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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. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. Vacuum plasma spray applications on liquid fuel rocket engines

    NASA Technical Reports Server (NTRS)

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

    1992-01-01

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

  10. Vacuum plasma spray applications on liquid fuel rocket engines

    NASA Astrophysics Data System (ADS)

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

    1992-07-01

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

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. The production of porous layers for the solid oxide fuel cell by vacuum plasma spraying

    SciTech Connect

    Fendler, E.; Henne, R.; Lang, M.

    1995-12-31

    The vacuum plasma spraying (VPS) method was used to produce porous perovskite and Ni/YSZ (Yttria Stabilized Zirconia) cermet layers as cathode and anode for a SOFC, respectively. The perovskite powder was deposited without decomposition of the perovskite phase due to the use of Laval-nozzles and the adaption of spray parameters. The deposition of porous Ni/YSZ cermets demanded a modification of the Laval-nozzle. With this modification high deposition rates compared to conventional nozzles could be attained. The deposition of NiAl-YSZ and subsequently etching of Al is a successful method to produce anode layers with very fine porosity. Up to now the feasibility of producing porous deposits was examined. The next step of investigation will be the electrochemical testing of the electrodes. The results of those tests will influence the further development of anode`s and cathode`s microstructure.

  1. A comparative study of high velocity oxygen fuel, vacuum plasma spray, and axial plasma spray for the deposition of CoNiCrAlY bond coat alloy

    NASA Astrophysics Data System (ADS)

    Scrivani, A.; Bardi, U.; Carrafiello, L.; Lavacchi, A.; Niccolai, F.; Rizzi, G.

    2003-12-01

    In the aerospace field as well as in the stationary gas turbine field, thermally sprayed coatings are used to improve the surface properties of nickel-super-alloys materials. Coatings are commonly used as bond coat and antioxidation materials (mainly MCrAlY alloys) and as thermal barrier coatings (mainly yttria partially stabilized zirconia). The purpose of the current study was to assess the properties of thermally sprayed bond coat CoNiCrAlY alloys comparing the performance of three different techniques: vacuum plasma spray (VPS), high velocity oxygen fuel (HVOF), and axial plasma spray (AxPS). The quality of the deposited films has been assessed and compared from the point of view of microstructural (porosity, oxide concentration, unmelted particles presence) and mechanical (hardness) characteristics. The surface composition and morphology of the coatings were also determined. Specific efficiency tests were performed for the three examined technologies. The highest quality coatings are obtained by VPS, but also high velocity oxygen fuel and AxPS sprayed films have interesting properties, which can make their use interesting for some applications.

  2. Tribological and Corrosion Behavior of Vacuum Plasma Sprayed Ti-Zr-Ni Quasicrystalline Coatings

    NASA Astrophysics Data System (ADS)

    Siegmann, Stephan; Kern, Philippe; Rohr, Lukas; Bandyopadhyay, Partha P.

    2007-12-01

    This investigation deals with a study of the friction, wear, and corrosion behavior of vacuum plasma sprayed quasicrystalline (QC) Ti41.5Zr41.5Ni17 coatings. During pin on disc experiments, a change in the mode of wear has been found to occur with corresponding changes in normal load and sliding velocity. The low thermal conductivity of quasicrystals and its brittleness play a vital role in determining the friction and wear behavior of such materials. When these coatings are subjected to rubbing for a longer period of time, wear occurs by subsurface crack propagation, and subsequent delamination within the coated layer. By comparing the QC to its polycrystalline counterpart during potentiodynamic measurements according to ASTM G 31, higher currents were found over the whole range of potentials for QC when immersed in 1 M HCl solution.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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 while maintaining the superior CuCrNb properties are also presented.

  8. Nd-Fe-B permanent magnets (thick films) produced by a vacuum-plasma-spraying process

    NASA Astrophysics Data System (ADS)

    Rieger, G.; Wecker, J.; Rodewald, W.; Sattler, W.; Bach, Fr.-W.; Duda, T.; Unterberg, W.

    2000-05-01

    Thick, hard-magnetic Nd-Fe-B films (˜1 mm) were deposited on different substrates (Cu, steel) by a low-pressure plasma-spraying process. The properties of the applied Nd-Fe-B powders (e.g., grain size, composition) and the conditions of the spraying process were optimized with respect to the mechanical and magnetic properties of the films. Film thicknesses up to 1.2 mm were achieved with good adhesive properties (bond strength>40 MPa). Cracks at the interface or within the films during the deposition process could be suppressed by adjusting the temperature profile of the substrate and controlling the deposition rate. Depending on the maximum temperature of the substrate and the thickness of the Nd-Fe-B films, either amorphous or microcrystalline structures were obtained. In general, the magnetic properties were improved by a postdeposition annealing treatment. Coercivities HcJ up to 16 kA/cm and isotropic remanences of about 0.6 T were achieved.

  9. 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.

  10. 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

  11. 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

  12. 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

  13. In vivo testing of canine prosthetic femoral components with HA-Ti ladder-type coating on vacuum plasma-sprayed Ti substrate.

    PubMed

    Zeng, Xian-lin; Li, Jing-feng; Yang, Shu-hua; Zheng, Qