and figure of merit are characterized from room temperature to 700 K. X-ray diffraction and scanning electron microscopy of the samples are obtained to assess how phase and microstructure influence the thermoelectric properties. Carrier concentration and Hall mobility are obtained from Hall Effect measurements, which provide further insight into the electrical conductivity and Seebeck coefficient mechanisms. Low-temperature electrical conductivity measurements suggest a 3D variable range hopping effect in the samples. VPS samples achieved a maximum ZT = 0.16 at 700 K, which is around 30% of the hot press sample ZT = 0.55 at 700 K using the same raw powder. The results suggest that thermal spray is a potential deposition technique for thermoelectric materials.

  4. Improvement of Ceramic Coatings for Electrostatic Adsorption Force Using Vacuum Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Takeuchi, Jun-Ichi; Yamasaki, Ryo; Tani, Kazumi; Takahashi, Yasuo

    The purpose of this study is to improve ceramic coatings having a high stable electrostatic adsorption force. The use of the coating is for the Johnsen-Rahbek force type electrostatic chucks used to fix silicon wafers inside vacuum chambers for processes such as Etch, CVD and PVD for semiconductor manufacturers. Previously the authors developed a dielectric substance ceramic coating for electrostatic chucks using Atmospheric Plasma Spraying (APS). This ceramic coating was not suitable because of its unstable electrostatic adsorption force. In a subsequent study, Vacuum Plasma Sprayed (VPS) Al2O3-7.5mass%TiO2 coating was investigated. As a result, it was found that the VPS coating has stable electrical resistivity and adsorption force. The dielectric constant of VPS Al2O3-TiO2 coating was sufficient for application to electrostatic chuck. On the other hand, it was suggested from results with respect to residual adsorption force and duration time after power off that the residual adsorption characteristic was not adequate.

  5. Net Shaped Component Fabrication of Refractory Metal Alloys using Vacuum Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Sen, S.; ODell, S.; Gorti, S.; Litchford, R.

    2006-01-01

    The vacuum plasma spraying (VPS) technique was employed to produce dense and net shaped components of a new tungsten-rhenium (W-Re) refractory metal alloy. The fine grain size obtained using this technique enhanced the mechanical properties of the alloy at elevated temperatures. The alloy development also included incorporation of thermodynamically stable dispersion phases to pin down grain boundaries at elevated temperatures and thereby circumventing the inherent problem of recrystallization of refractory alloys at elevated temperatures. Requirements for such alloys as related to high temperature space propulsion components will be discussed. Grain size distribution as a function of cooling rate and dispersion phase loading will be presented. Mechanical testing and grain growth results as a function of temperature will also be discussed.

  6. Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

    NASA Technical Reports Server (NTRS)

    Holmes, Richard R.; Elam, Sandra K.; McKechnie, Timothy N.; Power, Christopher A.

    2010-01-01

    In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

  7. Kinetic Study of the Solid-State Transformation of Vacuum-Plasma-Sprayed Ti-6Al-4V Alloy

    NASA Astrophysics Data System (ADS)

    Salimijazi, H. R.; Mousavi, Z. A.; Golozar, M. A.; Mostaghimi, J.; Coyle, T.

    2014-01-01

    Because of the nature of the plasma spraying process, the physical and mechanical properties of vacuum-plasma-sprayed structures of Ti-6Al-4V alloy are completely different from those of conventionally manufactured alloys such as bulk materials from casting and forging. To obtain desired mechanical and physical properties, vacancy and internal defects must be reduced, splat boundaries must be eliminated, and optimal phase compositions should be obtained through postdeposition heat treatments. To determine appropriate heat treatment processes, one needs to study the kinetic behavior of the as-sprayed microstructure at elevated temperatures. In the current study, the kinetics of the solid transformations found in Ti-6Al-4V alloys produced during the vacuum plasma spraying process was studied based on the Johnson-Mehl-Avrami theory. For the kinetic behavior of this alloy, the nonconstant temperature dependence of the transformation rate constant exhibits an irregularity at 900 °C, marking a change in the transformation mechanism. For the lower-temperature (<900 °C) curves, the constant gradient indicates a lack of change in the transformation mechanism, including homogeneous nucleation, with growth of α phase. For higher temperatures (>900 °C), a gradient change indicates a change in the transformation mechanism. The first mechanism was the formation of α-phase grain boundary, and the second mechanism was α-plate nucleation and growth from grain boundaries. The value of the transformation rate constant in the kinetics study of as-sprayed Ti-6Al-4V alloy was much higher than for material produced by the casting method. Using the results obtained from the kinetics of the phase transformation at different constant temperatures, a time-temperature-transformation (TTT) diagram for as-sprayed Ti-6Al-4V alloy was developed.

  8. Microstructure and Mechanical Properties of Vacuum Plasma Sprayed Cu-8Cr-4Nb

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Ellis, David; McKechnie, Timothy; Hickman, Robert

    1997-01-01

    This paper compares the tensile properties of Cu-8Cr-4Nb material produced by VPS to material previously produced by extrusion. The microstructure of the VPS material is also presented. The combustion chamber liner of rocket motors represents an extreme materials application. The liner hot wall is exposed to a 2760 C (5000 F) flame while the cold side is exposed to cryogenic hydrogen liquid. Materials for use in the combustion chamber liner require a combination of high temperature strength, creep resistance, and low cycle fatigue resistance along with high thermal conductivity. The hot side is also subject to localized cycles between reducing and oxidizing environments that degrade the liner by a process called blanching. A new Cu-8 at.% Cr-4 at% Nb (Cu-8Cr-4Nb) alloy has been developed at NASA Lewis Research Center as a replacement for the currently used alloy, NARloy-z (Cu-3 wt.% Ag-0.5 wt.% Zr). The alloy is strengthened by a fine dispersion of Cr2Nb particles. The alloy has better mechanical properties than NARloy-Z while retaining most of the thermal conductivity of pure copper. The alloy has been successfully consolidated by extrusion and hot isostatic pressing (HIPing). However, vacuum plasma spraying (VPS) offers several advantages over prior consolidation methods. VPS can produce a near net shape piece with the profile of the liner. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the liner hot wall during the VPS deposition. The low oxygen VPS Cu-8Cr-4Nb exhibits a higher strength than Cu-8Cr-4Nb produced by extrusion at elevated temperatures and a comparable strength at room temperature. Moduli and ductility were not significantly different. However, the ability to produce parts to near-net shape and maintain the good elevated temperature tensile properties of the extruded Cu-8Cr-4Nb makes VPS an attractive processing method for fabricating rocket engine combustion liners.

  9. 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

  10. The effect of ion implantation on the oxidation resistance of vacuum plasma sprayed CoNiCrAlY coatings

    NASA Astrophysics Data System (ADS)

    Jiang, Jie; Zhao, Huayu; Zhou, Xiaming; Tao, Shunyan; Ding, Chuanxian

    2012-11-01

    CoNiCrAlY coatings prepared by vacuum plasma spraying (VPS) were implanted with Nb and Al ions at a fluence of 1017 atoms/cm2. The effects of ion implantation on the oxidation resistance of CoNiCrAlY coatings were investigated. The thermally grown oxide (TGO) formed on each specimen was characterized by XRD, SEM and EDS, respectively. The results showed that the oxidation process of CoNiCrAlY coatings could be divided into four stages and the key to obtaining good oxidation resistance was to remain high enough amount of Al and promote the lateral growth of TGO. The implantation of Nb resulted in the formation of continuous and dense Al2O3 scale to improve the oxidation resistance. The Al implanted coating could form Al2O3 scale at the initial stage, however, the scale was soon broken and TGO transformed to non-protective spinel.

  11. Interaction Studies of Ceramic Vacuum Plasma Spraying for the Melting Crucible Materials

    SciTech Connect

    Jong Hwan Kim; Hyung Tae Kim; Yoon Myung Woo; Ki Hwan Kim; Chan Bock Lee; R. S. Fielding

    2013-10-01

    Candidate coating materials for re-usable metallic nuclear fuel crucibles, TaC, TiC, ZrC, ZrO2, and Y2O3, were plasmasprayed onto a niobium substrate. The microstructure of the plasma-sprayed coatings and thermal cycling behavior were characterized, and U-Zr melt interaction studies were carried out. The TaC and Y2O3 coating layers had a uniform thickness, and high density with only a few small closed pores showing good consolidation, while the ZrC, TiC, and ZrO2 coatings were not well consolidated with a considerable amount of porosity. Thermal cycling tests showed that the adhesion of the TiC, ZrC, and ZrO2 coating layers with niobium was relatively weak compared to the TaC and Y2O3 coatings. The TaC and Y2O3 coatings had better cycling characteristics with no interconnected cracks. In the interaction studies, ZrC and ZrO2 coated rods showed significant degradations after exposure to U-10 wt.% Zr melt at 1600 degrees C for 15 min., but TaC, TiC, and Y2O3 coatings showed good compatibility with U-Zr melt.

  12. Vacuum plasma sprayed coatings using ionic silver doped hydroxyapatite powder to prevent bacterial infection of bone implants.

    PubMed

    Guimond-Lischer, Stefanie; Ren, Qun; Braissant, Olivier; Gruner, Philipp; Wampfler, Bruno; Maniura-Weber, Katharina

    2016-06-01

    Fast and efficient osseointegration of implants into bone is of crucial importance for their clinical success; a process that can be enhanced by coating the implant surface with hydroxyapatite (HA) using the vacuum plasma spray technology (VPS). However, bacterial infections, especially the biofilm formation on implant surfaces after a surgery, represent a serious complication. With ever-increasing numbers of antibiotic-resistant bacteria, there is great interest in silver (Ag) as an alternative to classical antibiotics due to its broad activity against Gram-positive and Gram-negative bacterial strains. In the present study, silver ions were introduced into HA spray powder by ion exchange and the HA-Ag powder was applied onto titanium samples by VPS. The Ag-containing surfaces were evaluated for the kinetics of the silver release, its antibacterial effect against Staphylococcus aureus as well as Escherichia coli, and possible cytotoxicity against human bone cells. The HA-Ag coatings with different concentrations of Ag displayed mechanical and compositional properties that fulfill the regulatory requirements. Evaluation of the Ag release kinetic showed a high release rate in the first 24 h followed by a decreasing release rate over the four subsequent days. The HA-Ag coatings showed no cytotoxicity to primary human bone cells while exhibiting antibacterial activity to E. coli and S. aureus. PMID:26964530

  13. Porous Tantalum Coatings Prepared by Vacuum Plasma Spraying Enhance BMSCs Osteogenic Differentiation and Bone Regeneration In Vitro and In Vivo

    PubMed Central

    Tang, Ze; Xie, Youtao; Yang, Fei; Huang, Yan; Wang, Chuandong; Dai, Kerong; Zheng, Xuebin; Zhang, Xiaoling

    2013-01-01

    Tantalum, as a potential metallic implant biomaterial, is attracting more and more attention because of its excellent anticorrosion and biocompatibility. However, its significantly high elastic modulus and large mechanical incompatibility with bone tissue make it unsuitable for load-bearing implants. In this study, porous tantalum coatings were first successfully fabricated on titanium substrates by vacuum plasma spraying (VPS), which would exert the excellent biocompatibility of tantalum and alleviate the elastic modulus of tantalum for bone tissue. We evaluated cytocompatibility and osteogenesis activity of the porous tantalum coatings using human bone marrow stromal cells (hBMSCs) and its ability to repair rabbit femur bone defects. The morphology and actin cytoskeletons of hBMSCs were observed via electron microscopy and confocal, and the cell viability, proliferation and osteogenic differentiation potential of hBMSCs were examined quantitatively by PrestoBlue assay, Ki67 immunofluorescence assay, real-time PCR technology and ALP staining. For in vivo detection, the repaired femur were evaluated by histomorphology and double fluorescence labeling 3 months postoperation. Porous tantalum coating surfaces promoted hBMSCs adhesion, proliferation, osteogenesis activity and had better osseointegration and faster new bone formation rate than titanium coating control. Our observation suggested that the porous tantalum coatings had good biocompatibility and could enhance osseoinductivity in vitro and promote new bone formation in vivo. The porous tantalum coatings prepared by VPS is a promising strategy for bone regeneration. PMID:23776648

  14. Porous tantalum coatings prepared by vacuum plasma spraying enhance bmscs osteogenic differentiation and bone regeneration in vitro and in vivo.

    PubMed

    Tang, Ze; Xie, Youtao; Yang, Fei; Huang, Yan; Wang, Chuandong; Dai, Kerong; Zheng, Xuebin; Zhang, Xiaoling

    2013-01-01

    Tantalum, as a potential metallic implant biomaterial, is attracting more and more attention because of its excellent anticorrosion and biocompatibility. However, its significantly high elastic modulus and large mechanical incompatibility with bone tissue make it unsuitable for load-bearing implants. In this study, porous tantalum coatings were first successfully fabricated on titanium substrates by vacuum plasma spraying (VPS), which would exert the excellent biocompatibility of tantalum and alleviate the elastic modulus of tantalum for bone tissue. We evaluated cytocompatibility and osteogenesis activity of the porous tantalum coatings using human bone marrow stromal cells (hBMSCs) and its ability to repair rabbit femur bone defects. The morphology and actin cytoskeletons of hBMSCs were observed via electron microscopy and confocal, and the cell viability, proliferation and osteogenic differentiation potential of hBMSCs were examined quantitatively by PrestoBlue assay, Ki67 immunofluorescence assay, real-time PCR technology and ALP staining. For in vivo detection, the repaired femur were evaluated by histomorphology and double fluorescence labeling 3 months postoperation. Porous tantalum coating surfaces promoted hBMSCs adhesion, proliferation, osteogenesis activity and had better osseointegration and faster new bone formation rate than titanium coating control. Our observation suggested that the porous tantalum coatings had good biocompatibility and could enhance osseoinductivity in vitro and promote new bone formation in vivo. The porous tantalum coatings prepared by VPS is a promising strategy for bone regeneration. PMID:23776648

  15. The response of SiC fibres to vacuum plasma spraying and vacuum hot pressing during the fabrication of titanium matrix composites

    PubMed

    Baker; Grant; Jenkins

    1999-11-01

    Vacuum plasma spraying (VPS) and vacuum hot pressing (VHP) have been used to fabricate Ti-6Al-4V matrix composite material reinforced longitudinally with DERA Sigma C coated SiC 1140+ fibres. VPS of Ti-6Al-4V onto Sigma 1140+ SiC fibres caused no fibre/matrix interfacial reaction. During VHP a fibre/matrix reaction occurred, producing a mixture of fine (< 50 nm) TiCx (x

  16. 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.

  17. 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.

  18. Plasma spray forming metals, intermetallics, and composites

    NASA Astrophysics Data System (ADS)

    Sampath, Sanjay; Herman, Herbert

    1993-07-01

    Plasma spray processing is a droplet deposition method that combines the steps of melting, rapid solidification, and consolidation into a single step. The versatility of the technology enables the processing of freestanding bulk, near-net shapes of a wide range of alloys, intermetallics, ceramics, and composites, while still retaining the benefits of rapid solidification processing. In particular, it is possible to produce dense forms through vacuum plasma spraying.

  19. Programable Plasma-Spray System

    NASA Technical Reports Server (NTRS)

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

    1982-01-01

    NASA-funded research led to development of automated plasma-spray system programable and reproducible. System utilizes standard plasma-spray equipment with noncoherent light-measuring system and microprocessor. System monitors and controls surface contours and coating thickness. Other advantages of system are consistant coating reproducibility, exact blending and feathering operations, ability to handle complex shapes and ease of changing spray parameters.

  20. Induction plasma spraying of ceramics

    NASA Astrophysics Data System (ADS)

    Fan, Xiao-Bao; Gougeon, Patrick; Gitzhofer, Francois; Boulos, Maher

    A study is carried out on the influence of in-flight particle parameters on their splatting properties during the induction plasma deposition of ceramics. Results are presented for alumina powders with mean particle diameters of 21 microns and 82 microns under soft vacuum conditions. The chamber pressure was varied between 46.6 and 66.6 kPa. Measurements are carried out on the particle surface temperature and velocity prior to impact on stainless steel substrates. The form of the splat obtained is evaluated using SEM. The results are used for the parametric optimization of the induction plasma spraying process. Thick alumina coatings with total porosities as low as 2 percent were obtained.

  1. 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.

  2. Vacuum plasma coatings for turbine blades

    NASA Technical Reports Server (NTRS)

    Holmes, R. R.

    1985-01-01

    Turbine blades, vacuum plasma spray coated with NiCrAlY, CoCrAlY or NiCrAlY/Cr2O3, were evaluated and rated superior to standard space shuttle main engine (SSME) coated blades. Ratings were based primarily on 25 thermal cycles in the MSFC Burner Rig Tester, cycling between 1700 F (gaseous H2) and -423 F (liquid H2). These tests showed no spalling on blades with improved vacuum plasma coatings, while standard blades spalled. Thermal barrier coatings of ZrO2, while superior to standard coatings, lacked the overall performance desired. Fatigue and tensile specimens, machined from MAR-M-246(Hf) test bars identical to the blades were vacuum plasma spray coated, diffusion bond treated, and tested to qualify the vacuum plasma spray process for flight hardware testing and application. While NiCrAlY/Cr2O3 offers significant improvement over standard coatings in durability and thermal protection, studies continue with an objective to develop coatings offering even greater improvements.

  3. Vacuum application of thermal barrier plasma coatings

    NASA Technical Reports Server (NTRS)

    Holmes, R. R.; Mckechnie, T. N.

    1988-01-01

    Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.

  4. Plasma Spraying Reclaims Compressor Housings

    NASA Technical Reports Server (NTRS)

    Leissler, George W.; Yuhas, John S.

    1991-01-01

    Plasma-spraying process used to build up material in worn and pitted areas. Newly applied material remachined to specified surface contours. Effective technique for addition of metal to out-of-tolerance magnesium-alloy turbine-engine compressor housings.

  5. Feedback enhanced plasma spray tool

    DOEpatents

    Gevelber, Michael Alan; Wroblewski, Donald Edward; Fincke, James Russell; Swank, William David; Haggard, Delon C.; Bewley, Randy Lee

    2005-11-22

    An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.

  6. 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

  7. Vapor Phase Deposition Using Plasma Spray-PVD™

    NASA Astrophysics Data System (ADS)

    von Niessen, K.; Gindrat, M.; Refke, A.

    2010-01-01

    Plasma spray—physical vapor deposition (PS-PVD) is a low pressure plasma spray technology to deposit coatings out of the vapor phase. PS-PVD is a part of the family of new hybrid processes recently developed by Sulzer Metco AG (Switzerland) on the basis of the well-established low pressure plasma spraying (LPPS) technology. Included in this new process family are plasma spray—chemical vapor deposition (PS-CVD) and plasma spray—thin film (PS-TF) processes. In comparison to conventional vacuum plasma spraying and LPPS, these new processes use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility 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 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 EB-PVD coatings. This paper reports on the progress made at Sulzer Metco to develop functional coatings build up from vapor phase of oxide ceramics and metals.

  8. High velocity pulsed plasma thermal spray

    NASA Astrophysics Data System (ADS)

    Witherspoon, F. D.; Massey, D. W.; Kincaid, R. W.; Whichard, G. C.; Mozhi, T. A.

    2002-03-01

    The quality and durability of coatings produced by many thermal spray techniques could be improved by increasing the velocity with which coating particles impact the substrate. Additionally, better control of the chemical and thermal environment seen by the particles during flight is crucial to the quality of the coating. A high velocity thermal spray device is under development through a Ballistic Missile Defense Organization Small Business Innovation Research (SBIR) project, which provides significantly higher impact velocity for accelerated particles than is currently available with existing thermal spray devices. This device utilizes a pulsed plasma as the accelerative medium for powders introduced into the barrel. Recent experiments using a particle imaging diagnostic system showed that the device can accelerate stainless steel and WC-Co powders to velocities ranging from 1500 to 2200 m/s. These high velocities are accomplished without the use of combustible gases and without the need of a vacuum chamber, while maintaining an inert atmosphere for the particles during acceleration. The high velocities corresponded well to modeling predictions, and these same models suggest that velocities as high as 3000 m/s or higher are possible.

  9. 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.

  10. Metallurgy and properties of plasma spray formed materials

    NASA Technical Reports Server (NTRS)

    Mckechnie, T. N.; Liaw, Y. K.; Zimmerman, F. R.; Poorman, R. M.

    1992-01-01

    Understanding the fundamental metallurgy of vacuum plasma spray formed materials is the key to enhancing and developing full material properties. Investigations have shown that the microstructure of plasma sprayed materials must evolve from a powder splat morphology to a recrystallized grain structure to assure high strength and ductility. A fully, or near fully, dense material that exhibits a powder splat morphology will perform as a brittle material compared to a recrystallized grain structure for the same amount of porosity. Metallurgy and material properties of nickel, iron, and copper base alloys will be presented and correlated to microstructure.

  11. Investigation on the suitability of plasma sprayed Fe Cr Al coatings as tritium permeation barrier

    NASA Astrophysics Data System (ADS)

    Fazio, C.; Stein-Fechner, K.; Serra, E.; Glasbrenner, H.; Benamati, G.

    1999-08-01

    Results on the fabrication of a tritium permeation barrier by spraying Fe-Cr-Al powders are described. The sprayed coatings were deposited at temperatures below the Ac1 temperature of the ferritic-martensitic steel substrate and no post-deposition heat treatment was applied. The aim of the investigation was the determination of the efficiency of the coatings to act as tritium permeation barrier. Metallurgical investigations as well as hydrogen isotope permeation measurements were carried out onto the produced coatings. The depositions were performed on ferritic-martensitic steels by means of three types of spray techniques: high velocity oxy fuel, air plasma spray and vacuum plasma spray.

  12. Tailoring the Spray Conditions for Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Joulia, A.; Duarte, W.; Goutier, S.; Vardelle, M.; Vardelle, A.; Rossignol, S.

    2015-01-01

    The plasma spray process using suspensions as liquid feedstock allows the deposition of finely structured coatings with improved properties compared to that of coatings deposited by the conventional plasma spray techniques. The evaporation of the solvent, acceleration, heating, and melting of the fine solid particles within the plasma jet take place in a shorter time, as the substrate is located closer to the plasma torch when a mono-cathode mono-anode plasma torch is used, while the liquid material processing globally consumes more energy than a powder material. Therefore, achieving a coating with the expected properties requires a broad understanding of the process. In this study, a large range of plasma spray conditions have been used to achieve yttria-stabilized zirconia coatings by suspension plasma spraying. The properties of the plasma jet (velocity, enthalpy, and stability) as well as those of droplets (trajectories, number, and size) and particles (velocity) were measured and correlated to the coating microstructure. The operating conditions necessary for obtaining disk-shape splats and achieving homogeneous coatings are described including the plasma jet properties and substrate parameters.

  13. 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

  14. Monitoring Coating Thickness During Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.

    1990-01-01

    High-resolution video measures thickness accurately without interfering with process. Camera views cylindrical part through filter during plasma spraying. Lamp blacklights part, creating high-contrast silhouette on video monitor. Width analyzer counts number of lines in image of part after each pass of spray gun. Layer-by-layer measurements ensure adequate coat built up without danger of exceeding required thickness.

  15. Plasma Spraying Of Dense, Rough Bond Coats

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.; Edmonds, Brian J.; Leissler, George W.

    1988-01-01

    Simple modification of plasma torch facilitates spraying of coarse powders. Shape of nozzle changed to obtain decrease in velocity of gas and consequent increase in time particles spend in flame before impact on substrate. Increased residence time allows melting of coarser powders, spraying of which results in rougher bond surfaces.

  16. Vacuum arc plasma mass separator

    NASA Astrophysics Data System (ADS)

    Paperny, V. L.; Krasov, V. I.; Lebedev, N. V.; Astrakchantsev, N. V.; Chernikch, A. A.

    2015-02-01

    The propagation of a metal plasma flow in a transport system with a curvilinear magnetic field was studied experimentally. The flow was generated by a pulsed vacuum arc discharge with a composite (W+Fe) cathode. The ion energy measurements at the transport system output showed that all ion components were accelerated up to equal energies per charge unit, about 150 eV and 320 eV in the outer and inner areas of the curved plasma flow, respectively. The spatial separation of the atoms of the cathode material was measured at the system output by x-ray fluorescence spectrometry. The ions of the lighter element (Fe) were concentrated in the inner part of the cathodic plasma flow deflected by the magnetic field while the distribution of the heavy element (W) was substantially shifted toward the outer area of the flow. The maximum mass separation efficiency reached 45, the effective value being 7.7. Such a system is promising for use in plasma technology for reprocessing spent nuclear fuel, namely for the separation of the heavy radioactive fission product from nuclear waste.

  17. Plasma-Sprayed Coatings on Porous Surfaces

    NASA Technical Reports Server (NTRS)

    Leibert, C. H.

    1986-01-01

    Need for combining benefits of duplex thermal-barrier coatings with film cooling on gas-turbine vanes and blades stimulated development of improved method for plasma spraying these coatings. Method reduces blocking of holes by plasma-sprayed material and at same time reduces base-metal oxidation during coating operation. Features provide potential for increased engine efficiency and power, reduced fuel consumption, use of less costly materials or construction procedures, and extended life and durability.

  18. Creep of plasma sprayed zirconia

    NASA Technical Reports Server (NTRS)

    Firestone, R. F.; Logan, W. R.; Adams, J. W.

    1982-01-01

    Specimens of plasma-sprayed zirconia thermal barrier coatings with three different porosities and different initial particle sizes were deformed in compression at initial loads of 1000, 2000, and 3500 psi and temperatures of 1100 C, 1250 C, and 1400 C. The coatings were stabilized with lime, magnesia, and two different concentrations of yttria. Creep began as soon as the load was applied and continued at a constantly decreasing rate until the load was removed. Temperature and stabilization had a pronounced effect on creep rate. The creep rate for 20% Y2O3-80% ZrO2 was 1/3 to 1/2 that of 8% Y2O3-92% ZrO2. Both magnesia and calcia stabilized ZrO2 crept at a rate 5 to 10 times that of the 20% Y2O3 material. A near proportionality between creep rate and applied stress was observed. The rate controlling process appeared to be thermally activated, with an activation energy of approximately 100 cal/gm mole K. Creep deformation was due to cracking and particle sliding.

  19. Stress rupture and creep behavior of a low pressure plasma-sprayed NiCoCrAlY coating alloy in air and vacuum

    NASA Technical Reports Server (NTRS)

    Hebsur, M. G.; Miner, R. V.

    1987-01-01

    The creep behavior of a NiCoCrAlY coating alloy in air and vacuum at 660 and 850 C is studied. The microstructure of the coating alloy is described. Analysis of the creep curves reveal that the secondary creep rates, the transition from secondary to tertiary creep, and the strain-to-failure are affected by the environment, preexposure, stress, and temperature. It is observed that the rupture lives of the NiCoCrAlY alloy at 660 and 850 C are greater in air than in vacuum. Several mechanisms that may explain the lack of crack growth from surface-connected pores during tests in air are proposed.

  20. 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.

  1. Modelling the Plasma Jet in Multi-Arc Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.; Schein, J.; Zimmermann, S.; Möhwald, K.; Lummer, C.

    2016-08-01

    Particle in-flight characteristics in atmospheric plasma spraying process are determined by impulse and heat energy transferred between the plasma jet and injected powder particles. One of the important factors for the quality of the plasma-sprayed coatings is thus the distribution of plasma gas temperatures and velocities in plasma jet. Plasma jets generated by conventional single-arc plasma spraying systems and their interaction with powder particles were subject matter of intensive research. However, this does not apply to plasma jets generated by means of multi-arc plasma spraying systems yet. In this study, a numerical model has been developed which is designated to dealing with the flow characteristics of the plasma jet generated by means of a three-cathode spraying system. The upstream flow conditions, which were calculated using a priori conducted plasma generator simulations, have been coupled to the plasma jet simulations. The significances of the relevant numerical assumptions and aspects of the models are analyzed. The focus is placed on to the turbulence and diffusion/demixing modelling. A critical evaluation of the prediction power of the models is conducted by comparing the numerical results to the experimental results determined by means of emission spectroscopic computed tomography. It is evident that the numerical models exhibit a good accuracy for their intended use.

  2. Plasma-Spray Metal Coating On Foam

    NASA Technical Reports Server (NTRS)

    Cranston, J.

    1994-01-01

    Molds, forms, and other substrates made of foams coated with metals by plasma spraying. Foam might be ceramic, carbon, metallic, organic, or inorganic. After coat applied by plasma spraying, foam left intact or removed by acid leaching, conventional machining, water-jet cutting, or another suitable technique. Cores or vessels made of various foam materials plasma-coated with metals according to method useful as thermally insulating containers for foods, liquids, or gases, or as mandrels for making composite-material (matrix/fiber) parts, or making thermally insulating firewalls in automobiles.

  3. Plasma Sprayed Hydroxyapatite Coatings: Influence of Spraying Power on Microstructure

    SciTech Connect

    Mohd, S. M.; Abd, M. Z.; Abd, A. N.

    2010-03-11

    The plasma sprayed hydroxyapatite (HA) coatings are used on metallic implants to enhance the bonding between the implant and bone in human body. The coating process was implemented at different spraying power for each spraying condition. The coatings formed from a rapid solidification of molten and partly molten particles that impact on the surface of substrate at high velocity and high temperature. The study was concentrated on different spraying power that is between 23 to 31 kW. The effect of different power on the coatings microstructure was investigated using scanning electron microscope (SEM) and phase composition was evaluated using X-ray diffraction (XRD) analysis. The coatings surface morphology showed distribution of molten, partially melted particles and some micro-cracks. The produced coatings were found to be porous as observed from the cross-sectional morphology. The coatings XRD results indicated the presence of crystalline phase of HA and each of the patterns was similar to the initial powder. Regardless of different spraying power, all the coatings were having similar XRD patterns.

  4. Thermal analysis simulation for a spin-motor used in the advanced main combustion chamber vacuum plasma spray project using the SINDA computer program

    NASA Technical Reports Server (NTRS)

    Mcdonald, Gary H.

    1990-01-01

    One of the many design challenges of this project is predicting the thermal effects due to the environment inside the vacuum chamber on the turntable and spin motor spindle assembly. The objective of the study is to model the spin motor using the computer program System Improved Numerical Differencing Analyzer (SINDA). By formulating the appropriate input information concerning the motor's geometry, coolant flow path, material composition, and bearing and motor winding characteristics, SINDA should predict temperatures at various predefined nodes. From these temperatures, hopefully, one can predict if the coolant flow rate is sufficient or if certain mechanical elements such as bearings, O ring seals, or motor windings will exceed maximum design temperatures.

  5. Automatic targeting of plasma spray gun

    DOEpatents

    Abbatiello, Leonard A.; Neal, Richard E.

    1978-01-01

    A means for monitoring the material portion in the flame of a plasma spray gun during spraying operations is provided. A collimated detector, sensitive to certain wavelengths of light emission, is used to locate the centroid of the material with each pass of the gun. The response from the detector is then relayed to the gun controller to be used to automatically realign the gun.

  6. More About Plasma-Spraying Ceramics Onto Smooth Metals

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.; Doychak, Joseph

    1995-01-01

    Paper presents additional information on fabrication process described in "Plasma-Spraying Ceramics Onto Smooth Metallic Substrates" (LEW-15164). Provides additional information on specific substrate materials advantageously coated in two-stage plasma-spraying process.

  7. Thermophysical properties of plasma sprayed coatings

    NASA Technical Reports Server (NTRS)

    Wilkes, K. E.; Lagedrost, J. F.

    1973-01-01

    Thermophysical properties of plasma sprayed materials were determined for the following plasma sprayed materials: CaO - stabilized ZrO2, Y2O3 - stabilized ZerO2, Al2O3, HfO2 Mo, nichrome, NiAl, Mo-ZrO2, and MoAl2O3 mixtures. In all cases the thermal conductivity of the as-sprayed materials was found to be considerably lower than that of the bulk material. The flash-laser thermal diffusivity technique was used both for diffusivity determination of single-layer materials and to determine the thermal contact resistance at the interface of two-layer specimens.

  8. 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.

  9. 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.

  10. Porosity in plasma sprayed alumina coatings

    SciTech Connect

    Ilavsky, J.; Herman, H.; Berndt, C.C.; Goland, A.N.; Long, G.G.; Krueger, S.; Allen, A.J.

    1994-03-01

    Small-angle neutron scattering (SANS) was used to study the porosity of plasma sprayed deposits of alumina in as-sprayed and heat-treated conditions. SANS results were compared with mercury intrusion porosimetry (MIP) and water immersion techniques. Multiple small-angle neutron scattering yields a volume-weighted effective pore radius (R{sub eff}), for pores with sizes between 0.08 and 10{mu}m, the pore volume in this size region, and from the Porod region, the surface area of pores of all sizes.

  11. Adjustable Powder Injector For Vacuum Plasma Sprayer

    NASA Technical Reports Server (NTRS)

    Burns, D. H.; Woodford, W. H.; Mckechnie, T. N.; Mcferrin, D. C.; Davis, W. M.; Beason, G. P., Jr.

    1993-01-01

    Attachment for plasma spray gun provides four degrees of freedom for adjustment of position and orientation at which powder injected externally into plasma flame. Manipulator provides for adjustment of pitch angle of injection tube: set to inject powder at any angle ranging from perpendicular to parallel to cylindrical axis. Scribed lines on extension bar and manipulator indicate pitch angle of extension tube. Collar changed to adapt injector to different gun.

  12. Vacuum energy of a spherical plasma shell

    SciTech Connect

    Bordag, M.; Khusnutdinov, N.

    2008-04-15

    We consider the vacuum energy of the electromagnetic field interacting with a spherical plasma shell together with a model for the classical motion of the shell. We calculate the heat kernel coefficients, especially that for the TM mode, and carry out the renormalization by redefining the parameters of the classical model. It turns out that this is possible and results in a model which, in the limit of the plasma shell becoming an ideal conductor, reproduces the vacuum energy found by Boyer in 1968.

  13. 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.

  14. Investigation of adsorption properties of alumina produced by vacuum spray method

    NASA Astrophysics Data System (ADS)

    Khrustaleva, K.; Voronova, G.

    2016-02-01

    In this paper nanopowders obtained by vacuum spray method were studied. The phase composition of the obtained powders is γ - Al2O3. Obtained nanopowders have specific surface area about 200 m2/g. Adsorptive properties of these powders were studied by static adsorption from solutions. The anionic dye eosin was selected as adsorbate. It has been found that the powders obtained by vacuum spray method have significant capacity to adsorb eosin.

  15. Nonlinear quantum electrodynamics in vacuum and plasmas

    SciTech Connect

    Brodin, Gert; Lundin, Joakim; Marklund, Mattias

    2010-12-14

    We consider high field physics due to quantum electrodynamics, in particular those that can be studied in the next generation of laser facilities. Effective field theories based on the Euler-Heisenberg Lagrangian are briefly reviewed, and examples involving plasma- and vacuum physics are given.

  16. 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.

  17. Plasma-Spraying Ceramics Onto Smooth Metallic Substrates

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.; Brindley, William J.; Rouge, Carl J.; Leissler, George

    1992-01-01

    In fabrication process, plasma-sprayed ceramic coats bonded strongly to smooth metallic surfaces. Principal use of such coats in protecting metal parts in hot-gas paths of advanced gas turbine engines. Process consists of application of initial thin layer of ceramic on smooth surface by low-pressure-plasma spraying followed by application of layer of conventional, low-thermal-conductivity atmospheric-pressure plasma-sprayed ceramic.

  18. Studies of Plasma-Sprayed Alumina

    NASA Astrophysics Data System (ADS)

    Ilavsky, Jan

    1994-05-01

    Phase transformations and porosity of the plasma sprayed alumina deposits were examined. The dependence of the phase transformations on deposit chemistry was established. Porosity changes during heat treatment were studied and a model for the porosity is proposed. A novel technique in the field of plasma sprayed deposits--small-angle neutron scattering (SANS)--was successfully applied. Deposits were manufactured using the water-stabilized plasma spray system, PAL160, with an input of 160 kW. Phase transformations of the plasma sprayed alumina deposits were studied using XRD and DTA. The deposits were manufactured from 99.9% alumina, alumina-chromia (1.5% Cr_2O_3), gray alumina (3.7% TiO_2) and alumina -titania (17% TiO_2). The addition of chromia increases the temperature of the alpha phase formation by about 40^circ C and the addition of TiO_2 reduces this temperature by about 150^circ C for gray alumina and by about 175^ circC for alumina-titania. The amount of metastable theta phase was found to depend on the chemistry of the feedstock. Porosities of the deposits, made from alumina and gray alumina, were studied using mercury intrusion porosimetry, weighing method (Archimedean porosimetry), image analysis and SANS. Samples were studied in the as -sprayed condition and after heat treatment for 2 hours at 1300^circC and 1500 ^circC. Porosity depends on the deposit chemistry and on the heat treatment and varies from 5% to about 11%. Different porosity measurement techniques yield different results. Surface areas of 1.5 to 7.5 times 10^4 cm^2 /cm^3 (times 10^6 m^{ -1}) were measured using SANS and depend on heat treatment and on the deposit chemistry. The phase transformations can be associated with an increase in pore surface area and decrease in surface area at 1500 ^circC can be associated with sintering. The effective pore radius, R_{ rm eff}, as measured by SANS is a measure of the pore sizes in the 0.08 to 10 μm size range. The R_{rm eff} depends on deposit

  19. Influence of Cold-Sprayed, Warm-Sprayed, and Plasma-Sprayed Layers Deposition on Fatigue Properties of Steel Specimens

    NASA Astrophysics Data System (ADS)

    Cizek, J.; Matejkova, M.; Dlouhy, I.; Siska, F.; Kay, C. M.; Karthikeyan, J.; Kuroda, S.; Kovarik, O.; Siegl, J.; Loke, K.; Khor, Khiam Aik

    2015-06-01

    Titanium powder was deposited onto steel specimens using four thermal spray technologies: plasma spray, low-pressure cold spray, portable cold spray, and warm spray. The specimens were then subjected to strain-controlled cyclic bending test in a dedicated in-house built device. The crack propagation was monitored by observing the changes in the resonance frequency of the samples. For each series, the number of cycles corresponding to a pre-defined specimen cross-section damage was used as a performance indicator. It was found that the grit-blasting procedure did not alter the fatigue properties of the steel specimens (1% increase as compared to as-received set), while the deposition of coatings via all four thermal spray technologies significantly increased the measured fatigue lives. The three high-velocity technologies led to an increase of relative lives to 234% (low-pressure cold spray), 210% (portable cold spray), and 355% (warm spray) and the deposition using plasma spray led to an increase of relative lives to 303%. The observed increase of high-velocity technologies (cold and warm spray) could be attributed to a combination of homogeneous fatigue-resistant coatings and induction of peening stresses into the substrates via the impingement of the high-kinetic energy particles. Given the intrinsic character of the plasma jet (low-velocity impact of semi/molten particles) and the mostly ceramic character of the coating (oxides, nitrides), a hypothesis based on non-linear coatings behavior is provided in the paper.

  20. Film and interstitial formation of metals in plasma-sprayed ceramics

    NASA Technical Reports Server (NTRS)

    Hendricks, R. C.; Mcdonald, G.; Mullen, R. L.

    1985-01-01

    A method is described to electrodeposit noble metals such as platinum and ordinary metals such as copper on and within plasma-sprayed ceramic materials and ceramic fiber materials. Low-density ceramic fiber bodies were vacuum impregnated with plating solution and attached to an electrode. Light micrographs illustrating the density and location of deposited materials are presented and discussed. Voids in the plasma-sprayed ceramic were filled with deposits that vary from spherical to lens-shaped circular and have particle size corresponding to the full range of void size. Multiple coatings of ceramic and metal can be sequenced.

  1. Oxidation and degradation of a plasma-sprayed thermal barrier coating system

    SciTech Connect

    Haynes, J.A.; Ferber, M.K.; Porter, W.D.

    1996-04-01

    The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia top coatings was evaluated by thermogravimetric analysis at 1150{degrees}C for up to 200 hours. Coating durability was assessed by furnace cycling at 1150{degrees}C. Coatings and reaction products were identified by x-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy.

  2. Volatilization of metal powders in plasma sprays

    NASA Astrophysics Data System (ADS)

    Vardelle, A.; Vardelle, M.; Zhang, H.; Themelis, N. J.; Gross, K.

    2002-06-01

    Ideally, plasma spraying of metal powders must take place within a narrow processing “window” where the particles become fully molten before they hit the substrate, but are not overheated to the point that substantial volatilization occurs. Metal evaporation in flight results in a decrease in the deposition efficiency. In addiiton, the emission of vapors leads to the formation of metal and oxide fumes that are undesirable from the viewpoints of both resource conservation and environmental control. This study examines the vaporization and fume formation in the plasma spraying of iron powders of different size ranges. The experimental part involves the determination of the population (number density) of metal atoms at different cross sections along the trajectory of the plasma jet, and the collection of the submicronic particles resulting from vapor condensation. The experimental results are compared with the projections of a mathematical model that computes the gas/particle velocity and temperature fields within the jet envelope, projects the rate of heat/mass transfer at the surface of individual particles, and determines the rate of volatilization that results in the formation of metal and metal oxide fumes.

  3. Experimental Studies of Spray Deposition on a Flat Surface in a Vacuum Environment

    NASA Technical Reports Server (NTRS)

    Golliher, Eric L.; Yao, S. C.

    2015-01-01

    Cooling of spacecraft components in the space environment is an on-going research effort. The electronics used in modern spacecraft are always changing and the heat flux is increasing. New, one-of-a-kind missions require new approaches to thermal control. In this research, under vacuum conditions, a pulsed water spray impinged on a small disc, while a high speed data acquisition system recorded the temperature histories of this copper disc. The water droplets froze quickly and accumulated on the disc as the spray continued. After the spray stopped, the frozen water that remained on the disc then sublimated into the vacuum environment and cooled the disc. This paper examines two important aspects of this process: 1) the difference in spray start up and shutdown in a vacuum environment versus in a standard atmospheric pressure environment, and 2) the water utilization efficiency in a vacuum environment due to the effects of drop trajectories and drop bouncing on the surface. Both phenomena play a role during spray cooling in a vacuum. This knowledge should help spacecraft designers plan for spray cooling as an option to cool spacecraft electronics, human metabolic generated heat, and heat from other sources.

  4. Development of plasma spray coated cylinder liners

    SciTech Connect

    Tricard, M.; Hagan, J.; Redington, P.; Subramanian, K.; Haselkorn, M.

    1996-09-01

    Improved fuel economy and reduction of emissions can be achieved by insulation of the combustion chamber components to reduce heat rejection. However, such insulation will also increase the operating temperature of the piston ring/cylinder liner interface from approximately 150 C to over 300 C. Since existing ring/liner materials cannot withstand these higher operating temperatures alternatives are needed for this critical tribological interface. This paper describes the development of a cost effective ID grinding technique for machining the bores of plasma sprayed diesel engine cylinder liners.

  5. 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.

  6. 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.

  7. High heat flux properties of pure tungsten and plasma sprayed tungsten coatings

    NASA Astrophysics Data System (ADS)

    Liu, X.; Tamura, S.; Tokunaga, K.; Yoshida, N.; Noda, N.; Yang, L.; Xu, Z.

    2004-08-01

    High heat flux properties of pure tungsten and plasma sprayed tungsten coatings on carbon substrates have been studied by annealing and cyclic heat loading. The recrystallization temperature and an activation energy QR=126 kJ/mol for grain growth of tungsten coating by vacuum plasma spray (VPS) were estimated, and the microstructural changes of multi-layer tungsten and rhenium interface pre-deposited by physical vapor deposition (PVD) with anneal temperature were investigated. Cyclic load tests indicated that pure tungsten and VPS-tungsten coating could withstand 1000 cycles at 33-35 MW/m 2 heat flux and 3 s pulse duration, and inert gas plasma spray (IPS)-tungsten coating showed local cracks by 300 cycles but did not induce failure by further cycles. However, the failure of pure tungsten and VPS-tungsten coating by fatigue cracking was observed under higher heat load (55-60 MW/m 2) for 420 and 230 cycles, respectively.

  8. Molybdenum disilicide composites produced by plasma spraying

    SciTech Connect

    Castro, R.G.; Hollis, K.J.; Kung, H.H.; Bartlett, A.H.

    1998-05-25

    The intermetallic compound, molybdenum disilicide (MoSi{sub 2}) is being considered for high temperature structural applications because of its high melting point and superior oxidation resistance at elevated temperatures. The lack of high temperature strength, creep resistance and low temperature ductility has hindered its progress for structural applications. Plasma spraying of coatings and structural components of MoSi{sub 2}-based composites offers an exciting processing alternative to conventional powder processing methods due to superior flexibility and the ability to tailor properties. Laminate, discontinuous and in situ reinforced composites have been produced with secondary reinforcements of Ta, Al{sub 2}O{sub 3}, SiC, Si{sub 3}N{sub 4} and Mo{sub 5}Si{sub 3}. Laminate composites, in particular, have been shown to improve the damage tolerance of MoSi{sub 2} during high temperature melting operations. A review of research which as been performed at Los Alamos National Laboratory on plasma spraying of MoSi{sub 2}-based composites to improve low temperature fracture toughness, thermal shock resistance, high temperature strength and creep resistance will be discussed.

  9. 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.

  10. 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.

  11. Erosion-resistance of plasma sprayed coatings

    SciTech Connect

    Xia, Z.; Zhang, X.; Song, J.

    1999-12-01

    Cr{sub 3}C{sub 2}/NiCr, ZrO{sub 2}/NiCr, WTiC{sub 2}/NiCr, and X40 were plasma sprayed on the substrate 1Cr18NI9Ti in order to solve the erosion wear at high temperature encountered in the oil-refining industry. A series of properties of the coatings, including their microstructure, hardness, and erosion-behavior, have been tested. The test results show that the properties of the coatings have a significant effect on their erosion-resistant performance. Good erosion-resistant materials need to be hard and tough. Both Cr{sub 3}C{sub 2}/NiCr and X40 have good erosion resistance at elevated temperature.

  12. Diagnostics of thermal spraying plasma jets

    SciTech Connect

    Fauchais, P.; Coudert, J.F.; Vardelle, M.; Vardelle, A.; Denoirjean, A. )

    1992-06-01

    The development of diagnostic techniques for dc plasma spraying is reviewed with attention given to the need for thick highly reproducible coatings of good quality for aeronautic and other uses. Among the techniques examined are fast cameras, laser-Doppler anemometry (LDA), coherent anti-Stokes Raman spectroscopy (CARS), enthalpy probes, and emission spectroscopy. Particular emphasis is given to the effect of arc fluctuations on the spectroscopic measurements, and a method is introduced for obtaining temperature and species density of vapor clouds traveling with each particle in flight. Coating properties can be deduced from data on single particles, and statistical approaches are often unreliable without added data on surface temperature and particle velocity. Also presented is a method for deriving the temperature evolution of a cooled splat and successive layers and passes. These methods are of interest to the control of adhesion and cohesion in coatings for critical aerospace applications. 70 refs.

  13. Diagnostics of thermal spraying plasma jets

    NASA Astrophysics Data System (ADS)

    Fauchais, P.; Coudert, J. F.; Vardelle, M.; Vardelle, A.; Denoirjean, A.

    1992-06-01

    The development of diagnostic techniques for dc plasma spraying is reviewed with attention given to the need for thick highly reproducible coatings of good quality for aeronautic and other uses. Among the techniques examined are fast cameras, laser-Doppler anemometry (LDA), coherent anti-Stokes Raman spectroscopy (CARS), enthalpy probes, and emission spectroscopy. Particular emphasis is given to the effect of arc fluctuations on the spectroscopic measurements, and a method is introduced for obtaining temperature and species density of vapor clouds traveling with each particle in flight. Coating properties can be deduced from data on single particles, and statistical approaches are often unreliable without added data on surface temperature and particle velocity. Also presented is a method for deriving the temperature evolution of a cooled splat and successive layers and passes. These methods are of interest to the control of adhesion and cohesion in coatings for critical aerospace applications.

  14. SPRAY: Single Donor Plasma Product For Room Temperature Storage

    PubMed Central

    Booth, Garrett S.; Lozier, Jay N.; Nghiem, Khanh; Clibourn, Douglas; Klein, Harvey G.; Flegel, Willy A.

    2013-01-01

    Background Spray drying techniques are commonly utilized in the pharmaceutical, dairy and animal feed industries for processing liquids into powders but have not been applied to human blood products. Spray dried protein products are known to maintain stability during storage at room temperature. Study design and methods Plasma units collected at the donor facility were shipped overnight at room temperature to a processing facility where single-use spray drying occurred. After 48 hours storage at room temperature, the spray dried plasma product was split in two and rehydrated with 1.5% glycine or deionized water and assayed for chemistry analytes and coagulation factors. Matched fresh frozen plasma (FFP) was analyzed in parallel as controls. Results Reconstitution was achieved for both rehydration groups within five minutes (n=6). There was no statistically significant intergroup difference in recovery for total protein, albumin, IgG, IgA, and IgM (96% or higher). With the exception of factor VIII (58%), the recovery of clotting factors in the glycine reconstituted products ranged from 72% to 93%. Glycine reconstitution was superior to deionized water. Conclusion We documented proteins and coagulation activities were recovered in physiologic quantities in reconstituted spray dried plasma products. Further optimization of the spray drying method and reconstitution fluid may result in even better recoveries. Spray drying is a promising technique for preparing human plasma that can be easily stored at room temperature, shipped, and reconstituted. Rapid reconstitution of the microparticles results in a novel plasma product from single donors. PMID:22043873

  15. 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.

  16. Thermal properties of plasma-sprayed tungsten deposits

    NASA Astrophysics Data System (ADS)

    Kang, Hyun-Ki

    2004-10-01

    Tungsten powder was plasma-sprayed onto a graphite substrate in order to examine the microstructures, porosities, and thermal conductivities of tungsten deposits. Tungsten was partially oxidized to tungsten oxide (WO 3) after plasma spraying. Most pores were found in the vicinity of lamellar layers in association with oxidation. It was revealed that both tungsten oxide and the lamellar structure with pores have a significant influence on the electrical and thermal conductivity.

  17. 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

  18. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    NASA Astrophysics Data System (ADS)

    Cai, Yuxuan; Coyle, Thomas W.; Azimi, Gisele; Mostaghimi, Javad

    2016-04-01

    This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces.

  19. Effects of nonthermal electrons on plasma expansion into vacuum

    SciTech Connect

    Bennaceur-Doumaz, D. Bara, D.; Benkhelifa, E.; Djebli, M.

    2015-01-28

    The expansion of semi-infinite plasma into vacuum is analyzed with a hydrodynamic model for cold ions assuming electrons modelled by a kappa-type distribution. Similarly to Mora study of a plasma expansion into vacuum [P. Mora, Phys. Rev. Lett. 90, 185002 (2003)], we formulated empirical expressions for the electric field strength, velocity, and position of the ion front in one-dimensional nonrelativistic, collisionless isothermally expanding plasma. Analytic expressions for the maximum ion energy and the spectrum of the accelerated ions in the plasma were derived and discussed to highlight the electron nonthermal effects on enhancing the ion acceleration in plasma expansion into vacuum.

  20. Comparison of the characteristics of HVOF and plasma thermal spray

    SciTech Connect

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

    1994-12-31

    In spraying oxygen sensitive materials, such as WC:Co it is often observed that the carbide fraction present in the deposit is significantly less than in the original particles. This lowers the hardness of the coating, resulting in inferior wear resistance. The cause is the in-flight, high temperature decomposition of carbides by reaction with entrained oxygen. The degree of decomposition is determined by a combination of particle temperature, residence time and entrainment characteristics of the jet. The fundamental differences between HVOF and plasma thermal spray are examined in this context. Even though the HVOF process may actually subject a particle to greater oxygen exposure than plasma spraying, the lower particle temperatures experienced lead to coatings which exhibit less carbide loss than plasma sprayed coatings fabricated in air.

  1. Laboratory Experiments on Propagating Plasma Bubbles into Vacuum, Vacuum Magnetic Field, and Background Plasmas

    NASA Astrophysics Data System (ADS)

    Lynn, Alan G.; Zhang, Yue; Gilmore, Mark; Hsu, Scott

    2014-10-01

    We discuss the dynamics of plasma ``bubbles'' as they propagate through a variety of background media. These bubbles are formed by a pulsed coaxial gun with an externally applied magnetic field. Bubble parameters are typically ne ~1020 m-3, Te ~ 5 - 10 eV, and Ti ~ 10 - 15 eV. The structure of the bubbles can range from unmagnetized jet-like structures to spheromak-like structures with complex magnetic flux surfaces. Some of the background media the bubbles interact with are vacuum, vacuum with magnetic field, and other magnetized plasmas. These bubbles exhibit different qualitative behavior depending on coaxial gun parameters such as gas species, gun current, and gun bias magnetic field. Their behavior also depends on the parameters of the background they propagate through. Multi-frame fast camera imaging and magnetic probe data are used to characterize the bubble evolution under various conditions.

  2. Effect of vacuum conditions and plasma concentration on the chemical composition and adhesion of vacuum-plasma coatings

    NASA Astrophysics Data System (ADS)

    Borisov, D. P.; Kuznetsov, V. M.; Slabodchikov, V. A.

    2015-11-01

    The paper reports on the chemical composition of titanium nitride (TiN) and silicon (Si) coatings deposited with a new technological vacuum plasma setup which comprises magnetron sputtering systems, arc evaporators, and an efficient plasma generator. It is shown that due to highly clean vacuum conditions and highly clean surface treatment in the gas discharge plasma, both the coating-substrate interface and the coatings as such are almost free from oxygen and carbon. It is found that the coating-substrate interface represents a layer of thickness ≥ 60 nm formed through vacuum plasma mixing of the coating and substrate materials. The TiN coatings obtained on the new equipment display a higher adhesion compared to brass coatings deposited by industrial technologies via intermediate titanium oxide layers. It is concluded that the designed vacuum plasma equipment allows efficient surface modification of materials and articles by vacuum plasma immersion processes.

  3. Atmospheric pressure plasma jet for liquid spray treatment

    NASA Astrophysics Data System (ADS)

    Mitić, S.; Philipps, J.; Hofmann, D.

    2016-05-01

    Atmospheric pressure plasma jets have been intensively studied in recent years due to growing interest in their use for biomedical applications and surface treatments. Either surfaces can be treated by a plasma jet afterglow for cleaning or activation or a material can be deposited by a reactive gas component activated by plasma. Effects of plasma on liquid have been reported several times where the electron spin trapping method was used for radical detection. Here we propose another method of liquid treatment using the atmospheric pressure plasma jet. In the device presented here, liquid was sprayed in droplets from an inner electrode directly into a plasma jet where it was treated and sprayed out by gas flow. Optical end electrical measurements were done for diagnostics of the plasma while electron paramagnetic resonance measurements were used for detection of radicals (\\text{OH},\\text{OOH},\\text{CH} ) produced by plasma treatment of liquids.

  4. Quantum electrodynamics vacuum polarization modification of photon acceleration in plasma

    SciTech Connect

    Bu Zhigang; Ji Peiyong

    2010-07-15

    The modification of photon frequency shifting based on taking into account the nonlinear quantum electrodynamics vacuum properties in plasma is studied. Motion equations of a laser field propagating in a plasma are derived from the Heisenberg-Euler Lagrangian density. It is found that besides the classical density perturbation of the plasma electrons, the energy density perturbation of the laser field will induce the frequency shifting via the ponderomotive force of the laser field on the vacuum. In addition it is shown that the electron density will be suppressed, which is attributed to a screening effect on the plasma electrons via the quantum vacuum polarization.

  5. Occurrence of tungsten plasma in plasma spraying of WC/Co

    SciTech Connect

    Detering, B.A.; Knibloe, J.R.; Eddy, T.L.

    1990-01-01

    The conditions under which tungsten is vaporized and ionized during plasma spraying of WC/Co powders are investigated spectroscopically. Overheating of the powder results in less cobalt and decarburization of WC in the sprayed coating. The plasma is dominated by ionized tungsten and the resulting coating has a substantial amount of tungsten metal. 15 refs., 4 figs., 2 tabs.

  6. 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.

  7. Ultrasonic Spray Drying vs High Vacuum and Microwaves Technology for Blueberries

    NASA Astrophysics Data System (ADS)

    Candia-Muñoz, N.; Ramirez-Bunster, M.; Vargas-Hernández, Y.; Gaete-Garretón, L.

    Interest in high quality foods: good taste and a high content of nutrients with healthy beneficial effects are increasing. Fruits have good properties but, they are lost because the oxidation process, additionally, for different reasons a 40% of harvested fruit are lost. To conserve the fruit properties an ultrasonic assisted spray dryer was developed and tested, comparing its results with microwave-vacuum drying technology. Results did shown taste, color, smell, particle shape and size distribution better than the conventional one. The antioxidants conservation were quite good except in the anthocyanins, in which the microwave and vacuum technology shown best results.

  8. Surface decontamination using a teleoperated vehicle and Kelly spray/vacuum system

    SciTech Connect

    Zollinger, W.T.; Dyches, G.M.

    1990-01-01

    A commercial teleoperated wheeled vehicle was fitted with a modified commercial spray/vacuum decontamination system to allow floor and wall decontamination of an existing process room in one of the chemical separations areas at the Savannah River Site (SRS). Custom end-of-arm tooling was designed to provide sufficient compliance for routine cleaning operations. An operator console was designed to allow complete control of the vehicle base and are movements as well as viewing operations via multiple television monitors. 3 refs.

  9. Surface decontamination using a teleoperated vehicle and Kelly spray/vacuum system

    SciTech Connect

    Zollinger, W.T.; Dyches, G.M.

    1990-12-31

    A commercial teleoperated wheeled vehicle was fitted with a modified commercial spray/vacuum decontamination system to allow floor and wall decontamination of an existing process room in one of the chemical separations areas at the Savannah River Site (SRS). Custom end-of-arm tooling was designed to provide sufficient compliance for routine cleaning operations. An operator console was designed to allow complete control of the vehicle base and are movements as well as viewing operations via multiple television monitors. 3 refs.

  10. Modeling of Oxidation of Molybdenum Particles during Plasma Spray Deposition

    SciTech Connect

    Fincke, James Russell; Wan, Y. P.; Jiang, X. Y.; Sampath, S.; Prasad, V.; Herman, H.

    2001-06-01

    An oxidation model for molybdenum particles during the plasma spray deposition process is presented. Based on a well-verified model for plasma chemistry and the heating and phase change of particles in a plasma plume, this model accounts for the oxidant diffusion around the surface of particles or splats, oxidation on the surface, as well as oxygen diffusion in molten molybdenum. Calculations are performed for a single molybdenum particle sprayed under Metco-9MB spraying conditions. The oxidation features of particles during the flight are compared with those during the deposition. The result shows the dominance of oxidation of a molybdenum particle during the flight, as well as during deposition when the substrate temperature is high (above 400 °C).

  11. Characterization of plasma sprayed and explosively consolidated simulated lunar soil

    SciTech Connect

    Powell, S.J.; Inal, O.T.; Smith, M.F.

    1997-06-01

    Two methods for the use of lunar materials for the construction of shelters on the Moon are being proposed: explosive consolidation of the soil into structural components and plasma spraying of the soil to join components. The plasma-sprayed coating would also provide protection from the intense radiation. In this work, a mare simulant was plasma-sprayed onto a stainless steel substrate. Deposition of a 0.020 inch coating using power inputs of 23, 25, 27 and 29 kW were compared. Hardness of the coatings increased with each increase of power to the system, while porosity at the interface decreased. All coatings exhibited good adhesion. Simultaneously, an explosively consolidated sample was similarly characterized to afford a comparison of structural features associated with each mode of proposed use.

  12. Corrosion behavior of magnetic ferrite coating prepared by plasma spraying

    SciTech Connect

    Liu, Yi; Wei, Shicheng Tong, Hui; Tian, Haoliang; Liu, Ming; Xu, Binshi

    2014-12-15

    Graphical abstract: The saturation magnetization (M{sub s}) of the ferrite coating is 34.417 emu/g while the M{sub s} value of the ferrite powder is 71.916 emu/g. It can be seen that plasma spray process causes deterioration of the room temperature soft magnetic properties. - Highlights: • Spinel ferrite coatings have been prepared by plasma spraying. • The coating consists of nanocrystalline grains. • The saturation magnetization of the ferrite coating is 34.417 emu/g. • Corrosion behavior of the ferrite coating was examined in NaCl solution. - Abstract: In this study, spray dried spinel ferrite powders were deposited on the surface of mild steel substrate through plasma spraying. The structure and morphological studies on the ferrite coatings were carried out using X-ray diffraction, scanning electron microscope and Raman spectroscopy. It was showed that spray dried process was an effective method to prepare thermal spraying powders. The coating showed spinel structure with a second phase of LaFeO{sub 3}. The magnetic property of the ferrite samples were measured by vibrating sample magnetometer. The saturation magnetization (M{sub s}) of the ferrite coating was 34.417 emu/g. The corrosion behavior of coating samples was examined by electrochemical impedance spectroscopy. EIS diagrams showed three corrosion processes as the coating immersed in 3.5 wt.% NaCl solution. The results suggested that plasma spraying was a promising technology for the production of magnetic ferrite coatings.

  13. Plasma Spray for Difficult-To-Braze Alloys

    NASA Technical Reports Server (NTRS)

    Brennan, A.

    1982-01-01

    Nickel plating on surfaces makes brazing easier for some alloys. Sometimes nickel plating may not be feasible because of manufacturing sequence, size of hardware, or lack of suitable source for nickel plating. Alternative surface preparation in such cases is to grit-blast surface lightly and then plasma-spray 1 1/2 to 2 mils of fine nickel powder or braze-alloy material directly on surface. Powder is sprayed from plasma gun, using argon as carrier gas to prevent oxidation of nickel or braze alloy.

  14. Plasma sprayed and electrospark deposited zirconium metal diffusion barrier coatings

    SciTech Connect

    Hollis, Kendall J; Pena, Maria I

    2010-01-01

    Zirconium metal coatings applied by plasma spraying and electrospark deposition (ESD) have been investigated for use as diffusion barrier coatings on low enrichment uranium fuel for research nuclear reactors. The coatings have been applied to both stainless steel as a surrogate and to simulated nuclear fuel uranium-molybdenum alloy substrates. Deposition parameter development accompanied by coating characterization has been performed. The structure of the plasma sprayed coating was shown to vary with transferred arc current during deposition. The structure of ESD coatings was shown to vary with the capacitance of the deposition equipment.

  15. Phase analysis of plasma-sprayed zirconia-yttria coatings

    NASA Technical Reports Server (NTRS)

    Shankar, N. R.; Berndt, C. C.; Herman, H.

    1983-01-01

    Phase analysis of plasma-sprayed 8 wt pct-yttria-stabilized zirconia (YSZ) thermal barrier coatings and powders was carried out by X-ray diffraction. Step scanning was used for increased peak resolution. Plasma spraying of the YSZ powder into water or onto a steel substrate to form a coating reduced the cubic and monoclinic phases with a simultaneous increase in the tetragonal phase. Heat treatment of the coating at 1150 C for 10 h in an Ar atmosphere increased the amount of cubic and monoclinic phases. The implications of these transformations on coating performance and integrity are discussed.

  16. The Role of Spraying Parameters and Inert Gas Shrouding in Hybrid Water-Argon Plasma Spraying of Tungsten and Copper for Nuclear Fusion Applications

    NASA Astrophysics Data System (ADS)

    Matějíček, J.; Kavka, T.; Bertolissi, G.; Ctibor, P.; Vilémová, M.; Mušálek, R.; Nevrlá, B.

    2013-06-01

    Tungsten-based coatings have potential application in the plasma-facing components in future nuclear fusion reactors. By the combination of refractory tungsten with highly thermal conducting copper, or steel as a construction material, functionally graded coatings can be easily obtained by plasma spraying, and may result in the development of a material with favorable properties. During plasma spraying of these materials in the open atmosphere, oxidation is an important issue, which could have adverse effects on their properties. Among the means to control it is the application of inert gas shrouding, which forms the subject of this study and represents a lower-cost alternative to vacuum or low-pressure plasma spraying, potentially applicable also for spraying of large surfaces or spacious components. It is a continuation of recent studies focused on the effects of various parameters of the hybrid water-argon torch on the in-flight behavior of copper and tungsten powders and the resultant coatings. In the current study, argon shrouding with various configurations of the shroud was applied. The effects of torch parameters, such as power and argon flow rate, and powder morphology were also investigated. Their influence on the particle in-flight behavior as well as the structure, composition and properties of the coatings were quantified. With the help of auxiliary calculations, the mass changes of the powder particles, associated with oxidation and evaporation, were assessed.

  17. Laser acceleration in vacuum, gases, and plasmas withcapillary waveguide

    SciTech Connect

    Xie, Ming

    1998-07-01

    I propose a new method for laser acceleration of relativistic electrons using the leaky modes of a hollow dielectric waveguide. The hollow core of the waveguide can be either in vacuum or filled with uniform gases or plasmas. In case of vacuum and gases, TM01 mode is used for direct acceleration. In case of plasmas, EH11 mode is used to drive longitudinal plasma wave for acceleration. Structure damage due to high power laser can be avoided by choosing a core radius sufficiently larger than laser wavelength. Effect of nonuniform plasma density on waveguide performance is also analyzed.

  18. Plasma cleaning device. [designed for high vacuum environments

    NASA Technical Reports Server (NTRS)

    Shannon, R. L.; Gillette, R. B. (Inventor)

    1978-01-01

    High vacuum cleaning of contaminated surfaces such as hydrocarbon containment films can be accomplished by a plasma cleaning device which includes a plasma discharge housing to permit generation of a plasma in an environment having a higher pressure than the surface which is to be cleaned. A ground electrode and a radio frequency electrode partially surround a quartz plasma tube, for the introduction of an ionizable gas. These electrodes ionize the gas and help generate the plasma. This plasma flows through a non-constrictive aperture, through the plasma discharge housing and then on to the contaminated surface.

  19. 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.

  20. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    PubMed Central

    Cai, Yuxuan; Coyle, Thomas W.; Azimi, Gisele; Mostaghimi, Javad

    2016-01-01

    This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces. PMID:27091306

  1. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray.

    PubMed

    Cai, Yuxuan; Coyle, Thomas W; Azimi, Gisele; Mostaghimi, Javad

    2016-01-01

    This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces. PMID:27091306

  2. Improved Small-Particle Powders for Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Nguyen, QuynhGiao, N.; Miller, Robert A.; Leissler, George W.

    2005-01-01

    Improved small-particle powders and powder-processing conditions have been developed for use in plasma spray deposition of thermal-barrier and environmental barrier coatings. Heretofore, plasma-sprayed coatings have typically ranged in thickness from 125 to 1,800 micrometers. As explained below, the improved powders make it possible to ensure complete coverage of substrates at unprecedently small thicknesses of the order of 25 micrometers. Plasma spraying involves feeding a powder into a hot, high-velocity plasma jet. The individual powder particles melt in the plasma jet as they are propelled towards a substrate, upon which they splat to build up a coating. In some cases, multiple coating layers are required. The size range of the powder particles necessarily dictates the minimum thickness of a coating layer needed to obtain uniform or complete coverage. Heretofore, powder particle sizes have typically ranged from 40 to 70 micrometers; as a result, the minimum thickness of a coating layer for complete coverage has been about 75 micrometers. In some applications, thinner coatings or thinner coating layers are desirable. In principle, one can reduce the minimum complete-coverage thickness of a layer by using smaller powder particles. However, until now, when powder particle sizes have been reduced, the powders have exhibited a tendency to cake, clogging powder feeder mechanisms and feed lines. Hence, the main problem is one of synthesizing smaller-particle powders having desirable flow properties. The problem is solved by use of a process that begins with a spray-drying subprocess to produce spherical powder particles having diameters of less than 30 micrometers. (Spherical-particle powders have the best flow properties.) The powder is then passed several times through a commercial sifter with a mesh to separate particles having diameters less than 15 micrometers. The resulting fine, flowable powder is passed through a commercial fluidized bed powder feeder into a

  3. 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.

  4. Tensile adhesion test measurements on plasma-sprayed coatings

    NASA Technical Reports Server (NTRS)

    Berndt, C. C.

    1986-01-01

    Adhesion measurements on plasma-sprayed coatings are briefly studied, including a critical analysis of the experimental scatter for duplicate tests. The application of a simple method which presents adhesion strength data in a fracture mechanics perspective is demonstrated. Available data are analyzed in a way which suggests an approach to finding the overall defect contribution to reducing the apparent strength of coatings.

  5. 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.

  6. Crystallization behavior of plasma-sprayed lanthanide magnesium hexaaluminate coatings

    NASA Astrophysics Data System (ADS)

    Huang, Liang-liang; Meng, Hui-min; Tang, Jing

    2014-12-01

    LaMgAl11O19 thermal barrier coatings (TBCs) were prepared by atmospheric plasma spraying. The crystallization behavior of the coatings and the synthesis mechanism of LaMgAl11O19 powders were researched. The results showed that the plasma-sprayed coatings contained some amorphous phase, and LaMgAl11O19 powders were partially decomposed into Al2O3, LaAlO3, and MgAl2O4 in the plasma spraying process. The amorphous phase was recrystallized at a temperature of approximately 1174.9°C, at which level the decomposed Al2O3, LaAlO3, and MgAl2O4 reacted again. The resynthesis temperature of LaMgAl11O19 in the plasma-sprayed coatings was lower than that of LaMgAl11O19 in the original raw powders. The synthesis mechanism of LaMgAl11O19 powders can be summarized as follows: during the first part of the overall reaction, La2O3 reacts with Al2O3 to form LaAlO3 at approximately 900°C, and then LaAlO3 further reacts with Al2O3 and MgAl2O4 to produce LaMgAl11O19 at approximately 1200°C.

  7. Mechanical and physical properties of plasma-sprayed stabilized zirconia

    NASA Technical Reports Server (NTRS)

    Siemers, P. A.; Mehan, R. L.

    1983-01-01

    Physical and mechanical properties were determined for plasma-sprayed MgO- or Y2O3-stabilized ZrO2 thermal barrier coatings. Properties were determined for the ceramic coating in both the freestanding condition and as-bonded to a metal substrate. The properties of the NiCrAlY bond coating were also investigated.

  8. Plasma tests of sprayed coatings for rocket thrust chambers

    NASA Technical Reports Server (NTRS)

    Curren, A. N.; Love, W. K.

    1974-01-01

    Several plasma-sprayed coating systems were evaluated for structural stability in hydrogen plasma and in oxygen plasma mixed with hydrogen plasma. The principal test heat flux was 15 Btu per inch squared seconds. The system consisted of a number of thin 0.002 to 0.020 in. layers of metal oxides and/or metals. The principal materials included are molybdenum nichrome, alumina, and zirconia. The study identifies important factors in coating system fabrication and describes the durability of the coating systems in the test environments. Values of effective thermal conductivity for some of the systems are indicated.

  9. Influence of Glass Content on Damping Properties of Plasma-Sprayed Mixtures of Zirconia and Glass

    NASA Astrophysics Data System (ADS)

    Torvik, P. J.; Henderson, J. P.

    2012-07-01

    The addition by vacuum infiltration of small quantities of a polymer has been found to increase significantly the ability of a plasma-sprayed coating to dissipate vibratory energy at temperatures in the glassy-rubbery transition range of the polymer. As vitreous enamels and glasses undergo a glassy transition, but at much higher temperatures, the addition of a small amount of glass to a ceramic has the potential of providing high damping at such temperatures. Mixtures of yttria-stabilized zirconia (YSZ) and a glass frit were plasma sprayed on specimens with bond coats. Measures of system response (resonant frequencies and loss factors) were extracted from frequency responses to excitations of cantilever beam specimens over a range of excitation amplitudes. Comparisons of values determined before and after coating were used to determine the damping properties of the coatings alone as functions of strain, at temperatures of special interest. Emphasis was given to identifying the lowest level of glass giving significantly more damping than that of the plasma-sprayed ceramic alone. Coatings with weight fractions of 5, 2, 1, ½, and 0% glass were tested. The inclusion of glass at all weight fractions considered was found to yield significant increases in both the stiffness and dissipation of the coatings.

  10. Induction suspension plasma sprayed biological-like hydroxyapatite coatings.

    PubMed

    Loszach, Max; Gitzhofer, François

    2015-04-01

    Substituted hydroxyapatite coatings with different ions (Mg, Na, K, Cl, F) have been developed by the induction suspension plasma spray process. Suspensions were prepared with sol-gel. The main objective of this study was to demonstrate that induction suspension plasma spray technology possesses high material composition flexibility that allows as-sprayed coatings to closely mimic natural bone composition. Long-term in vitro behaviour of as-sprayed substituted coatings was evaluated with simulated body fluid. Data on the suspensions showed the formation of a pure hydroxyapatite phase. Transmission electron microscopy characterized various preparation stages of the suspensions. As-sprayed samples were distinguished by X-ray diffraction and scanning electron microscopy. Substituted elements were quantified by neutron activation. A well-crystallized hydroxyapatite phase was produced with concentration in various substitutions very close to natural bone composition. Ca/P and (Ca + Mg + Na + K)/P ratios provided evidence of the introduction of different cations into apatite structures. The immersion of samples into simulated body fluid led to the nucleation and growth of a flake-like octacalcium phosphate crystal layer at the surface of as-sprayed coatings after one week. Proof of octacalcium phosphate transformation and its partial dissolution and direct re-precipitation into apatite was disclosed by local energy dispersive spectroscopy and microstructure observation. Formation of a Ca/P ratio gradient from the precipitated layer surface to the as-sprayed coatings interface was observed after four weeks once the octacalcium phosphate crystals reached a critical size, resulting in the formation of a rich apatite layer at the interface after six weeks. A set of mechanisms has been proposed to explain these findings. PMID:25586411

  11. Electroform/Plasma-Spray Laminates for X-Ray Optics

    NASA Technical Reports Server (NTRS)

    Ulmer, Melville P.; Graham, Michael; Vaynman, Semyon

    2007-01-01

    Electroform/plasma-spray laminates have shown promise as lightweight, strong, low-thermal-expansion components for xray optics. The basic idea is to exploit both (1) the well-established art of fabrication of optical components by replication and (2) plasma spraying as a means of reinforcing a thin replica optic with one or more backing layer(s) having tailorable thermomechanical properties. In x-ray optics as in other applications, replication reduces the time and cost of fabrication because grinding and polishing can be limited to a few thick masters, from which many lightweight replicas can thereafter be made. The first step in the fabrication of a component of the type in question is to make a replica optic by electroforming a thin layer of nickel on a master. Through proper control of the electroforming process conditions, it is possible to minimize residual stress and, hence, to minimize distortion in the replica. Next, a powder comprising ceramic particles coated with a metal compatible with the electroformed nickel is plasma-sprayed onto the backside of the nickel replica. Then through several repetitions and variations of the preceding steps or perhaps a small compressive stress, alternating layers of electroformed nickel and plasma-sprayed metal-coated ceramic powder are deposited. The thicknesses of the layers and the composition of the metal-coated ceramic powder are chosen to optimize the strength, areal mass density, and toughness of the finished component. An important benefit of using both electroforming and plasma spraying is the possibility of balancing stresses to a minimum level, which could be zero or perhaps a small net compressive stress designed to enhance the function of the component in its intended application.

  12. Plasma spray coating of spray-dried Cr2O3/wt.% TiO2 powder

    NASA Astrophysics Data System (ADS)

    Kim, B. K.; Lee, D. W.; Ha, G. H.

    2001-03-01

    An agglomerated Cr2O3/wt.%TiO2 powder has been fabricated by the spray drying process under different parameters. The spray-dried powder has well-agglomerated particles of spherical shape. In the conditions of the high slurry feed rate and low binder concentration in the slurry, the powder has large cavities inside some particles and ruggedness over their surface. The optimum plasma spray feed rate has been found by examining the spraying behavior of the powder and melted state of particles. The plasma spray coating has been performed under different process variables such as spraying distance and plasma power. These parameters strongly affect the characteristics of the coated layer: microstructure, hardness, and bond strength.

  13. Nitrite spray treatment to promote red color stability of vacuum packaged beef.

    PubMed

    Song, Xiao; Cornforth, Daren; Whittier, Dick; Luo, Xin

    2015-01-01

    Sodium nitrite solutions were sprayed on select grade boneless rib (M. longissimus thoracis) and bottom round (mainly M. biceps femoris) steaks individually, to form bright red nitric oxide myoglobin (NO-Mb) in vacuum packages. Our objective was to determine the optimum level of nitrite in spray for stable raw steak redness, low or no residual nitrite, and low surface pinking (ham-like cured color) after cooking. Results showed that steaks sprayed with 100-350 ppm nitrite solutions had 3.0-3.6g weight gain and a calculated level of 1.3-5.3mg nitrite added/kg steak, but very low (<1 ppm) residual nitrite. Nitrite sprays of 250-350 ppm were optimum for raw steak color during 21 days of storage at 1°C (a*>10; chroma C*>16). Raw steak redness was less stable in round than rib. Visual scores for pinkness after cooking were low, indicating that cooked color at even the highest nitrite treatment (350 ppm) was acceptable. PMID:25280357

  14. Capillary waveguide for laser acceleration in vacuum, gases and plasmas

    SciTech Connect

    Xie, Ming

    1998-06-01

    The authors propose a new method for laser acceleration of relativistic electrons using the leaky modes of a hollow dielectric waveguide. The hollow core of the waveguide can be either in vacuum or filled with uniform gases or plasmas. In of vacuum and gases, TM{sub 01} mode is used for direct acceleration. In case of plasmas, EH{sub 11} mode is used to drive longitudinal plasma wave for acceleration. Structure damage by high power laser is avoided by choosing a core radius much larger than laser wavelength.

  15. Spheroidized Hydroxyapatite (HA) Powders Plasma Spraying of Combustion Flame

    NASA Astrophysics Data System (ADS)

    Khor, K. A.; Wang, Y.; Cheang, P.

    1998-06-01

    Tailoring powder characteristics to suit the plasma spray process can alleviate difficulties associated with the preparation of hydroxyapatite (HA) coatings. Commercial HA feedstock normally exhibit an angular morphology and a wide particle size range that present difficulties in powder transport from the powder hopper to the plasma spray gun and in nonuniform melting of the powders in the plasma flame. Hence, combustion flame spheroidized hydroxyapatite (SHA) was used as the feedstock for plasma spraying. Spherical particles within a narrow particle size range are found to be more effective for the plasma spray processes. Results show coatings generated from spheroidized HA powders have unique surface and microstructure characteristics. Scanning electron microscope (SEM) observation of the coating surface revealed well-formed splats that spread and flatten into disc configurations with no disintegration, reflecting adequate melting of the HA in the plasma and subsequent deposition consistency. The surface topography is generally flat with good overlapping of subsequent spreading droplets. Porosity in the form of macropores is substantially reduced. The cross-section microstructure reveals a dense coating comprised of randomly stacked lamellae. The tensile bond strengths of the SHA coatings, phase composition, and characteristics of the coatings generated with different particle sizes (125 to 75 µm, 45 to 75 µm, 20 to 45 µm, and 5 to 20 µm) showed that a high bond strength of ˜16 MPa can be obtained with SHA in the size range from 20 to 45 µm. This can be improved further by a postspray treatment by hot isostatic pressing (HIP). However, larger particle size ranges exhibited higher degrees of crystallinity and relatively higher HA content among the various calcium phosphate phases found in the coatings.

  16. Investigation of plasma flow in vacuum arc with hot cathode

    NASA Astrophysics Data System (ADS)

    Amirov, R.; Vorona, N.; Gavrikov, A.; Lizyakin, G.; Polistchook, V.; Samoylov, I.; Smirnov, V.; Usmanov, R.; Yartsev, I.

    2014-11-01

    One of the crucial problems which appear under development of plasma technology processing of spent nuclear fuel (SNF) is the design of plasma source. The plasma source must use solid SNF as a raw material. This article is devoted to experimental study of vacuum arc with hot cathode made of gadolinium that may consider as the simple model of SNF. This vacuum discharge was investigated in wide range of parameters. During the experiments arc current and voltage, cathode temperature, and heat flux to the cathode were measured. The data on plasma spectrum and electron temperature were obtained. It was shown that external heating of the cathode allows change significantly the main parameters of plasma. It was established by spectral and probe methods that plasma jet in studied discharge may completely consist of single charged ions.

  17. Steam chemical reactivity of plasma-sprayed beryllium

    SciTech Connect

    Anderl, R.A.; Pawelko, R.J.; Smolik, G.R.; Castro, R.G.

    1998-07-01

    Plasma-spraying with the potential for in-situ repair makes beryllium a primary candidate for plasma facing and structural components in experimental magnetic fusion machines. Deposits with good thermal conductivity and resistance to thermal cycling have been produced with low pressure plasma-spraying (LPPS). A concern during a potential accident with steam ingress is the amount of hydrogen produced by the reactions of steam with hot components. In this study the authors measure the reaction rates of various deposits produced by LPPS with steam from 350 C to above 1,000 C. They correlate these reaction rates with measurements of density, open porosity and BET surface areas. They find the reactivity to be largely dependent upon effective surface area. Promising results were obtained below 600 C from a 94% theoretical dense (TD) deposit with a BET specific surface area of 0.085 m{sup 2}/g. Although reaction rates were higher than those for dense consolidated beryllium they were substantially lower, i.e., about two orders of magnitude, than those obtained from previously tested lower density plasma-sprayed deposits.

  18. Vacuum arc plasma thrusters with inductive energy storage driver

    NASA Technical Reports Server (NTRS)

    Schein, Jochen (Inventor); Gerhan, Andrew N. (Inventor); Woo, Robyn L. (Inventor); Au, Michael Y. (Inventor); Krishnan, Mahadevan (Inventor)

    2004-01-01

    An apparatus for producing a vacuum arc plasma source device using a low mass, compact inductive energy storage circuit powered by a low voltage DC supply acts as a vacuum arc plasma thruster. An inductor is charged through a switch, subsequently the switch is opened and a voltage spike of Ldi/dt is produced initiating plasma across a resistive path separating anode and cathode. The plasma is subsequently maintained by energy stored in the inductor. Plasma is produced from cathode material, which allows for any electrically conductive material to be used. A planar structure, a tubular structure, and a coaxial structure allow for consumption of cathode material feed and thereby long lifetime of the thruster for long durations of time.

  19. Electrochemical Evaluation of Pyrite Films Prepared by Plasma Spraying

    SciTech Connect

    Guidotti, R.A.; Reinhardt, F.W.

    1998-10-30

    Thermally activated batteries use electrodes that are typically fabricated by cold pressing of powder. In the LiSi/FeS2 system, natural (mineral) pyrite is used for the cathode. In an effort to increase the energy density and specific energy of these batteries, flame and plasma spraying to form thin films of pyrite cathodes were evaluated. The films were deposited on a 304 stainless steel substrate (current collector) and were characterized by scanning electron microscopy and x-ray dlfllaction. The films were electrochemically tested in single cells at 5000C and the petiormance compared to that of standard cells made with cold-pressed powders. The best results were obtained with material deposited by de-arc plasma spraying with a proprietq additive to suppress thermal decomposion of the pyrite.

  20. Effects of plasma spray parameters on two layer thermal barrier

    NASA Technical Reports Server (NTRS)

    Stecura, S.

    1981-01-01

    The power level and the type of arc gas used during plasma spraying of a two layer thermal barrier system (TBS) were found to affect the life of the system. Life at 1095 C in a cyclic furnace test was improved by about 140 percent by increasing the power during plasma spray applications of the bond and thermal barrier coatings. This improvement is due to increases in the densities of the bond and thermal barrier coatings by 3 and 5 percent, respectively. These increases in densities are equivalent to about 45 and 30 percent reduction in mean porosities, respectively. The addition of hydrogen to the argon arc gas had the same effect as the reduction in power level and caused a reduction in TBS life.

  1. Phase distributions in plasma-sprayed zirconia-yttria

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Garlick, R. G.; Smialek, J. L.

    1983-01-01

    The distribution of phases in plasma-sprayed zirconia-yttria has been determined over a range of yttria levels from 0 to 26.1 molpct YO(1.5) using room temperature X-ray diffractometry. Pure, plasma-sprayed zirconia is composed almost entirely of the monoclinic phase. At levels of yttria between 4 and 10 percent, a quenched-in tetragonal phase predominates, and at higher levels the cubic phase predominates. The phase distributions are compared with previously reported test lives of thermal barrier coatings formed from these materials. Regions of optimal lives were found to correlate with regions having high amounts of the tetragonal phase, small but nonzero amounts of the monoclinic phase, and little or none of the cubic phase. Possible relationships between phase composition and coating performance are discussed.

  2. dc-plasma-sprayed electronic-tube device

    DOEpatents

    Meek, T.T.

    1982-01-29

    An electronic tube and associated circuitry which is produced by dc plasma arc spraying techniques is described. The process is carried out in a single step automated process whereby both active and passive devices are produced at very low cost. The circuitry is extremely reliable and is capable of functioning in both high radiation and high temperature environments. The size of the electronic tubes produced are more than an order of magnitude smaller than conventional electronic tubes.

  3. Graded plasma spraying of premixed metalceramic powders on metallic substrates

    NASA Astrophysics Data System (ADS)

    Lima, C. R. C.; Trevisan, R.-E.

    1997-06-01

    The mismatch between the thermal expansion coefficients of ceramics and metals and the differential stresses it causes at the interface create problems in metal to ceramic joining. Research has been con-ducted to solve this problem in thermal barrier coating technology. Previous studies have considered met-al-ceramic multilayers or graded-coatings, which include a metallic bond coat. In this study, a graded plasma-sprayed metal-ceramic coating is developed using the deposition of premixed metal and ceramic powders without the conventional metallic bond coat. Influences of thickness variations, number, and composition of the layers are investigated. Coatings are prepared by atmospheric plasma-spraying on In-conel 718 superalloy substrates. Ni-Cr-Al and ZrO2 -8 % Y2O3 powders are used for plasma spraying. Ad-hesive and cohesive strength of the coatings are determined. The concentration profile of the elements is determined by x-ray energy-dispersive analysis. The microstructure and morphology of the coatings are investigated by optical and scanning electron microscopy (SEM). Results show that the mixed metal-ce-ramic coating obtained with the deposition of premixed powders is homogeneous. The morphology and microstructure of the coatings are considered satisfactory.

  4. Advanced Microstructural Study of Suspension Plasma Sprayed Hydroxyapatite Coatings

    NASA Astrophysics Data System (ADS)

    Podlesak, Harry; Pawlowski, Lech; D'Haese, Romain; Laureyns, Jacky; Lampke, Thomas; Bellayer, Severine

    2010-03-01

    Fine, home-synthesized, hydroxyapatite powder was formulated with water and alcohol to obtain a suspension used to plasma spray coatings onto a titanium substrate. The deposition process was optimized using statistical design of 2 n experiments with two variables: spray distance and electric power input to plasma. X-ray diffraction (XRD) was used to determine quantitatively the phase composition of obtained deposits. Raman microscopy and electron probe microanalysis (EPMA) enabled localization of the phases in different positions of the coating cross sections. Transmission electron microscopic (TEM) study associated with energy-dispersive x-ray spectroscopy (EDS) enabled visualization and analysis of a two-zone microstructure. One zone contained crystals of hydroxyapatite, tetracalcium phosphate, and a phase rich in calcium oxide. This zone included lamellas, usually observed in thermally sprayed coatings. The other zone contained fine hydroxyapatite grains that correspond to nanometric and submicrometric solids from the suspension that were agglomerated and sintered in the cold regions of plasma jet and on the substrate.

  5. Weak stability of the plasma-vacuum interface problem

    NASA Astrophysics Data System (ADS)

    Catania, Davide; D'Abbicco, Marcello; Secchi, Paolo

    2016-09-01

    We consider the free boundary problem for the two-dimensional plasma-vacuum interface in ideal compressible magnetohydrodynamics (MHD). In the plasma region, the flow is governed by the usual compressible MHD equations, while in the vacuum region we consider the Maxwell system for the electric and the magnetic fields. At the free interface, driven by the plasma velocity, the total pressure is continuous and the magnetic field on both sides is tangent to the boundary. We study the linear stability of rectilinear plasma-vacuum interfaces by computing the Kreiss-Lopatinskiĭ determinant of an associated linearized boundary value problem. Apart from possible resonances, we obtain that the piecewise constant plasma-vacuum interfaces are always weakly linearly stable, independently of the size of tangential velocity, magnetic and electric fields on both sides of the characteristic discontinuity. We also prove that solutions to the linearized problem obey an energy estimate with a loss of regularity with respect to the source terms, both in the interior domain and on the boundary, due to the failure of the uniform Kreiss-Lopatinskiĭ condition, as the Kreiss-Lopatinskiĭ determinant associated with this linearized boundary value problem has roots on the boundary of the frequency space. In the proof of the a priori estimates, a crucial part is played by the construction of symmetrizers for a reduced differential system, which has poles at which the Kreiss-Lopatinskiĭ condition may fail simultaneously.

  6. Rheological properties of suspensions containing cross-linked starch nanoparticles prepared by spray and vacuum freeze drying methods.

    PubMed

    Shi, Ai-min; Li, Dong; Wang, Li-jun; Adhikari, Benu

    2012-11-01

    The rheological behavior of suspensions containing vacuum freeze dried and spray dried starch nanoparticles was investigated to explore the effect of these two drying methods in producing starch nanoparticles which were synthesized using high pressure homogenization and mini-emulsion cross-linking technique. Suspensions containing 10% (w/w) spray dried and vacuum freeze dried nanoparticles were prepared. The continuous shear viscosity tests, temperature sweep tests, the frequency sweep and creep-recovery tests were carried out, respectively. The suspensions containing vacuum freeze dried nanoparticles showed higher apparent viscosity within shear rate range (0.1-100 s(-1)) and temperature range (25-90 °C). The suspensions containing vacuum freeze dried nanoparticles were found to have more shear thinning and less thixotropic behavior compared to those containing spray dried nanoparticles. In addition, the suspensions containing vacuum freeze dried particles had stronger elastic structure. However, the suspensions containing spray dried nanoparticles had more stiffness and greater tendency to recover from the deformation. PMID:22944440

  7. Smart coating technology by gas tunnel type plasma spraying

    NASA Astrophysics Data System (ADS)

    Kobayashi, Akira

    2008-10-01

    Nano-science & technology is one of the most important scientific fields, and the material processing using the nano-technology is now advanced towards more precise and controllable smart stage. Regarding thermal processing, plasma system with high precise, has been expected for smart thermal processing. The gas tunnel type plasma system developed by the author exhibits high energy density and also high efficiency. Among the applications to the various thermal processing, one practical application is plasma spraying of ceramics such as A12O3 and ZrO2. The characteristics of these ceramic coatings were superior to the conventional ones. The ZrO2 composite coating has the possibility of the development of high functionally graded TBC (thermal barrier coating). In this study, the performance such as the mechanical properties, thermal behavior and high temperature oxidation resistance of the alumina/zirconia functionally graded TBCs produced by gas tunnel type plasma spraying was investigated and discussed. The results showed that the alumina/zirconia composite system exhibited the improvement of mechanical properties and oxidation resistance. Now, one of the advanced plasma application, a smart coating technology, is expected to obtain the desired characteristics of ceramics with improved corrosion resistance, thermal resistance, and wear resistance.

  8. Influence of Oxidation Behavior of Feedstock on Microstructure and Ablation Resistance of Plasma-Sprayed Zirconium Carbide Coating

    NASA Astrophysics Data System (ADS)

    Hu, Cui; Ge, Xuelian; Niu, Yaran; Li, Hong; Huang, Liping; Zheng, Xuebin; Sun, Jinliang

    2015-10-01

    Plasma spray is one of the suitable technologies to deposit carbide coatings with high melting point, such as ZrC. However, in the spray processes performed under atmosphere, oxidation of the carbide powder is inevitable. To investigate the influence of the oxidation behavior of feedstock on microstructure and ablation resistance of the deposited coating, ZrC coatings were prepared by atmospheric and vacuum plasma spray (APS and VPS) technologies, respectively. SiC-coated graphite was applied as the substrate. The obtained results showed that the oxidation of ZrC powder in APS process resulted in the formation of ZrO and Zr2O phases. Pores and cracks were more likely to be formed in the as-sprayed APS-ZrC coating. The VPS-ZrC coating without oxides possessed denser microstructure, higher thermal diffusivity, and lower coefficients of thermal expansion as compared with the APS-ZrC coating. A dense ZrO2 layer would be formed on the surface of the VPS-ZrC-coated sample during the ablation process and the substrate can be protected sufficiently after being ablated in high temperature plasma jet. However, the ZrO2 layer, formed by oxidation of the APS-ZrC coating having loose structure, was easy to be washed away by the shearing action of the plasma jet.

  9. Vacuum polarization and electron-positron plasma oscillations

    SciTech Connect

    Ruffini, R.; Vereshchagin, G. V.; Xue, S.-S.

    2008-01-03

    We study plasma oscillations of electrons-positron pairs created by the vacuum polarization in an uniform electric field. Our treatment, encompassing also the case of E>E{sub c}, shows the existence in both cases of a maximum Lorentz factor acquired by electrons and positrons and allows determination of the a maximal length of oscillation. We quantitatively estimate how plasma oscillations reduce the rate of pair creation and increase the time scale of the pair production.

  10. Handling Vacuum Regions in a Hybrid Plasma Solver

    NASA Astrophysics Data System (ADS)

    Holmström, M.

    2013-04-01

    In a hybrid plasma solver (particle ions, fluid mass-less electrons) regions of vacuum, or very low charge density, can cause problems since the evaluation of the electric field involves division by charge density. This causes large electric fields in low density regions that can lead to numerical instabilities. Here we propose a self consistent handling of vacuum regions for hybrid solvers. Vacuum regions can be considered having infinite resistivity, and in this limit Faraday's law approaches a magnetic diffusion equation. We describe an algorithm that solves such a diffusion equation in regions with charge density below a threshold value. We also present an implementation of this algorithm in a hybrid plasma solver, and an application to the interaction between the Moon and the solar wind. We also discuss the implementation of hyperresistivity for smoothing the electric field in a PIC solver.

  11. Suspension plasma spraying of nanostructured WC-12Co coatings

    NASA Astrophysics Data System (ADS)

    Berghaus, J. Oberste; Marple, B.; Moreau, C.

    2006-12-01

    Nanostructured WC-12% Co coatings were deposited by suspension plasma spraying of submicron feedstock powders, using an internal injection plasma torch. The liquid carrier used in this approach allows for controlled injection of much finer particles than in conventional thermal spraying, leading to thin coatings with a fine surface finish. A polyethylene-imine (PEI) dispersant was used to stabilize the colloidal suspension in an ethanol carrier. In-flight particle states were measured for a number of operating conditions of varying plasma gas flow rates, feed rates, and standoff distances and were related to the resulting microstructure, phase composition (EDS, SEM, XRD), and Vickers hardness. High in-flight particle velocities (>800 m/s) were generated, leading to dense coatings. It was observed that the coating quality was generally compromised by the high temperature and reactivity of the small particles. To compensate for this shortcoming, the suspension feed rate was adjusted, thereby varying the thermal load on the plasma. Results showed that a slightly larger agglomerate size, in conjunction with low particle jet temperatures, could somewhat limit the decomposition of WC into brittle W2C/W3C and amorphous cobalt containing binder phases.

  12. Post-treatment of Plasma-Sprayed Amorphous Ceramic Coatings by Spark Plasma Sintering

    NASA Astrophysics Data System (ADS)

    Chraska, T.; Pala, Z.; Mušálek, R.; Medřický, J.; Vilémová, M.

    2015-04-01

    Alumina-zirconia ceramic material has been plasma sprayed using a water-stabilized plasma torch to produce free standing coatings. The as-sprayed coatings have very low porosity and are mostly amorphous. The amorphous material crystallizes at temperatures above 900 °C. A spark plasma sintering apparatus has been used to heat the as-sprayed samples to temperatures above 900 °C to induce crystallization, while at the same time, a uniaxial pressure of 80 MPa has been applied to their surface. After such post-treatment, the ceramic samples are crystalline and have very low open porosity. The post-treated material exhibits high hardness and significantly increased flexural strength. The post-treated samples have a microstructure that is best described as nanocomposite with the very small crystallites embedded in an amorphous matrix.

  13. Microstructure and abrasion resistance of plasma sprayed titania coatings

    NASA Astrophysics Data System (ADS)

    Ctibor, P.; Neufuss, K.; Chraska, P.

    2006-12-01

    Agglomerated titania nanopowder and a “classical” titania were sprayed by the high throughput water-stabilized plasma (WSP) and thoroughly compared. Optical microscopy with image analysis as well as mercury intrusion porosimetry were used for quantification of porosity. Results indicate that the “nano” coatings in general exhibit finer pores than coatings of the “conventional” micron-sized powders. Mechanical properties such as Vickers microhardness and slurry abrasion response were measured and linked to the structural investigation. Impact of the variation in the slurry composition on wear resistance of tested coatings and on character of the wear damage is discussed. The overall results, however, suggest that the “nano” coatings properties are better only for carefully selected sets of spraying parameters, which seem to have a very important impact.

  14. Caracterisation of Titanium Nitride Layers Deposited by Reactive Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Roşu, Radu Alexandru; Şerban, Viorel-Aurel; Bucur, Alexandra Ioana; Popescu, Mihaela; Uţu, Dragoş

    2011-01-01

    Forming and cutting tools are subjected to the intense wear solicitations. Usually, they are either subject to superficial heat treatments or are covered with various materials with high mechanical properties. In recent years, thermal spraying is used increasingly in engineering area because of the large range of materials that can be used for the coatings. Titanium nitride is a ceramic material with high hardness which is used to cover the cutting tools increasing their lifetime. The paper presents the results obtained after deposition of titanium nitride layers by reactive plasma spraying (RPS). As deposition material was used titanium powder and as substratum was used titanium alloy (Ti6Al4V). Macroscopic and microscopic (scanning electron microscopy) images of the deposited layers and the X ray diffraction of the coatings are presented. Demonstration program with layers deposited with thickness between 68,5 and 81,4 μm has been achieved and presented.

  15. Smart Coating Technology by Gas Tunnel Type Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Kobayashi, A.

    2008-07-01

    Nano-science & technology is one of the most important scientific fields, and the material processing using the nano-technology is now advanced towards more precise and controllable smart stage. Regarding thermal processing, an important key should be the the performance of the applied heat source. A plasma is fundamentally the most superior heat source, because of high temperature, high energy density, easy controllable, etc. Therefore more precious plasma system has been expected for smart thermal processing. The gas tunnel type plasma system developed by the author has high energy density and also high efficiency. The concept and the feature of this plasma system are explained and the applications to the various thermal processing are described in this report. One practical application is plasma spraying of ceramics such as Al_2O_3 and ZrO_2. The characteristics of these ceramic coatings were superior to the conventional ones. The ZrO_2 composite coating has the possibility of the development of high functionally graded TBC (thermal barrier coating). Another application of gas tunnel type plasma is surface modification of metals. For example the TiN films were formed in a very short time of 5 s. Now, advanced plasma application of spraying methods as a smart coating technology is expected to obtain the desired characteristics of ceramics such as corrosion resistance, thermal resistance, and wear resistance by reducing the porosity and increasing the coating density. One application of the smart coating technology is a formation of the metallic glass coating with high function, and another is Hydroxiapatite coating for bio-medical application. The formation process of those coatings and the coating characteristics were investigated in this study.

  16. An interchangeable-cathode vacuum arc plasma source

    SciTech Connect

    Olson, David K.; Peterson, Bryan G.; Hart, Grant W.

    2010-01-15

    A simplified vacuum arc design [based on metal vapor vacuum arc (MeVVA) concepts] is employed as a plasma source for a study of a {sup 7}Be non-neutral plasma. The design includes a mechanism for interchanging the cathode source. Testing of the plasma source showed that it is capable of producing on the order of 10{sup 12} charges at confinable energies using a boron-carbide disk as the cathode target. The design is simplified from typical designs for lower energy and lower density applications by using only the trigger spark rather than the full vacuum arc in high current ion beam designs. The interchangeability of the cathode design gives the source the ability to replace only the source sample, simplifying use of radioactive materials in the plasma source. The sample can also be replaced with a completely different conductive material. The design can be easily modified for use in other plasma confinement or full MeVVA applications.

  17. Nanostructural Characteristics of Vacuum Cold-Sprayed Hydroxyapatite/Graphene-Nanosheet Coatings for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Liu, Yi; Huang, Jing; Li, Hua

    2014-10-01

    Development of novel biocompatible nanomaterials has provided insights into their potential biomedical applications. Bulk fabrication of the nanomaterials in the form of coatings remains challenging. Here, we report hydroxyapatite (HA)/graphene-nanosheet (GN) composite coatings deposited by vacuum cold spray (VCS). Significant shape changes of HA nanograins during the coating deposition were revealed. The nanostructural features of HA together with curvature alternation of GN gave rise to dense structures. Based on the microstructural characterization, a structure model was proposed to elucidate the nanostructural characteristics of the HA-GN nanocomposites. Results also showed that addition of GN significantly enhanced fracture toughness and elastic modulus of the HA-based coatings, which is presumably accounted for by crack bridging offered by GN in the composites. The VCS HA-GN coatings show potential for biomedical applications for the repair or replacement of hard tissues.

  18. Effects of Feedstock Decomposition and Evaporation on the Composition of Suspension Plasma-Sprayed Coatings

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Schlegel, N.; Guignard, A.; Vaßen, R.; Guillon, O.

    2015-10-01

    Emerging new applications and growing demands of plasma-sprayed coatings have initiated the development of new plasma spray processes. One of them is suspension plasma spraying (SPS). The use of liquid feedstock such as suspensions yields higher flexibility compared to the conventional atmospheric plasma spray processes as even submicron-to nano-sized particles can be processed. This allows achieving particular microstructural features, e.g., porous segmented or columnar-structured thermal barrier coatings. To exploit the potentials of such novel plasma spray processes, the plasma-feedstock interaction must be understood better. In this study, decomposition and evaporation of feedstock material during SPS were investigated, since particular difficulties can occur with respect to stoichiometry and phase composition of the deposits. Plasma conditions were analyzed by optical emission spectroscopy (OES). Experimental results are given, namely for gadolinium zirconate and for lanthanum strontium cobalt ferrite deposition. Moreover, the applied OES approach is validated by comparison with the simpler actinometry method.

  19. Laser driven electron acceleration in vacuum, gases and plasmas

    SciTech Connect

    Sprangle, P.; Esarey, E.; Krall, J.

    1996-04-19

    This paper discusses some of the important issues pertaining to laser acceleration in vacuum, neutral gases and plasmas. The limitations of laser vacuum acceleration as they relate to electron slippage, laser diffraction, material damage and electron aperture effects, are discussed. An inverse Cherenkov laser acceleration configuration is presented in which a laser beam is self guided in a partially ionized gas. Optical self guiding is the result of a balance between the nonlinear self focusing properties of neutral gases and the diffraction effects of ionization. The stability of self guided beams is analyzed and discussed. In addition, aspects of the laser wakefield accelerator are presented and laser driven accelerator experiments are briefly discussed.

  20. 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

  1. Plasma spray nozzle with low overspray and collimated flow

    NASA Technical Reports Server (NTRS)

    Beason, Jr., George P. (Inventor); McKechnie, Timothy N. (Inventor); Power, Christopher A. (Inventor)

    1996-01-01

    An improved nozzle for reducing overspray in high temperature supersonic plasma spray devices comprises a body defining an internal passageway having an upstream end and a downstream end through which a selected plasma gas is directed. The nozzle passageway has a generally converging/diverging Laval shape with its upstream end converging to a throat section and its downstream end diverging from the throat section. The upstream end of the passageway is configured to accommodate a high current cathode for producing an electrical arc in the passageway to heat and ionize the gas flow to plasma form as it moves along the passageway. The downstream end of the nozzle is uniquely configured through the methodology of this invention to have a contoured bell-shape that diverges from the throat to the exit of the nozzle. Coating material in powder form is injected into the plasma flow in the region of the bell-shaped downstream end of the nozzle and the powder particles become entrained in the flow. The unique bell shape of the nozzle downstream end produces a plasma spray that is ideally expanded at the nozzle exit and thus virtually free of shock phenomena, and that is highly collimated so as to exhibit significantly reduced fanning and diffusion between the nozzle and the target. The overall result is a significant reduction in the amount of material escaping from the plasma stream in the form of overspray and a corresponding improvement in the cost of the coating operation and in the quality and integrity of the coating itself.

  2. Superior Thermal Barrier Coatings Using Solution Precursor Plasma Spray

    NASA Astrophysics Data System (ADS)

    Jordan, E. H.; Xie, L.; Gell, M.; Padture, N. P.; Cetegen, B.; Ozturk, A.; Ma, X.; Roth, J.; Xiao, T. D.; Bryant, P. E. C.

    2004-03-01

    A novel process, solution precursor plasma spray (SPPS), is presented for depositing thermal barrier coatings (TBCs), in which aqueous chemical precursors are injected into a standard direct current plasma spray system. The resulting coatings microstructure has three unique features: (1) ultra fine splats (1 µm), (2) nanometer and micron-sized interconnected porosity, and (3) closely spaced, through-thickness cracks. Coatings over 3 mm thick can be readily deposited using the SPPS process. Coating durability is excellent, with SPPS coatings showing, in furnace cycling tests, 2.5 times the spallation life of air plasma coatings (APS) and 1.5 times the life of electron beam physical vapor deposited (EB-PVD) coatings. The conductivity of SPPS coatings is lower than EB-PVD coatings and higher than the best APS coatings. Manufacturing cost is expected to be similar to APS coatings and much lower than EB-PVD coatings. The SPPS deposition process includes droplet break-up and material arriving at the deposition surface in various physical states ranging from aqueous solution, gel phase, to fully-molten ceramic. The relation between the arrival state of the material and the microstructure is described.

  3. Plasma-sprayed dual density ceramic turbine seal system

    NASA Technical Reports Server (NTRS)

    Clingman, D. L.; Schechter, B.; Cross, K. R.; Cavanagh, J. R.

    1979-01-01

    Dual density, plasma sprayed ceramic coating systems were investigated for possible application as abradable turbine tip seal systems in small gas turbine engines. Abradability, erosion resistance, internal leakage, and microstructural characterization were investigated for polyester and cenosphere filled zirconium oxide composites. Results indicate the polyester system is more abradable but displays significantly less erosion resistance than the cenosphere system. It is also stated that the absence of significant blade tip damage during abradability testing of both systems suggests additional effort may result in a more nearly optimum balance of abradability and erosion resistance.

  4. Front surface thermal property measurements of air plasma spray coatings

    SciTech Connect

    Bennett, Ted; Kakuda, Tyler; Kulkarni, Anand

    2009-04-15

    A front-surface measurement for determining the thermal properties of thermal barrier coatings has been applied to air plasma spray coatings. The measurement is used to determine all independent thermal properties of the coating simultaneously. Furthermore, with minimal requirements placed on the sample and zero sample preparation, measurements can be made under previously impossible conditions, such as on serviceable engine parts. Previous application of this technique was limited to relatively thin coatings, where a one-dimensional heat transfer model is applied. In this paper, the influence of heat spreading on the measurement of thicker coatings is investigated with the development of a two-dimensional heat transfer model.

  5. Vacuum laser acceleration of relativistic electrons using plasma mirror injectors

    NASA Astrophysics Data System (ADS)

    Thévenet, M.; Leblanc, A.; Kahaly, S.; Vincenti, H.; Vernier, A.; Quéré, F.; Faure, J.

    2016-04-01

    Accelerating particles to relativistic energies over very short distances using lasers has been a long-standing goal in physics. Among the various schemes proposed for electrons, vacuum laser acceleration has attracted considerable interest and has been extensively studied theoretically because of its appealing simplicity: electrons interact with an intense laser field in vacuum and can be continuously accelerated, provided they remain at a given phase of the field until they escape the laser beam. But demonstrating this effect experimentally has proved extremely challenging, as it imposes stringent requirements on the conditions of injection of electrons in the laser field. Here, we solve this long-standing experimental problem by using a plasma mirror to inject electrons in an ultraintense laser field, and obtain clear evidence of vacuum laser acceleration. With the advent of petawatt lasers, this scheme could provide a competitive source of very high charge (nC) and ultrashort relativistic electron beams.

  6. Adhesion of plasma sprayed zirconia splats on stainless steel

    NASA Astrophysics Data System (ADS)

    Rangarajan, Srinivasan

    2000-10-01

    Thermal spray technology is an alternative material fabrication technique to the traditional solidification and powder processing methods for producing thick coatings and bulk free-forms. Extensive research has enabled the extension of this technique to a wider range of material classes including polymers, bioceramics and functionally gradient materials. A key area of application of thermal spraying is the formation of thermal barrier coatings for turbine components used in power generation and propulsion. Continuing research intends to improve the quality of coatings produced by this technique to compete with other technologies like physical vapor deposition to make use of some of the advantages like higher throughput that thermal spraying affords. Understanding the adhesion of plasma sprayed coatings is essential to improving the service life of coated components. Progressively research has focussed on the nature of the unique building blocks of plasma sprayed coatings called splats. The current research intends to characterize the microadhesion at the splat substrate interface using nondestructive methods based on the analysis of images obtained using the scanning electron microscope (SEM). A model system of yttria stabilized zirconia, a traditional thermal barrier material, on steel substrate is chosen for the study. Two techniques are developed based on the analysis of through thickness crack distribution and fragmentation of thin brittle films on ductile substrates and that based on the analysis of interface cracking. A novel imaging technique is used to determine the extent of interface cracking from the contrast observed in SEM images. Based on the understanding of ceramic splat formation on metal substrates a shear lag theory of tensile residual stress generation is used to explain the fragmentation observed in splats. An earlier analysis of cracking in brittle films due to uniaxial stress is extended to the present case of equibiaxial thermal residual

  7. Research and development of plasma sprayed tungsten coating on graphite and copper substrates

    NASA Astrophysics Data System (ADS)

    Liu, Xiang; Zhang, Fu; Tao, Shunyan; Cao, Yunzhen; Xu, Zengyu; Liu, Yong; Noda, N.

    2007-06-01

    Vacuum plasma sprayed tungsten coating on graphite and copper substrates has been prepared. VPS-W coated graphite has multilayered silicon and tungsten interface pre-deposited by physical vapor deposition (PVD) and VPS-W coated copper has graded transition interlayer. VPS-W coating was characterized, and then the high heat flux properties of the coating were examined. Experimental results indicated that both VPS-W coated graphite and VPS-W coated copper could endure 1000 cycles without visible failure under a heat flux of approximately 5 MW/m2 absorbed power density and 5 s pulse duration. A comparison between the present VPS-W coated graphite and VPS-W coated carbon fiber composite (CX-2002U) with Re interface made by Plansee Aktiengesllshaft was carried out. Results show that both Re and Si are suitable as intermediate layer for tungsten coating on carbon substrates.

  8. Metallic targets ablation by laser plasma production in a vacuum

    NASA Astrophysics Data System (ADS)

    Beilis, I. I.

    2016-03-01

    A model of metallic target ablation and metallic plasma production by laser irradiation is reported. The model considers laser energy absorption by the plasma, electron emission from hot targets and ion flux to the target from the plasma as well as an electric sheath produced at the target-plasma interface. The proposed approach takes into account that the plasma, partially shields the laser radiation from the target, and also converts absorbed laser energy to kinetic and potential energies of the charged plasma particles, which they transport not only through the ambient vacuum but also through the electrostatic sheath to the solid surface. Therefore additional plasma heating by the accelerated emitted electrons and target heating caused by bombardment of it by the accelerated ions are considered. A system of equations, including equations for solid heat conduction, plasma generation, and plasma expansion, is solved self-consistently. The results of calculations explain the measured dependencies of ablation yield (μ g/pulse) for Al, Ni, and Ti targets on laser fluence in range of (5-21)J/cm2 published previously by Torrisi et al.

  9. Expansion of a multi-ion plasma into a vacuum

    NASA Technical Reports Server (NTRS)

    Singh, N.; Schunk, R. W.

    1983-01-01

    A numerical investigation of the expansion of a plasma with two ion species into a vacuum is presented. A set of Vlasov equations describe the ion behavior and the electrostatic potential is modelled by the Poisson equation. Electrons are assumed to follow Boltzmann's law. A plasma with H(+) and O(+) ions is considered, with the ions forming various combinations. Hydrodynamic calculations are performed for ions and electrons at equal temperatures, and for the presence of hot electrons. Self-similarity is shown to be valid where charge neutrality is dominant. An absence of significant quantities of ion-acoustic oscillations were observed.

  10. Dissolution behavior of plasma-sprayed hydroxyapatite coatings.

    PubMed

    Fazan, F; Marquis, P M

    2000-12-01

    The long-term stability of plasma-sprayed hydroxyapatite coatings is influenced by the dissolution behavior of the coating in in vivo conditions. Plasma-spraying generates a mixture of phases and this study has focused on how the balance of phases affects the in vitro dissolution behavior of the coatings in double distilled-deionized water and in tris-buffer solutions. The pH changes in double distilled-deionized water were monitored, whilst the pH value was maintained at 7.25 for the tris-buffer solution at 37 degrees C with 5% CO2 atmosphere. The phosphate and calcium ions released were measured using UV-Visible Spectrophotometer and Atomic Absorption Spectroscopy respectively. Changes in crystal and surface topology were also studied. The results indicate that the dissolution behavior of the coatings depends on several factors. The rate of release of phosphate ions was found to increase significantly for the tris-buffer solution compared to the deionized water, indicating that the presence of electrolyte constituents affects the dissolution behavior of the coatings. The Ca/P ratio in the tris-buffer solution is approximately three. Increases in the level of crystallinity of the coatings significantly decreased the dissolution rate and hence, the amount of phosphate ions released. The higher the percentage of crystallinity, the higher the stability of the coating under in vitro conditions. PMID:15348061

  11. Plasma-Sprayed Titanium Patterns for Enhancing Early Cell Responses

    NASA Astrophysics Data System (ADS)

    Shi, Yunqi; Xie, Youtao; Pan, Houhua; Zheng, Xuebin; Huang, Liping; Ji, Fang; Li, Kai

    2016-06-01

    Titanium coating has been widely used as a biocompatible metal in biomedical applications. However, the early cell responses and long-term fixation of titanium implants are not satisfied. To obviate these defects, in this paper, micro-post arrays with various widths (150-1000 μm) and intervals (100-300 μm) were fabricated on the titanium substrate by template-assisted plasma spraying technology. In vitro cell culture experiments showed that MC3T3-E1 cells exhibited significantly higher osteogenic differentiation as well as slightly improved adhesion and proliferation on the micro-patterned coatings compared with the traditional one. The cell number on the pattern with 1000 µm width reached 130% after 6 days of incubation, and the expressions of osteopontin (OPN) as well as osteocalcin (OC) were doubled. No obvious difference was found in cell adhesion on various size patterns. The present micro-patterned coatings proposed a new modification method for the traditional plasma spraying technology to enhance the early cell responses and convenience for the bone in-growth.

  12. Fully plasma-sprayed compliant backed ceramic turbine seal

    NASA Technical Reports Server (NTRS)

    Bill, R. C.; Wisander, D. W. (Inventor)

    1981-01-01

    A seal with a high temperature abradable lining material which encircles the tips of turbine blades in turbomachinery was designed. The seal is directed to maintaining the minimum operating clearances between the blade tips and the lining of a high pressure turbine. A low temperature easily decomposable material in powder form is blended with a high temperature oxidation resistant metal powder. The two materials are simultaneously deposited on a substrate formed by the turbine casing. Alternately, the polymer powder may be added to the metal powder during plasma spraying. A ceramic layer is then deposited directly onto the metal-polymer composite. The polymer additive mixed with the metal is then completely volatilized to provide a porous layer between the ceramic layer and the substrate. Thermal stresses are reduced by the porous structure which gives a cushion effect. No brazing is required by using only plasma spraying for depositing both the powders of the metal and polymer material as well as the ceramic powder.

  13. Plasma-Sprayed Titanium Patterns for Enhancing Early Cell Responses

    NASA Astrophysics Data System (ADS)

    Shi, Yunqi; Xie, Youtao; Pan, Houhua; Zheng, Xuebin; Huang, Liping; Ji, Fang; Li, Kai

    2016-05-01

    Titanium coating has been widely used as a biocompatible metal in biomedical applications. However, the early cell responses and long-term fixation of titanium implants are not satisfied. To obviate these defects, in this paper, micro-post arrays with various widths (150-1000 μm) and intervals (100-300 μm) were fabricated on the titanium substrate by template-assisted plasma spraying technology. In vitro cell culture experiments showed that MC3T3-E1 cells exhibited significantly higher osteogenic differentiation as well as slightly improved adhesion and proliferation on the micro-patterned coatings compared with the traditional one. The cell number on the pattern with 1000 µm width reached 130% after 6 days of incubation, and the expressions of osteopontin (OPN) as well as osteocalcin (OC) were doubled. No obvious difference was found in cell adhesion on various size patterns. The present micro-patterned coatings proposed a new modification method for the traditional plasma spraying technology to enhance the early cell responses and convenience for the bone in-growth.

  14. Predicting ion charge state distributions of vacuum arc plasmas

    SciTech Connect

    Anders, A.; Schulke, T.

    1996-04-01

    Multiply charged ions are present in vacuum arc plasmas. The ions are produced at cathode spots, and their charge state distributions (CSDs) depend on the cathode material but only little on the arc current or other parameters as long as the current is relatively low and the anode is not actively involved in the plasma production. There are experimental data of ion CSDs available in the literature for 50 different cathode materials. The CSDs can be calculated based on the assumption that thermodynamic equilibrium is valid in the vicinity of the cathode spot, and the equilibrium CSDs `freeze` at a certain distance from the cathode spot (transition to a non-equilibrium plasma). Plasma temperatures and densities at the `freezing points` have been calculated, and, based on the existence of characteristic groups of elements in the Periodic Table, predictions of CSDs can be made for metallic elements which have not yet been used as cathode materials.

  15. Engineering the Microstructure of Solution Precursor Plasma-Sprayed Coatings

    NASA Astrophysics Data System (ADS)

    Bertolissi, G.; Chazelas, C.; Bolelli, G.; Lusvarghi, L.; Vardelle, M.; Vardelle, A.

    2012-12-01

    This study examines the fundamental reactions that occur in-flight during the solution precursor plasma spraying (SPPS) of solutions containing Zr- and Y-based salts in water or ethanol solvent. The effect of plasma jet composition (pure Ar, Ar-H2 and Ar-He-H2 mixtures) on the mechanical break-up and thermal treatment of the solution, mechanically injected in the form of a liquid stream, was investigated. Observation of the size evolution of the solution droplets in the plasma flow by means of a laser shadowgraphy technique, showed that droplet break-up was more effective and solvent evaporation was faster when the ethanol-based solution was injected into binary or ternary plasma gas mixtures. In contrast with water-based solutions, residual liquid droplets were always detected at the substrate location. The morphology and structure of the material deposited onto stainless steel substrates during single-scan experiments were characterised by SEM, XRD and micro-Raman spectroscopy and were shown to be closely related to in-flight droplet behaviour. In-flight pyrolysis and melting of the precursor led to well-flattened splats, whereas residual liquid droplets at the substrate location turned into non pyrolysed inclusions. The latter, although subsequently pyrolysed by the plasma heat during the deposition of entire coatings, resulted in porous "sponge-like" structures in the deposit.

  16. PLASMA WINDOW FOR VACUUM - ATMOSPHERE INTERFACE AND FOCUSING LENS OF SOURCES FOR NON-VACUUM MATERIAL MODIFICATION.

    SciTech Connect

    HERSHCOVITCH,A.

    1997-09-07

    Material modifications by ion implantation, dry etching, and micro-fabrication are widely used technologies, all of which are performed in vacuum, since ion beams at energies used in these applications are completely attenuated by foils or by long differentially pumped sections, which ate currently used to interface between vacuum and atmosphere. A novel plasma window, which utilizes a short arc for vacuum-atmosphere interface has been developed. This window provides for sufficient vacuum atmosphere separation, as well as for ion beam propagation through it, thus facilitating non-vacuum ion material modification.

  17. Phase transformation and wear studies of plasma sprayed yttria stabilized zirconia coatings containing various mol% of yttria

    SciTech Connect

    Aruna, S.T. Balaji, N.; Rajam, K.S.

    2011-07-15

    Plasma sprayable grade zirconia powders doped with various mol% of yttria (0, 2, 3, 4, 6, 8 and 12 mol%) were synthesized by a chemical co-precipitation route. The coprecipitation conditions were adjusted such that the powders possessed good flowability in the as calcined condition and thus avoiding the agglomeration step like spray drying. Identical plasma spray parameters were used for plasma spraying all the powders on stainless steel plates. The powders and plasma sprayed coatings were characterized by X-ray diffractometry, Scanning Electron Microscopy and Raman spectroscopy. Zirconia powders are susceptible to phase transformations when subjected to very high temperatures during plasma spraying and XRD is insensitive to the presence of some non crystalline phases and hence Raman spectroscopy was used as an important tool. The microstructure of the plasma sprayed coatings showed a bimodal distribution containing fully melted and unmelted zones. The microhardness and wear resistance of the plasma sprayed coatings were determined. Among the plasma sprayed coatings, 3 mol% yttria stabilized zirconia coating containing pure tetragonal zirconia showed the highest wear resistance. - Research Highlights: {yields} Preparation plasma sprayable YSZ powders without any agglomeration process and plasma spraying {yields} Phase transformation studies of plasma sprayed YSZ coatings by XRD and Raman spectroscopy {yields} Microstructure of the plasma sprayed coatings exhibited bimodal distribution {yields} Plasma sprayed 3 mol% YSZ coating exhibited the highest wear resistance {yields} Higher wear resistance is due to the higher fracture toughness of tetragonal 3 mol% YSZ phase.

  18. Strength degradation of SiC fiber during manufacture of titanium matrix composites by plasma spraying and hot pressing

    NASA Astrophysics Data System (ADS)

    Baik, K. H.; Grant, P. S.

    2001-12-01

    Titanium matrix composites (TMCs) reinforced with Sigma 1140+ SiC fiber have been manufactured by a combination of low pressure plasma spraying (LPPS spray/wind) and simultaneous fiber winding, followed by vacuum hot pressing (VHP). Fiber damage during TMC manufacture has been evaluated by measuring fiber tensile strength after fiber extraction from the TMCs at various processing stages, followed by fitting of these data to a Weibull distribution function. The LPPS spray/wind processing caused a decrease in mean fiber strength and Weibull modulus in comparison with as-received fibers. A number of fiber surface flaws, primarily in the outer C layer of the fiber, formed as a result of mechanical impact of poorly melted particles from the plasma spray. Coarse feedstock powders promoted an increase in the population of fiber surface flaws, leading to significant reduction in fiber strength. The VHP consolidation promoted further development of fiber surface flaws by fiber bending and stress localization because of nonuniform matrix shrinkage, resulting in further degradation in fiber strength. In the extreme case of fibers touching, the stress concentration on the fibers was sufficient to cause fiber cracking. Fractographic studies revealed that low strength fibers failed by surface flaw induced failure and contained a large fracture mirror zone. Compared with the more widely investigated foil-fiber-foil route to manufacture TMCs, LPPS/VHP resulted in less degradation in fiber strength for Sigma 1140+ fiber. Preliminary results for Textron SCS-6 fiber indicated a much greater tolerance to LPPS/VHP damage.

  19. Calcium phosphate coating on titanium using laser and plasma spray

    NASA Astrophysics Data System (ADS)

    Roy, Mangal

    Though calcium phosphate (CaP) coated implants are commercially available, its acceptance is still not wide spread due to challenges related to weaker interfacial bonding between metal and ceramic, and low crystallinity of hydroxyapatite (HA). The objectives of this research are to improve interfacial strength, crystallinity, phase purity and bioactivity of CaP coated metallic implants for orthopaedic applications. The rationale is that forming a diffuse and gradient metal-ceramic interface will improve the interfacial strength. Moreover, reducing CaP particles exposure to high temperature during coating preparation, can lead to improvement in both crystallinity and phase purity of CaP. In this study, laser engineered net shaping (LENS(TM)) was used to coat Ti metal with CaP. LENS(TM) processing enabled generation of Ti+TCP (tricalcium phosphate) composite coating with diffused interface, that also increased the coating hardness to 1049+/-112 Hv compared to a substrate hardness of 200+/-15 Hv. In vitro bone cell-material interaction studies confirmed the bioactivity of TCP coatings. Antimicrobial properties of the TCP coatings were improved by silver (Ag) electrodeposition. Along with LENS(TM), radio frequency induction plasma spray, equipped with supersonic plasma nozzle, was used to prepare HA coatings on Ti with improved crystallinity and phase purity. The coating was made of multigrain HA particles of ˜200 nm in size, which consisted of 15--20 nm HA grains. In vitro bone cell-material interaction and in vivo rat model studies confirmed the HA coatings to be bioactive. Furthermore, incorporation of Sr2+ improved bone cell of HA coatings interaction. A combination of LENS(TM) and plasma spray was used to fabricate a compositionally graded HA coatings on Ti where the microstructure varied from pure HA at the surface to pure Ti substrate with a diffused Ti+TCP composite region in between. The plasma spray system was used to synthesize spherical HA nano powder from

  20. 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

  1. Decontamination of beef carcass surface tissue by steam vacuuming alone and combined with hot water and lactic acid sprays.

    PubMed

    Castillo, A; Lucia, L M; Goodson, K J; Savell, J W; Acuff, G R

    1999-02-01

    Hot beef carcass surface regions (outside round, brisket, and clod) contaminated with feces spread over a 5-cm2 (1-in2) area were cleaned using a steam-vacuum spot-cleaning system alone or combined with subsequent sanitizing treatments of hot water (95 degrees C at the nozzle), or warm (55 degrees C) 2% lactic acid spray, or combinations of these two sanitizing methods. These treatments were compared for effectiveness in reducing aerobic plate counts (APC) and counts of Enterobacteriaceae, total coliforms, thermotolerant coliforms, and Escherichia coli. All treatments significantly reduced the numbers of each group of bacteria on beef carcass surfaces. However, reductions obtained by steam vacuuming were significantly smaller than those obtained by a combination of steam vacuuming with any sanitizing treatment. No differences in bacterial reductions were observed between different carcass surface regions. Steam vacuuming reduced the number of different indicator organisms tested by ca. 3.0 log cycles but also spread the bacterial contamination to areas of the carcass surface adjacent to the contaminated sites. This relocated contamination after steam vacuuming was most effectively reduced by spraying with hot water and then lactic acid. This combined treatment consistently reduced the numbers of Enterobacteriaceae, total and thermotolerant coliforms, and E. coli to undetectable levels (<1.0 log10 CFU/cm2) on areas outside the initial 5-cm2 inoculated areas. PMID:10030633

  2. Numerical simulation of alumina spraying in argon-helium plasma jet

    NASA Astrophysics Data System (ADS)

    Chang, C. H.

    A numerical model is described for simulating thermal plasmas containing entrained particles, with emphasis on plasma spraying applications. The plasma is represented as a continuum multicomponent chemically reacting ideal gas, while the particles are tracked as discrete Lagrangian entities coupled to the plasma. Computational results are presented from a transient simulation of alumina spraying in a turbulent argon-helium plasma jet in air environment, including torch geometry, substrate, and multiple species with chemical reactions. Particle-plasma interactions including turbulent dispersion have been modeled in a fully self-consistent manner. Interactions between the plasma and the torch and substrate walls are modeled using wall functions.

  3. Wear and microstructural integrity of ceramic plasma sprayed coatings

    NASA Astrophysics Data System (ADS)

    Erickson, Lynn C.

    1999-10-01

    In this work a series of ceramic plasma sprayed (PS) coatings, both alumina- and chromia-based, were sprayed according to a matrix of deposition parameters in order to produce a broad range of microstructures. To investigate the effect of splat size on the coating response, a series of mono-crystalline a -alumina powders with very narrow particle size ranges, nominally 5, 10 and 18 microns in diameter, was sprayed. The coatings were extensively characterized for a variety of microstructural features, including porosity, the angular distribution and density of microcracks as well as the lamellar, or splat, dimensions, using techniques of metallurgical analysis and electron microscopy. The coatings were then evaluated using a series of micromechanical techniques, including indentation, controlled scratch testing, abrasion and dry particle erosion, to investigate their response to different contact situations. It was found that the microstructural features with the most influence on the behaviour of ceramic PS coatings during contact, or wear, by hard particles include, in order of importance: (1) macro-porosity, (2) horizontal crack density, (3) degree of flattening of the splats and (4) volume of unmelted particles, which are all linked to the level and strength of interlamellar bonding in the coating. The major effect of the inter-lamellar bonding in ceramic PS coatings was seen in the wear mechanism transitions. As the level of inter-splat bonding in the coating decreases, the contact load at which the transition from plastic deformation to splat fracture and debonding occurs does as well. However, the load at which catastrophic brittle fracture and spalling occur is increased. All of the micromechanical and wear methods evaluated in the present work were sensitive to differences in the coating microstructures to varying degrees. The low load abrasion results showed the most sensitivity to the microstructural differences of the coatings, followed by controlled

  4. Plasma Spray-PVD: Plasma Characteristics and Impact on Coating Properties

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Vaßen, R.

    2012-12-01

    Typical plasma characteristics of the plasma spray-physical vapour deposition (PS-PVD) process were investigated by optical emission spectroscopy. Electron temperatures were determined by Boltzmann plots while temperatures of the heavy species as well as electron densities were obtained by broadening analysis of spectral lines. The results show how the plasma properties and thermodynamic equilibrium conditions are affected by the admixture of hydrogen and the ambient chamber pressure. Some experimental examples of PS-PVD coatings demonstrate the impact on feedstock treatment and deposited microstructures.

  5. Thin films by metal-organic precursor plasma spray

    SciTech Connect

    Schulz, Douglas L.; Sailer, Robert A.; Payne, Scott; Leach, James; Molz, Ronald J.

    2009-07-15

    While most plasma spray routes to coatings utilize solids as the precursor feedstock, metal-organic precursor plasma spray (MOPPS) is an area that the authors have investigated recently as a novel route to thin film materials. Very thin films are possible via MOPPS and the technology offers the possibility of forming graded structures by metering the liquid feed. The current work employs metal-organic compounds that are liquids at standard temperature-pressure conditions. In addition, these complexes contain chemical functionality that allows straightforward thermolytic transformation to targeted phases of interest. Toward that end, aluminum 3,5-heptanedionate (Al(hd){sub 3}), triethylsilane (HSi(C{sub 2}H{sub 5}){sub 3} or HSiEt{sub 3}), and titanium tetrakisdiethylamide (Ti(N(C{sub 2}H{sub 5}){sub 2}){sub 4} or Ti(NEt{sub 2}){sub 4}) were employed as precursors to aluminum oxide, silicon carbide, and titanium nitride, respectively. In all instances, the liquids contain metal-heteroatom bonds envisioned to provide atomic concentrations of the appropriate reagents at the film growth surface, thus promoting phase formation (e.g., Si-C bond in triethylsilane, Ti-N bond in titanium amide, etc.). Films were deposited using a Sulzer Metco TriplexPro-200 plasma spray system under various experimental conditions using design of experiment principles. Film compositions were analyzed by glazing incidence x-ray diffraction and elemental determination by x-ray spectroscopy. MOPPS films from HSiEt{sub 3} showed the formation of SiC phase but Al(hd){sub 3}-derived films were amorphous. The Ti(NEt{sub 2}){sub 4} precursor gave MOPPS films that appear to consist of nanosized splats of TiOCN with spheres of TiO{sub 2} anatase. While all films in this study suffered from poor adhesion, it is anticipated that the use of heated substrates will aid in the formation of dense, adherent films.

  6. Deposition of Hard Chrome Coating onto Heat Susceptible Substrates by Low Power Microwave Plasma Spray

    NASA Astrophysics Data System (ADS)

    Redza, Ahmad; Yasui, Toshiaki; Fukumoto, Masahiro

    2016-02-01

    Microwave plasma spray requires relatively low power, which is lower than 1 kW in comparison to other plasma spraying method. Until now, we are able to deposit Cu and Hydroxyapatite coating onto heat susceptible substrate, CFRP which are difficult for conventional plasma spray due to the excessive heat input. In this paper, a hard chromium coating was deposited onto SUS304 and CFRP by a low power microwave plasma spray technique. By controlling the working gas flow rate and spraying distance, a hard chrome coating with thickness of approximately 30 μm was successfully deposited onto CFRP substrate with hardness of 1110 Hv0.05. Furthermore, the coating produced here is higher than that produced by hard chrome plating.

  7. Laser-induced plasma generation and evolution in a transient spray.

    PubMed

    Kawahara, Nobuyuki; Tsuboi, Kazuya; Tomita, Eiji

    2014-01-13

    The behaviors of laser-induced plasma and fuel spray were investigated by visualizing images with an ultra-high-speed camera. Time-series images of laser-induced plasma in a transient spray were visualized using a high-speed color camera. The effects of a shockwave generated from the laser-induced plasma on the evaporated spray behavior were investigated. The interaction between a single droplet and the laser-induced plasma was investigated using a single droplet levitated by an ultrasonic levitator. Two main conclusions were drawn from these experiments: (1) the fuel droplets in the spray were dispersed by the shockwave generated from the laser-induced plasma; and (2) the plasma position may have shifted due to breakdown of the droplet surface and the lens effect of droplets. PMID:24921999

  8. High resolution video monitoring of coating thickness during plasma spraying

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.

    1988-01-01

    A new approach to monitoring the thickness of plasma sprayed coatings during application is described. The method employs a high resolution video camera and width analyzer to accurately measure the dimensions of samples having simple geometries. This approach is best suited for cylindrical or flat substrates but it may also work for selected locations on more complex geometries. Measurement accuracy is a function of specimen dimensions and extent of magnification. Tolerances of plus or minus 0.5 mil (0.13 mm) on final coating thickness can be achieved. Additionally, the plot of cumulative coating thickess versus the number of passes has proven to be a useful diagnostic tool. While the ideal plot is linear, strong deviations from linearity - indicating the need for corrective action - may be observed.

  9. Program for plasma-sprayed self-lubricating coatings

    NASA Technical Reports Server (NTRS)

    Walther, G. C.

    1979-01-01

    A method for preparing composite powders of the three coating components was developed and a procedure that can be used in applying uniform coatings of the composite powders was demonstrated. Composite powders were prepared by adjusting particle sizes of the components and employing a small amount of monoaluminum phosphate as an inorganic binder. Quantitative microscopy (image analysis) was found to be a convenient method of characterizing the composition of the multiphase plasma-sprayed coatings. Area percentages and distribution of the components were readily obtained by this method. The adhesive strength of the coating to a nickel-chromium alloy substrate was increased by about 40 percent by a heat treatment of 20 hours at 650 C.

  10. Fully plasma-sprayed compliant backed ceramic turbine seal

    NASA Technical Reports Server (NTRS)

    Bill, R. C.; Wisander, D. W. (Inventor)

    1982-01-01

    A seal having a high temperature abradable lining material encircling the tips of turbine blades in turbomachinery is discussed. The minimum operating clearances between the blade tips and the lining of a high pressure turbine are maintained. A low temperature easily decomposable material, such as a polymer, in powder form is blended with a high temperature oxidation resistant metal powder. The two materials are simultaneously deposited on a substrate formed by the turbine casing. Alternately, the polymer powder may be added to the metal powder during plasma spraying. A ceramic layer is then deposited directly onto the metal polymer composite. The polymer additive mixed with the metal is then completely volatilized to provide a porous layer between the ceramic layer and the substrate.

  11. Fabrication and testing of plasma-spray formed MoSi{sub 2} and MoSi{sub 2} composite tubes

    SciTech Connect

    Castro, R.G.; Hellman, J.R.; Segall, A.E.; Shelleman, D.L.

    1993-12-31

    Plasma-spray forming has been used to fabricate thick-wall tubes of MoSi{sub 2} and MoSi{sub 2} containing concentric layers of Al{sub 2}O{sub 3}. This process is being investigated as a potential fabrication method for producing tubular components of MoSi{sub 2} and MoSi{sub 2} composites for use in high temperature fuel-burner applications. Results are reported on spray forming method used to produce various tube sizes. Room temperature strength of pure MoSi{sub 2} tubes in the as-deposited condition, and after heat-treating at 1500 C for 2 hours in vacuum is also reported. Strength of plasma sprayed MoSi{sub 2} tubes were measured via diametral compression of O-ring and C-ring sections in air at room temperature. Prediction of the strength distribution was based on Weibull statistical theory.

  12. Absolute calibration of vacuum ultraviolet spectrograph system for plasma diagnostics

    SciTech Connect

    Yoshikawa, M.; Kubota, Y.; Kobayashi, T.; Saito, M.; Numada, N.; Nakashima, Y.; Cho, T.; Koguchi, H.; Yagi, Y.; Yamaguchi, N.

    2004-10-01

    A space- and time-resolving vacuum ultraviolet (VUV) spectrograph system has been applied to diagnose impurity ions behavior in plasmas produced in the tandem mirror GAMMA 10 and the reversed field pinch TPE-RX. We have carried out ray tracing calculations for obtaining the characteristics of the VUV spectrograph and calibration experiments to measure the absolute sensitivities of the VUV spectrograph system for the wavelength range from 100 to 1100 A. By changing the incident angle, 50.6 deg. -51.4 deg., to the spectrograph whose nominal incident angle is 51 deg., we can change the observing spectral range of the VUV spectrograph. In this article, we show the ray tracing calculation results and absolute sensitivities when the angle of incidence into the VUV spectrograph is changed, and the results of VUV spectroscopic measurement in both GAMMA 10 and TPE-RX plasmas.

  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. 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. Plasma plume characterization of a vacuum arc thruster

    NASA Astrophysics Data System (ADS)

    Sekerak, Michael James

    A Vacuum Arc Thruster (VAT) is a thruster that uses the plasma created in a vacuum arc, an electrical discharge in a vacuum that creates high velocity and highly ionized plasmas, as the propellant without additional acceleration. A VAT would be a small and inexpensive low thrust ion thruster, ideal for small satellites and formation flying spacecraft. The purpose of this thesis was to quantitatively and qualitatively examine the VAT plasma plume to determine operating characteristics and limitations. A VAT with a titanium cathode was operated in two regimes: (A) single ˜100mus pulse, discharge current JD=510A, and (B) multiple ˜1500mus pulses at f=40.8Hz, JD=14A. The cathode was 3.18mm diameter Ti rod, surrounded by a 0.80mm thick alumina insulator, set in a molybdenum anode. Three Configurations were tested: Cfg1 (Regime A, cathode recessed 3.00mm from anode), Cfg2 (Regime A, cathode and anode flush), Cfg3 (Regime B, cathode recessed 3.00mm). A semi-empirical model was derived for VAT performance based on the MHD equation of motion using data for ion velocity, ion charge state distribution, ion current fraction (F), and ion current density distribution (ICDD). Additional performance parameters were a2, the peak ion current density angular offset from the cathode normal, and a3, the width of the ion current distribution. Measurements were taken at 162 points on a plane in the plasma plume using a custom faraday probe, and the ICDD empirical form was determined to be a Gaussian. The discharge voltage (VD) and F were Cfg1: VD=25.5V, F=0.025-0.035; Cfg2: VD=40.7V, F=0.08-0.10; Cfg3: VD=14.9V, F=0.006-0.021. For Cfg1, a2 started 15° off-axis while a2˜0 for Cfg2 and 3. In Cfg1, a 3=0.7-0.6, and in Cfg2 a3=1.0-1.1, so the recessed cathode focused the plasma more. However, F is more important for VAT performance because upper and lower bounds for thrust, specific impulse, thrust-to-power, and efficiency were calculated and Cfg2 had the highest performance. High

  16. Preparation of artificial canine femoral stem with HA-Ti ladder-type coating on plasma-sprayed pure Ti substrate and its performance evaluation

    NASA Astrophysics Data System (ADS)

    Zeng, Xianlin; Li, Jingfeng; Yang, Shuhua; Zheng, Qixin; Zou, Zhenwei

    2012-03-01

    An ideal, biological-type, artificial femoral stem prosthesis has good stability and improved bone-prosthesis bonding capacity. In the current study, pure hydroxyapatite (HA)-coated, cementless, artificial femoral stems were prepared by adopting different plasma spray powers and distances and were tested in terms of shear strength. The pure titanium (Ti) substrates, HA coatings, and composite Ti-HA ladder-type coatings prepared under vacuum and atmospheric conditions were examined to compare the shear strengths, microscopic constitutions, and structures of the coatings. The coating was fabricated and the bond strength was improved by adopting 35 kW of spray power and an 80 mm spray distance. The comparisons show that the shear strength of the Ti coating prepared under vacuum conditions was higher than that of the coating prepared under atmospheric conditions (P < 0.05). Moreover, the pressure-shear strength of the Ti + HAG + Ti + V group coating was statistically significantly different from those of the HA + Ti + V and HA + Ti + A groups (P < 0.05). The coatings were compared using scanning electron microscopy, X-ray diffraction, and infrared spectrum analysis. The composite HA-Ti ladder-type coating group, where pure Ti substrate was sprayed onto the Ti alloy under vacuum conditions, had a successive laminate structure. In addition, the intergranular bond in the HA surface layer on the gradient coating was compact and highly crystallized. Under vacuum conditions, the plasma-sprayed layer was characterized by higher tightness, moderate porosity, higher bonding strength to HA, and higher HA crystallinity. The proposed coating can be used in new, cementless, artificial femoral stems with improved bone-prosthesis bonding capacity and stability.

  17. The effect of annealing on the creep of plasma sprayed ceramics

    NASA Technical Reports Server (NTRS)

    Hendricks, R. C.; Mcdonald, G.; Mullen, R. L.

    1983-01-01

    The creep of plasma sprayed ZrO2-8Y2O3 was measured at temperatues from 98 to 1250 C (180 to 220 F), and compared to creep of identical samples after annealing at temperatures from 98 to 1316 C (1800 to 2400 F). Loads and temperatures which produced significant creep of as sprayed ceramics produced no creep after annealing.

  18. Inactivation of Listeria monocytogenes on hams shortly after vacuum packaging by spray application of lauric arginate.

    PubMed

    Taormina, P J; Dorsa, W J

    2009-12-01

    This study measured and compared the short-term efficacy levels of lauric arginate (LAE) as a postlethality treatment against Listeria monocytogenes present on varied surfaces of large-diameter hams. Preliminary in vitro work demonstrated a 5-log inactivation of L. monocytogenes in 5,000- and 9,090-ppm LAE solutions within 180 min at 4.4 and 23 degrees C. Six different whole-muscle ham types were inoculated with L. monocytogenes at ca. 7-log CFU per ham and spray treated with between 15 and 29 ml of a 9,090-ppm LAE solution, or an equal volume of water (control), prior to vacuum packaging. After 48 h at 4.4 degrees C, populations were recovered from ham and interior packaging surfaces by using a surface rinse method with Dey-Engley neutralizing broth followed by plating on modified Oxford medium. Logarithmic reductions of L. monocytogenes exceeding 2 log CFU/cm(2) of ham surfaces were achieved by LAE treatment on all ham types. Hams with 1,129 cm(2) of surface area that had been processed by drenching in liquid smoke had 3.84 and 2.67 CFU/cm(2) 48 h following treatment with 18 ml of water or LAE, respectively, but increasing treatment volumes to 22 ml significantly reduced (P < 0.05) L. monocytogenes levels to 0.65 log CFU/cm(2). This study demonstrated the efficacy of LAE against L. monocytogenes on several ham types, thereby validating it as a postlethality treatment for inactivation of the pathogen. PMID:20003733

  19. Influence of internal cold gas flow and of nozzle contour on spray properties of an atmospheric plasma spray torch

    SciTech Connect

    Henne, R.H.; Borck, V.; Mayr, W.; Landes, K.; Reusch, A.

    1995-12-31

    With an automated Laser Doppler Anemometry (LDA) equipment trajectories, distributions and velocities of spray particles were measured operating a plasma spray torch under atmospheric pressure conditions. For this purpose a standard APS torch (PT F4) was used, applying different gas distribution rings and nozzle modifications to study the influence of internal plasma gas flow and of plasma jet formation. The main results are: (1) An inclined injection of the plasma cold gas results in a considerable spin of the plasma jet and a significant deviation of the particle trajectories around the plasma jet center. (2) With a plasma cold gas injection parallel to the torch axis no spin is observable, but torch voltage and the plasma jet enthalpy show considerably diminished values. (3) The flow of injected powder may be split up, if it is injected too fast. (4) In comparison with cylindrical nozzles, specially developed nozzles with a controlled expanding contour, lead to broader temperature profiles across the plasma jet and hence to better melting conditions for the particles.

  20. Plasma sprayed rutile titania-nanosilver antibacterial coatings

    NASA Astrophysics Data System (ADS)

    Gao, Jinjin; Zhao, Chengjian; Zhou, Jingfang; Li, Chunxia; Shao, Yiran; Shi, Chao; Zhu, Yingchun

    2015-11-01

    Rutile titania (TiO2) coatings have superior mechanical properties and excellent stability that make them preferential candidates for various applications. In order to prevent infection arising from bacteria, significant efforts have been focused on antibacterial TiO2 coatings. In the study, titania-nanosilver (TiO2/Ag) coatings with five different kinds of weight percentages of silver nanoparticles (AgNPs) were prepared by plasma spray. The feedstock powders, which had a composition of rutile TiO2 powders containing 1-10,000 ppm AgNPs, were double sintered and deposited on stainless steel substrates with optimized spraying parameters. X-Ray diffraction and scanning electron microscopy were used to analysize the phase composition and surface morphology of TiO2/Ag powders and coatings. Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus) were employed to examine the antibacterial activity of the as-prepared coatings by bacterial counting method. The results showed that silver existed homogeneously in the TiO2/Ag coatings and no crystalline changed happened in the TiO2 structure. The reduction ratios on the TiO2/Ag coatings with 10 ppm AgNPs were as high as 94.8% and 95.6% for E. coli and S. aureus, respectively, and the TiO2/Ag coatings with 100-1000 ppm AgNPs exhibited 100% bactericidal activity against E. coli and S. aureus, which indicated the TiO2/Ag coatings with more than 10 ppm AgNPs had strong antibacterial activity. Moreover, the main factors influencing the antibacterial properties of TiO2/Ag coatings were discussed with grain size and the content of silver as well as the microstructure of the coatings.

  1. Numerical analysis of the plasma-produced region in a plasma spraying system

    SciTech Connect

    Matsuo, T.; Sakata, N.; Kato, S.; Nagayama, T.; Fujita, K.

    1999-07-01

    For this study, the Arcjet Plasmodynamic Analysis Code (APAC) developed by Fujita has been significantly modified in order to investigate the physical phenomena of the plasma-produced region in a plasma spraying system. For self-consistent determination of the heating process of working gas, plasma flow, which contains complicated physical phenomena, is obtained by interconnecting flow field analysis with electric field analysis. The main conclusions obtained are summarized as follows: (1) Discharge voltage decreased with discharge current significantly. On the other hand, it increases slightly with hydrogen flow rate. (2) Current density distribution governs physical phenomena in plasma flow. (3) Temperature and velocity distribution at the nozzle exit depend on the discharge current.

  2. 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.

  3. Plasma-sprayed metal-glass fluoride coatings for lubrication to 1170 K (1650 F)

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1974-01-01

    Plasma spray of Nichrome matrix composite contains dispersed glass for oxidation protection and calcium fluoride for lubrication. Coatings can be applied to bearing journals and bearing bores. Coating was easily machinable and had excellent bond strength on substrate metal.

  4. 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.

  5. Improved uniformity of multiphase ceramic-metal plasma-sprayed coats

    NASA Technical Reports Server (NTRS)

    Nakamura, H. H.; Logan, W. R.; Harada, Y.; Jacobson, T. P.; Sliney, H. E.

    1982-01-01

    Processing-technology development of a multiphase, self-lubricating, plasma-spray powder resulted in greater uniformity and reproducibility of plasma-sprayed coats. The effect of particle-size variation, binder concentration, and reproducible processing parameters are reported. Greater adhesive strengths of coats to substrates were achieved by particle-size variation, use of an intermediate bond coat such as Ni-Cr, or heat treatment. Quantitative analyses of polished, coated specimens are also given.

  6. Electrocatalytically Active Nickel-Based Electrode Coatings Formed by Atmospheric and Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Aghasibeig, M.; Mousavi, M.; Ben Ettouill, F.; Moreau, C.; Wuthrich, R.; Dolatabadi, A.

    2014-01-01

    Ni-based electrode coatings with enhanced surface areas, for hydrogen production, were developed using atmospheric plasma spray (APS) and suspension plasma spray (SPS) processes. The results revealed a larger electrochemical active surface area for the coatings produced by SPS compared to those produced by APS process. SEM micrographs showed that the surface microstructure of the sample with the largest surface area was composed of a large number of small cauliflower-like aggregates with an average diameter of 10 μm.

  7. Life modeling of atmospheric and low pressure plasma-sprayed thermal-barrier coating

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Argarwal, P.; Duderstadt, E. C.

    1984-01-01

    The cycles-to-failure vs cycle duration data for three different thermal barrier coating systems, which consist of atmospheric pressure plasma-sprayed ZrO2-8 percent Y2O3 over similarly deposited or low pressure plasma sprayed Ni-base alloys, are presently analyzed by means of the Miller (1980) oxidation-based life model. Specimens were tested at 1100 C for heating cycle lengths of 1, 6, and 20 h, yielding results supporting the model's value.

  8. Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys

    NASA Technical Reports Server (NTRS)

    Miller, Robert A. (Inventor); Doychak, Joseph (Inventor)

    1994-01-01

    A thermal barrier coating system consists of two layers of a zirconia-yttria ceramic. The first layer is applied by low pressure plasma spraying. The second layer is applied by conventional atmospheric pressure plasma spraying. This facilitates the attachment of a durable thermally insulating ceramic coating directly to the surface of a highly oxidation resistant NiAl-based intermetallic alloy after the alloy has been preoxidized to promote the formation of a desirable Al2O3 scale.

  9. 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.

  10. Reactive Atmospheric Plasma Spraying of AlN Coatings: Influence of Aluminum Feedstock Particle Size

    NASA Astrophysics Data System (ADS)

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

    2011-03-01

    Feedstock powder characteristics (size distribution, morphology, shape, specific mass, and injection rate) are considered to be one of the key factors in controlling plasma-sprayed coatings microstructure and properties. The influence of feedstock powder characteristics to control the reaction and coatings microstructure in reactive plasma spraying process (RPS) is still unclear. This study, investigated the influence of feedstock particle size in RPS of aluminum nitride (AlN) coatings, through plasma nitriding of aluminum (Al) feedstock powders. It was possible to fabricate AlN-based coatings through plasma nitriding of all kinds of Al powders in atmospheric plasma spray (APS) process. The nitriding ratio was improved with decreasing the particle size of feedstock powder, due to improving the nitriding reaction during flight. However, decreasing the particle size of feedstock powder suppressed the coatings thickness. Due to the loss of the powder during the injection, the excessive vaporization of fine Al particles and the completing nitriding reaction of some fine Al particles during flight. The feedstock particle size directly affects on the nitriding, melting, flowability, and the vaporization behaviors of Al powders during spraying. It concluded that using smaller particle size powders is useful for improving the nitriding ratio and not suitable for fabrication thick AlN coatings in reactive plasma spray process. To fabricate thick AlN coatings through RPS, enhancing the nitriding reaction of Al powders with large particle size during spraying is required.

  11. Effect of Microstructure on the Electrical Properties of Nano-Structured TiN Coatings Deposited by Vacuum Cold Spray

    NASA Astrophysics Data System (ADS)

    Wang, Y.-Y.; Liu, Y.; Yang, G.-J.; Feng, J.-J.; Kusumoto, K.

    2010-12-01

    TiN coatings on Al2O3 substrates were fabricated by vacuum cold spray (VCS) process using ultrafine starting ceramic powders of 20 nm in size at room temperature (RT). Microstructure analysis of the samples was carried out by scanning electron microscopy, transmission electron microscopy, and x-ray diffraction. Sheet resistance of the VCS TiN coatings was measured with a four-point probe. The effects of microstructure on the electrical properties of the coatings were investigated. It was found that the sheet resistance and electrical resistivity of TiN coatings were significantly associating with the spray distance, nozzle traversal speed, and deposition chamber pressure. A minimum sheet resistance of 127 Ω was achieved. The microstructural changes can be correlated to the electrical resistivity of TiN coatings.

  12. 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

  13. Fabrication of copper-based anodes via atmosphoric plasma spraying techniques

    DOEpatents

    Lu, Chun

    2012-04-24

    A fuel electrode anode (18) for a solid oxide fuel cell is made by presenting a solid oxide fuel cell having an electrolyte surface (15), mixing copper powder with solid oxide electrolyte in a mixing step (24, 44) to provide a spray feedstock (30,50) which is fed into a plasma jet (32, 52) of a plasma torch to melt the spray feed stock and propel it onto an electrolyte surface (34, 54) where the spray feed stock flattens into lamellae layer upon solidification, where the layer (38, 59) is an anode coating with greater than 35 vol. % based on solids volume.

  14. New generation of plasma-sprayed mullite coatings on silicon carbide

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Miller, Robert A.; Jacobson, Nathan S.

    1995-01-01

    Mullite is promising as a protective coating for silicon-based ceramics in aggressive high-temperature environments. Conventionally plasma-sprayed mullite on SiC tends to crack and debond on thermal cycling. It is shown that this behavior is due to the presence of amorphous mullite in the conventionally sprayed mullite. Heating the SiC substrate during the plasma spraying eliminated the amorphous phase and produced coatings with dramatically improved properties. The new coating exhibits excellent adherence and crack resistance under thermal cycling between room temperature and 1000 to 1400 C. Preliminary tests showed good resistance to Na2CO3-induced hot corrosion.

  15. Plasma sprayed coatings as surface treatments of aluminum adherends

    SciTech Connect

    Davis, G.D.; Whisnant, P.L.; Groff, G.B.; Shaffer, D.K.

    1996-12-31

    Plasma sprayed coatings have been evaluated as surface treatments for aluminum substrates being prepared for adhesive bonding. Blends of an aluminum-silicon alloy and polyester give the best performance. To establish durability performance, wedge tests were done using four common epoxy adhesives without primers. In all cases, the 60%Al-Si/40%polyester coating gave results superior to those of FPL-etched specimens and, in some cases, performance equivalent to PAA specimens. This roughness provides excellent opportunity for mechanical interlocking or physical bonding and allows a complex interphase to be formed as the adhesive penetrates into the coating. Crack growth measurements and subsequent failure analysis using x-ray photoelectron spectroscopy (XPS) indicate that crack propagation occurs within this complex interphase. The results also show that the aluminum and polyester components are synergistic and blends of the two give better performance than either component by itself The aluminum gives strength to the coating while the polyester provides toughness and improves moisture resistance.

  16. Predicting radiative transport properties of plasma sprayed porous ceramics

    NASA Astrophysics Data System (ADS)

    Wang, B. X.; Zhao, C. Y.

    2016-03-01

    The typical yttria-stabilized zirconia material for making the thermal barrier coatings (TBCs) is intrinsically semitransparent to thermal radiation, and the unique disordered microstructures in TBCs make them surprisingly highly scattering. To quantitatively understand the influence of disordered microstructures, this paper presents a quantitative prediction on the radiative properties, especially the transport scattering coefficient of plasma sprayed TBC based on microstructure analysis and rigorous electromagnetic theory. The impact of the porosity, shape, size, and orientation of different types of voids on transport scattering coefficient is comprehensively investigated under the discrete dipole approximation. An inverse model integrating these factors together is then proposed to quantitatively connect transport scattering coefficient with microstructural information, which is also validated by available experimental data. Afterwards, an optimization procedure is carried out based on this model to obtain the optimal size and orientation distribution of the microscale voids to achieve the maximal radiation insulation performance at different operating temperatures, providing guidelines for practical coating design and fabrication. This work suggests that the current model is effective and also efficient for connecting scattering properties to microstructures and can be implemented as a quantitative tool for further studies like non-destructive infrared imaging as well as micro/nanoscale thermal design of TBCs.

  17. Filter media properties of mineral fibres produced by plasma spray.

    PubMed

    Prasauskas, Tadas; Matulevicius, Jonas; Kliucininkas, Linas; Krugly, Edvinas; Valincius, Vitas; Martuzevicius, Dainius

    2016-06-01

    The purpose of this study was to determine the properties of fibrous gas filtration media produced from mineral zeolite. Fibres were generated by direct current plasma spray. The paper characterizes morphology, chemical composition, geometrical structure of elementary fibres, and thermal resistance, as well as the filtration properties of fibre media. The diameter of the produced elementary fibres ranged from 0.17 to 0.90 μm and the length ranged from 0.025 to 5.1 mm. The release of fibres from the media in the air stream was noticed, but it was minimized by hot-pressing the formed fibre mats. The fibres kept their properties up to the temperature of 956°C, while further increase in temperature resulted in the filter media becoming shrunk and brittle. The filtration efficiency of the prepared filter mats ranged from 95.34% to 99.99% for aerosol particles ranging in a size between 0.03 and 10.0 μm. Unprocessed fibre media showed the highest filtration efficiency when filtering aerosol particles smaller than 0.1 µm. Hot-pressed filters were characterized by the highest quality factor values, ranging from 0.021 to 0.064 Pa(-1) (average value 0.034 Pa(-1)). PMID:26583905

  18. Note: Triggering behavior of a vacuum arc plasma source

    NASA Astrophysics Data System (ADS)

    Lan, C. H.; Long, J. D.; Zheng, L.; Dong, P.; Yang, Z.; Li, J.; Wang, T.; He, J. L.

    2016-08-01

    Axial symmetry of discharge is very important for application of vacuum arc plasma. It is discovered that the triggering method is a significant factor that would influence the symmetry of arc discharge at the final stable stage. Using high-speed multiframe photography, the transition processes from cathode-trigger discharge to cathode-anode discharge were observed. It is shown that the performances of the two triggering methods investigated are quite different. Arc discharge triggered by independent electric source can be stabilized at the center of anode grid, but it is difficult to achieve such good symmetry through resistance triggering. It is also found that the triggering process is highly correlated to the behavior of emitted electrons.

  19. Note: Triggering behavior of a vacuum arc plasma source.

    PubMed

    Lan, C H; Long, J D; Zheng, L; Dong, P; Yang, Z; Li, J; Wang, T; He, J L

    2016-08-01

    Axial symmetry of discharge is very important for application of vacuum arc plasma. It is discovered that the triggering method is a significant factor that would influence the symmetry of arc discharge at the final stable stage. Using high-speed multiframe photography, the transition processes from cathode-trigger discharge to cathode-anode discharge were observed. It is shown that the performances of the two triggering methods investigated are quite different. Arc discharge triggered by independent electric source can be stabilized at the center of anode grid, but it is difficult to achieve such good symmetry through resistance triggering. It is also found that the triggering process is highly correlated to the behavior of emitted electrons. PMID:27587176

  20. 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.

  1. A sputtered zirconia primer for improved thermal shock resistance of plasma-sprayed ceramic turbine seals

    NASA Technical Reports Server (NTRS)

    Bill, R. C.; Sovey, J.; Allen, G. P.

    1981-01-01

    It is shown that the application of sputtered Y2O3-stabilized ZrO2 (YSZ) primer in plasma-sprayed YSZ ceramic-coated turbine blades results in an improvement, by a factor of 5-6, in the thermal shock life of specimens with a sprayed, porous, Ni-Cr-Al-Y intermediate layer. Species with and without the primer were found to be able to survive 1000 cycles when the intermediate layer was used, but reduced laminar cracking was observed in the specimen with the primer. It is suggested that the sputtered YZS primer-induced properties are due to (1) more effective wetting and adherence of the plasma-sprayed YZS particles to the primer, and (2) the primer's retardation of impinging, molten plasma sprayed particles solidification rates, which result in a less detrimental residual stress distribution.

  2. Design of a new nozzle for direct current plasma guns with improved spraying parameters

    NASA Astrophysics Data System (ADS)

    Jankovic, M.; Mostaghimi, J.; Pershin, V.

    2000-03-01

    A new design is proposed for direct current plasma spray gas-shroud attachments. It has curvilinearly shaped internal walls aimed toward elimination of the cold air entrainment, recorded for commercially available conical designs of the shrouded nozzle. The curvilinear nozzle design was tested; it proved to be capable of withstanding high plasma temperatures and enabled satisfactory particle injection. Parallel measurements with an enthalpy probe were performed on the jet emerging from two different nozzles. Also, corresponding calculations were made to predict the plasma flow parameters and the particle parameters. Adequate spray tests were performed by spraying iron-aluminum and MCrAlY coatings onto stainless steel substrates. Coating analyses were performed, and coating qualities, such as microstructure, open porosity, and adhesion strength, were determined. The results indicate that the coatings sprayed with a curvilinear nozzle exhibited lower porosity, higher adhesion strength, and an enhanced microstructure.

  3. 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.

  4. Modeling of evaporation and oxidation phenomena in plasma spraying of metal powders

    NASA Astrophysics Data System (ADS)

    Zhang, Hanwei

    Plasma spraying of metals in air is usually accompanied by evaporation and oxidation of the sprayed material. Optimization of the spraying process must ensure that the particles are fully molten during their short residence time in the plasma jet and prior to hitting the substrate, but not overheated to minimize evaporation losses. In atmospheric plasma spraying (ASP), it is also clearly desirable to be able to control the extent of oxide formation. The objective of this work to develop an overall mathematical model of the oxidization and volatilization phenomena involved in the plasma-spraying of metallic particles in air atmosphere. Four models were developed to simulate the following aspects of the atmospheric plasma spraying (APS) process: (a) the particle trajectories and the velocity and temperature profiles in an Ar-H 2 plasma jet, (b) the heat and mass transfer between particles and plasma jet, (c) the interaction between the evaporation and oxidation phenomena, and (d) the oxidation of liquid metal droplets. The resulting overall model was generated by adapting the computational fluid dynamics code FIDAP and was validated by experimental measurements carried out at the collaborating plasma laboratory of the University of Limoges. The thesis also examined the environmental implications of the oxidization and volatilization phenomena in the plasma spraying of metals. The modeling results showed that the combination of the standard k-s model of turbulence and the Boussinesq eddy-viscosity model provided a more accurate prediction of plasma gas behavior. The estimated NOx generation levels from APS were lower than the U.S.E.P.A. emission standard. Either enhanced evaporation or oxidation can occur on the surface of the metal particles and the relative extent is determined by the process parameters. Comparatively, the particle size has the greatest impact on both evaporation and oxidation. The extent of particle oxidation depends principally on gas

  5. Reactive Plasma Nitriding of AL2O3 Powder in Thermal Spray

    NASA Astrophysics Data System (ADS)

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

    Among advanced ceramics, aluminum nitride (AlN) had attracted much attention in the field of electrical and structural applications due to its outstanding properties. However, it is difficult to fabricate AlN coating by conventional thermal spray processes directly. Due to the thermal decomposition of feedstock AlN powder during spraying without a stable melting phase (which is required for deposition in thermal spray). Reactive plasma spraying (RPS) has been considered as a promising technology for in-situ formation of AlN thermally sprayed coatings. In this study the possibility of fabrication of AlN coating by reactive plasma nitriding of alumina (Al2O3) powder using N2/H2 plasma was investigated. It was possible to fabricate a cubic-AlN (c-AlN) based coating and the fabricated coating consists of c-AlN, α-Al2O3, Al5O6N and γ-Al2O3. It was difficult to understand the nitriding process from the fabricated coatings. Therefore, the Al2O3 powders were sprayed and collected in water. The microstructure observation of the collected powder and its cross section indicate that the reaction started from the surface. Thus, the sprayed particles were melted and reacted in high temperature reactive plasma and formed aluminum oxynitride which has cubic structure and easily nitride to c-AlN. During the coatings process the particles collide, flatten, and rapidly solidified on a substrate surface. The rapid solidification on the substrate surface due to the high quenching rate of the plasma flame prevents AlN crystal growth to form the hexagonal phase. Therefore, it was possible to fabricate c-AlN/Al2O3 based coatings through reactive plasma nitriding reaction of Al2O3 powder in thermal spray.

  6. Plasma-spraying synthesis of high-performance photocatalytic TiO2 coatings

    NASA Astrophysics Data System (ADS)

    Takahashi, Yasuo; Shibata, Yoshitaka; Maeda, Masakatsu; Miyano, Yasuyuki; Murai, Kensuke; Ohmori, Akira

    2014-08-01

    Anatase (A-) TiO2 is a photocatalytic material that can decompose air-pollutants, acetaldehyde, bacteria, and so on. In this study, three kinds of powder (A-TiO2 without HAp, TiO2 + 10mass%HAp, and TiO2+30mass%HAp, where HAp is hydroxyapatite and PBS is polybutylene succinate) were plasma sprayed on biodegradable PBS substrates. HAp powder was mixed with A-TiO2 powder by spray granulation in order to facilitate adsorption of acetaldehyde and bacteria. The crystal structure was almost completely maintained during the plasma spray process. HAp enhanced the decomposition of acetaldehyde and bacteria by promoting adsorption. A 10mass% HAp content was the most effective for decomposing acetaldehyde when plasma preheating of the PBS was not carried out before the plasma spraying. The plasma preheating of PBS increased the yield rate of the spray process and facilitated the decomposition of acetaldehyde by A-TiO2 coatings without HAp. HAp addition improved photocatalytic sterilization when plasma preheating of the PBS was performed.

  7. Broadband Plasma-Sprayed Anti-reflection Coating for Millimeter-Wave Astrophysics Experiments

    NASA Astrophysics Data System (ADS)

    Jeong, O.; Lee, A.; Raum, C.; Suzuki, A.

    2016-02-01

    We have developed a plasma-sprayed anti-reflection (AR) coating technology for millimeter-wave astrophysics experiments with cryogenic optics which achieves minimal dissipative loss and broad bandwidth and is easily and accurately applied. Plasma spraying is a coating process through which melted or heated materials are sprayed onto a substrate. The dielectric constants of the plasma-sprayed coatings were tuned between 2.7 and 7.9 by mixing hollow ceramic microspheres with alumina powder as the base material and varying the plasma energy of the spray. By spraying low loss ceramic materials with a tunable dielectric constant, we can apply multiple layers of AR coating for broadband millimeter-wave detection. At 300 K, we achieved a fractional bandwidth of 106 over 90% transmission using a three-layer AR coating. Applying ceramic coatings on ceramic lenses offers an additional benefit of preventing cryogenic delamination of the coatings. We report on methodology of coating application and measurement of uniformity, repeatability, transmission property, and cryogenic adhesion performance.

  8. Effect of gun current on the microstructure and crystallinity of plasma sprayed hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Morks, M. F.; Kobayashi, A.

    2007-06-01

    Hydroxyapatite (HA) is a bioactive material because its chemical structure is close to the natural bone. Its bioactive properties make it attractive material in biomedical applications. Gas tunnel type plasma spraying (GTPS) technique was employed in the present study to deposit HA coatings on SUS 304 stainless steel substrate. GTPS is composed of two plasma sources: gun which produces internal low power plasma (1.3-8 kW) and vortex which produces the main plasma with high power level (10-40 kW). Controlling the spraying parameters is the key role for spraying high crystalline HA coatings on the metallic implants. In this study, the arc gun current was changed while the vortex arc current was kept constant at 450 A during the spraying process of HA coatings. The objective of this study is to investigate the influence of gun current on the microstructure, phase crystallinity and hardness properties of HA coatings. The surface morphology and microstructure of as-sprayed coatings were examined by scanning electron microscope. The phase structure of HA coatings was investigated by X-ray diffraction analysis. HA coatings sprayed at high gun current (100 A) are dense, and have high hardness. The crystallinity of HA coatings was decreased with the increasing in the gun current. On the other hand, the hardness was slightly decreased and the coatings suffer from some porosity at gun currents 0, 30 and 50 A.

  9. T55-L-712 turbine engine compressor housing refurbishment-plasma spray project

    NASA Technical Reports Server (NTRS)

    Leissler, George W.; Yuhas, John S.

    1988-01-01

    A study was conducted to assess the feasibility of reclaiming T55-L-712 turbine engine compressor housings with an 88 wt percent aluminum to 12 wt percent silicon alloy applied by a plasma spray process. Tensile strength testing was conducted on as-sprayed and thermally cycled test specimens which were plasma sprayed with 0.020 to 0.100 in. coating thicknesses. Satisfactory tensile strength values were observed in the as-sprayed tensile specimens. There was essentially no decrease in tensile strength after thermally cycling the tensile specimens. Furthermore, compressor housings were plasma sprayed and thermally cycled in a 150-hr engine test and a 200-hr actual flight test during which the turbine engine was operated at a variety of loads, speeds and torques. The plasma sprayed coating system showed no evidence of degradation or delamination from the compressor housings. As a result of these tests, a procedure was designed and developed for the application of an aluminum-silicon alloy in order to reclaim T55-L-712 turbine engine compressor housings.

  10. Broadband Plasma-Sprayed Anti-reflection Coating for Millimeter-Wave Astrophysics Experiments

    NASA Astrophysics Data System (ADS)

    Jeong, O.; Lee, A.; Raum, C.; Suzuki, A.

    2016-08-01

    We have developed a plasma-sprayed anti-reflection (AR) coating technology for millimeter-wave astrophysics experiments with cryogenic optics which achieves minimal dissipative loss and broad bandwidth and is easily and accurately applied. Plasma spraying is a coating process through which melted or heated materials are sprayed onto a substrate. The dielectric constants of the plasma-sprayed coatings were tuned between 2.7 and 7.9 by mixing hollow ceramic microspheres with alumina powder as the base material and varying the plasma energy of the spray. By spraying low loss ceramic materials with a tunable dielectric constant, we can apply multiple layers of AR coating for broadband millimeter-wave detection. At 300 K, we achieved a fractional bandwidth of 106 over 90% transmission using a three-layer AR coating. Applying ceramic coatings on ceramic lenses offers an additional benefit of preventing cryogenic delamination of the coatings. We report on methodology of coating application and measurement of uniformity, repeatability, transmission property, and cryogenic adhesion performance.

  11. The evolution of ion charge states in cathodic vacuum arc plasmas: a review

    SciTech Connect

    Anders, Andre

    2011-12-18

    Cathodic vacuum arc plasmas are known to contain multiply charged ions. 20 years after “Pressure Ionization: its role in metal vapour vacuum arc plasmas and ion sources” appeared in vol. 1 of Plasma Sources Science and Technology, it is a great opportunity to re-visit the issue of pressure ionization, a non-ideal plasma effect, and put it in perspective to the many other factors that influence observable charge state distributions, such as the role of the cathode material, the path in the density-temperature phase diagram, the “noise” in vacuum arc plasma as described by a fractal model approach, the effects of external magnetic fields and charge exchange collisions with neutrals. A much more complex image of the vacuum arc plasma emerges putting decades of experimentation and modeling in perspective.

  12. Microstructure of Nanostructured TIO2 Coating Prepared by Atmospheric Plasma Spraying and its Photocatalytic Properties

    NASA Astrophysics Data System (ADS)

    Yu, Qinghe; Huang, Hui; Zhou, Chungen

    The starting nano-TiO2 feedstock was agglomerated by spray-drying process. Nano-TiO2 coatings on transparent glasses were prepared by atmospheric plasma spraying (APS). The variation of the anatase content, porosity and grain size with the arc current is investigated extensively. Result shows that the nano-TiO2 phase is composed of anatase and rutile phase. The content of anatase in the sprayed coatings decreased and the grain size increased with the arc current increasing, and the porosity first increased and then decreased. As-sprayed nano-TiO2 coatings obtained at the spraying current of 400 A have the best photocatalytic property due to the synergistic effect of the fractions of anatase phase and the rate of porosity.

  13. Efficiency of surface cleaning by a glow discharge for plasma spraying coating

    NASA Astrophysics Data System (ADS)

    Kadyrmetov, A. M.; Kashapov, N. F.; Sharifullin, S. N.; Saifutdinov, A. I.; Fadeev, S. A.

    2016-06-01

    The article presents the results of experimental studies of the quality of cleaning steel surfaces by a glow discharge for plasma spraying. Shows the results of measurements of the angle of surface wetting and bond strength of the plasma coating to the surface treated. The dependence of the influence of the glow discharge power, chamber pressure, distance between the electrodes and the processing time of the surface on cleaning efficiency. Optimal fields of factors is found. It is shown increase joint strength coating and base by 30-80% as a result of cleaning the substrate surface by a glow discharge plasma spraying.

  14. Characterisation of the TiO2 coatings deposited by plasma spraying

    NASA Astrophysics Data System (ADS)

    Benea, M. L.; Benea, L. P.

    2016-02-01

    Plasma spraying of materials such as ceramics and non-metals, which have high melting points, has become a well-established commercial process. Such coatings are increasingly used in aerospace, automobile, textile, medical, printing and electrical industries to impart proprieties such as corrosion resistance, thermal resistance, wear resistance, etc. One of the most important characteristics of thermal barrier coatings is the ability to undergo fast temperature changes without failing, the so called thermal shock resistance. The formation of residual stresses in plasma sprayed ceramic and metallic coatings is a very complex process. Several factors, such as substrate material, substrate thickness, physical properties of both the substrate and the coating material, deposition rate, relative velocity of the plasma torch, etc. determine the final residual stress state of the coating at room temperature. Our objective is to characterize the titanium oxide and aluminium oxide coatings deposited by plasma spraying in structural terms, the resistance to thermal shock and residual stresses.

  15. Understanding tin plasmas in vacuum: A new approach to tin whisker risk assessment

    SciTech Connect

    Mason, M. S.; Eng, G.

    2007-11-15

    This study examines the mechanisms governing sustained tin plasma formation in vacuum. The authors have experimentally demonstrated that sustained tin plasmas can form in vacuum at dc power supply voltages as low as 4 V, and present a qualitative model for the observed voltage and current signatures associated with tin plasma formation. Engineering estimates were developed to help quantify tin whisker risk as a function of power supply voltage. Implications for space applications are also discussed.

  16. Surface modification of air plasma spraying WC-12%Co cermet coating by laser melting technique

    NASA Astrophysics Data System (ADS)

    Afzal, M.; Ajmal, M.; Nusair Khan, A.; Hussain, A.; Akhter, R.

    2014-03-01

    Tungsten carbide cermet powder with 12%Co was deposited on stainless steel substrate by air plasma spraying method. Two types of coatings were produced i.e. thick (430 µm) and thin (260 µm) with varying porosity and splat morphology. The coated samples were treated with CO2 laser under the shroud of inert atmosphere. A series of experimentation was done in this regard, to optimize the laser parameters. The plasma sprayed coated surfaces were then laser treated on the same parameters. After laser melting the treated surfaces were characterized and compared with as-sprayed surfaces. It was observed that the thickness of the sprayed coatings affected the melt depth and the achieved microstructures. It was noted that phases like Co3W3C, Co3W9C4 and W were formed during the laser melting in both samples. The increase in hardness was attributed to the formation of these phases.

  17. Developing empirical relationships to estimate porosity and Young's modulus of plasma sprayed YSZ coatings

    NASA Astrophysics Data System (ADS)

    Karthikeyan, S.; Balasubramanian, V.; Rajendran, R.

    2014-03-01

    Plasma spraying process is an effective thermal spray process to deposit thermal barrier coatings (TBCs) on the components of propulsion and land based gas turbines to enhance its performance. In this work, empirical relationships were developed to estimate TBCs performance characteristics (porosity and Young's modulus) of yttria stabilized zirconia coatings by incorporating independently controllable atmospheric plasma spray operational parameters (input power, standoff distance and powder feed rate) using response surface methodology (RSM). A central composite rotatable design with three factors and five levels was chosen to minimize the number of experimental conditions. Within the scope of the design space, the input power and the standoff distance appeared to be the most significant two parameters affecting the coating quality characteristics among the three investigated process parameters. Further, correlating the spray parameters with coating properties enables identification of characteristics regime to achieve desired quality of YSZ coatings.

  18. Use of plasma sprayed coatings as surface treatments for aluminum adherends

    SciTech Connect

    Davis, G.D.; Whisnant, P.L.; Groff, G.B.

    1996-12-31

    Surface treatments for metal adherends prior to adhesive bonding typically use chromates and/or strong acids and bases. Such materials are hazardous to personnel and harmful to the environment following disposal. To reduce release of these substances into the environment and lower disposal costs, plasma spray treatments are being developed as surface treatments for aluminum adherends. These treatments eliminate liquid and gaseous wastes and provide bond strength and durability comparable to that provided by the conventional chemical treatments. They have other potential advantages of being more suited for repair/refurbishment and less sensitive to metallurgical differences from alloy to alloy. Plasma sprayed coatings are used in a variety of applications where a coating tailored for specific properties is needed that may or may not be chemically or structurally similar to the base substrate. Plasma spraying has been shown to provide excellent high-temperature bond performance with titanium (unlike conventional oxidation treatments) and durability approaching that of phosphoric acid anodization for aluminum. Success has also been reported using other coatings on aluminum, titanium, and steel. Plasma spraying has the important advantage of versatility. A wide range of coatings (metals, ceramics, and polymers) can be deposited onto an equally wide range of substrates, and the coating properties can be optimized for a given application, independent of the substrate. Because of this versatility, plasma-sprayed coatings have been used for wear resistance, thermal barriers, EMI/RF shielding, corrosion resistance, slip/slide resistance, and biocompatibility in addition to adhesion.

  19. Elastic properties of porous structural ceramics produced by plasma-spraying

    SciTech Connect

    Wanner, A.

    1998-12-31

    This study focuses on the relationship between porosity and elastic stiffness of structural ceramic materials produced by plasma-spraying. Mg-Al-spinel was chosen as a model material and studied in as-sprayed condition as well as upon annealing to increasingly higher temperatures up to 1650 C. The detailed analysis of the stiffness and mass density evolution offers a deep insight into the initial microstructural state of the material and into the morphological changes that occur upon heat treatment.

  20. The effect of annealing on the creep of plasma-sprayed ceramics

    NASA Technical Reports Server (NTRS)

    Hendricks, R. C.; Mcdonald, G.; Mullen, R. L.

    1983-01-01

    The creep of plasma sprayed ZrO2-8Y2O3 was measured at temperatures from 98 to 1250 C (180 to 220 F), and compared to creep of identical samples after annealing at temperatures from 98 to 1316 C (1800 to 2400 F). Loads and temperatures which produced significant creep of as sprayed ceramics produced no creep after annealing. Previously announced in STAR as N83-24799

  1. Multiple ionization of metal ions by ECR heating of electrons in vacuum arc plasmas

    NASA Astrophysics Data System (ADS)

    Vodopyanov, A. V.; Golubev, S. V.; Zorin, V. G.; Razin, S. V.; Vizir, A. V.; Nikolaev, A. G.; Oks, E. M.; Yushkov, G. Yu.

    2004-05-01

    A joint research and development effort has been initiated, whose ultimate goal is the enhancement of the mean ion charge states in vacuum arc metal plasmas by a combination of a vacuum arc discharge and electron cyclotron resonance (ECR) heating. Metal plasma was generated by a special vacuum arc mini-gun. Plasma was pumped by high frequency gyrotron-generated microwave radiation. The results have demonstrated substantial multiple ionization of metal ions. For a lead plasma, ECR heating increased the maximum attainable ion charge state from Pb2+ up to Pb6+. The confinement parameter was as high as ˜109 cm-3 s. Further increase of the ion charge states will be attained by increasing the vacuum arc plasma density and optimizing the ECR heating conditions.

  2. Effects of Anode Arc Root Fluctuation on Coating Quality During Plasma Spraying

    NASA Astrophysics Data System (ADS)

    An, Lian-Tong; Gao, Yang; Sun, Chengqi

    2011-06-01

    To obtain a coating of high quality, a new type of plasma torch was designed and constructed to increase the stability of the plasma arc and reduce the air entrainment into the plasma jet. The torch, called bi-anode torch, generates an elongated arc with comparatively high arc voltage and low arc fluctuation. Spraying experiments were carried out to compare the quality of coatings deposited by a conventional torch and a bi-anode torch. Alumina coatings and tungsten carbide coatings were prepared to appraise the heating of the sprayed particles in the plasma jets and the entrainment of the surrounding air into the plasma jets, respectively. The results show that anode arc root fluctuation has only a small effect on the melting rate of alumina particles. On the other hand, reduced air entrainment into the plasma jet of the bi-anode torch will drastically reduce the decarbonization of tungsten carbide coatings.

  3. Structural, Mechanical and Erosion Properties of Yttrium Oxide Coatings by Axial Suspension Plasma Spraying for Electronics Applications

    NASA Astrophysics Data System (ADS)

    Kitamura, Junya; Tang, Zhaolin; Mizuno, Hiroaki; Sato, Kazuto; Burgess, Alan

    2011-01-01

    Yttrium oxide (Y2O3) coatings have been prepared by axial suspension plasma spraying with fine powders. It is clarified that the coatings have high hardness, low porosity, high erosion resistance against CF4 -containing plasma and retention of smooth eroded surface. This suggests that the axial suspension plasma spraying of Y2O3 is applicable to fabricating equipment for electronic devices, such as dry etching. Surface morphologies of the slurry coatings with splats are similar to conventional plasma-sprayed Y2O3 coatings, identified from microstructural analysis. Dense coating structures with no lamellar boundaries have been seen, which is apparently different from the conventional coatings. It has also been found that crystal structure of the suspension coatings mainly composed of metastable monoclinic phase, whereas the powders and the conventional plasma spray coatings have stable cubic phase. Mechanism of coating formation by plasma spraying with fine powder slurries is discussed based on the results.

  4. Multi-scale Phenomena and Structures Observed in Fabrication of Thermal Barrier Coatings by Using Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Kuroda, Seiji; Murakami, Hideyuki; Watanabe, Makoto; Itoh, Kaita; Shinoda, Kentaro; Zhang, Xiancheng

    Thermal barrier coatings (TBC) fabricated by plasma spray can exhibit a wide range of microstructures due to differences in feedstock powders and spraying conditions. Since different microstructures naturally result in different thermal and mechanical properties and service life as thermal barrier coatings, it is of great importance to understand the relationship among the feedstock characteristics, spray conditions and the coating microstructures. Recent research efforts of the author's group to understand fundamental phenomena in plasma spraying of TBC are reviewed from microscopic to macroscopic viewpoints, i.e., direct observation of single droplet impact of molten zirconia by an ultra fast video camera, detection of acoustic emission (AE) signals during plasma spraying by using laser AE technique, and in-situ measurement of the curvature and temperature of a substrate during plasma spraying, from which strain-stress relationships and residual stresses of TBC can be evaluated.

  5. Influence of Microstructure on Thermal Properties of Axial Suspension Plasma-Sprayed YSZ Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    Ganvir, Ashish; Curry, Nicholas; Markocsan, Nicolaie; Nylén, Per; Joshi, Shrikant; Vilemova, Monika; Pala, Zdenek

    2016-01-01

    Suspension plasma spraying is a relatively new thermal spaying technique to produce advanced thermal barrier coatings (TBCs) and enables production of coatings with a variety of structures—highly dense, highly porous, segmented, or columnar. This work investigates suspension plasma-sprayed TBCs produced using axial injection with different process parameters. The influence of coating microstructure on thermal properties was of specific interest. Tests carried out included microstructural analysis, phase analysis, determination of porosity, and pore size distribution, as well as thermal diffusivity/conductivity measurements. Results showed that axial suspension plasma spraying process makes it possible to produce various columnar-type coatings under different processing conditions. Significant influence of microstructural features on thermal properties of the coatings was noted. In particular, the process parameter-dependent microstructural attributes, such as porosity, column density, and crystallite size, were shown to govern the thermal diffusivity and thermal conductivity of the coating.

  6. Oxidation Control of Atmospheric Plasma Sprayed FeAl Intermetallic Coatings Using Dry-Ice Blasting

    NASA Astrophysics Data System (ADS)

    Song, Bo; Dong, Shujuan; Coddet, Pierre; Hansz, Bernard; Grosdidier, Thierry; Liao, Hanlin; Coddet, Christian

    2013-03-01

    The performance of atmospheric plasma sprayed FeAl coatings has been remarkably limited because of oxidation and phase transformation during the high-temperature process of preparation. In the present work, FeAl intermetallic coatings were prepared by atmospheric plasma spraying combined with dry-ice blasting. The microstructure, oxidation, porosity, and surface roughness of FeAl intermetallic coatings were investigated. The results show that a denser FeAl coating with a lower content of oxide and lower degree of phase transformation can be achieved because of the cryogenic, the cleaning, and the mechanical effects of dry-ice blasting. The surface roughness value decreased, and the adhesive strength of FeAl coating increased after the application of dry-ice blasting during the atmospheric plasma spraying process. Moreover, the microhardness of the FeAl coating increased by 72%, due to the lower porosity and higher dislocation density.

  7. Feasibility study of plasma sprayed Al2O3 coatings as diffusion barrier on CFC components

    NASA Astrophysics Data System (ADS)

    Bobzin, Kirsten; Zhao, Lidong; Kopp, Nils; Warda, Thomas

    2012-12-01

    Carbon fibre reinforced carbon (CFC) materials are increasingly applied as sample carriers in modern furnaces. Only their tendency to react with different metals at high temperatures by C-diffusion is a disadvantage, which can be solved by application of diffusion barriers. Within this study the feasibility of plasma sprayed Al2O3 coatings as diffusion barrier was studied. Al2O3 coatings were prepared by air plasma spraying (APS). The coatings were investigated in terms of their microstructure, bonding to CFC substrates and thermal stability. The results showed that Al2O3 could be well deposited onto CFC substrates. The coatings had a good bonding and thermal shock behavior at 1060°C. At higher temperature of 1270°C, crack network formed within the coating, showing that the plasma sprayed Al2O3 coatings are limited regarding to their application temperatures as diffusion barrier on CFC components.

  8. 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.

  9. D. C. Plasma-Sprayed Coatings of Nanostructured Alumina-Titania-Silica

    NASA Astrophysics Data System (ADS)

    Jiang, Xian-liang; Liu, Min

    2002-10-01

    Nanocrystalline powders of w(Al2O3) = 95%, w(TiO2) = 3%, and w(SiO2) = 2%, were reprocessed into agglomerated particles for plasma spraying, by using consecutive steps of ball milling, slurry forming, spray drying, and heat treatment. D. C. plasma was used to spray the agglomerated nanocrystalline powders, and resultant coatings were deposited on the substrate of stainless steel. Scanning electron microscopy (SEM) was used to examine the morphology of the agglomerated powders and the cross section of the alumina-titania-silica coatings. Experimental results show that the agglomerated noncrystalline particles are spherical, with a size from (10-90) μm. The flow ability of the nanocrystalline powders is greatly improved after the reprocessing. The coatings deposited by the plasma spraying are mainly of nanostructure. Unlike conventional plasma-sprayed coatings, no laminar layer could be found in the nanostructured coatings. Although the nanostructured coatings have a lower microhardness than conventional microstructured coatings, the toughness of the nanostructured ceramic coatings is significantly improved.

  10. Very low pressure plasma sprayed yttria-stabilized zirconia coating using a low-energy plasma gun

    NASA Astrophysics Data System (ADS)

    Zhu, Lin; Zhang, Nannan; Bolot, Rodolphe; Planche, Marie-Pierre; Liao, Hanlin; Coddet, Christian

    2011-12-01

    In the present study, a more economical low-energy plasma source was used to perform a very low pressure plasma-spray (VLPPS) process. The plasma-jet properties were analyzed by means of optical emission spectroscopy (OES). Moreover, yttria-stabilized zirconia coating (YSZ) was elaborated by a F100 low-power plasma gun under working pressure of 1 mbar, and the substrate specimens were partially shadowed by a baffle-plate during plasma spraying for obtaining different coating microstructures. Based on the SEM observation, a column-like grain coating was deposited by pure vapor deposition at the shadowed region, whereas, in the unshadowed region, the coating exhibited a binary microstructure which was formed by a mixed deposition of melted particles and evaporated particles. The mechanical properties of the coating were also well under investigation.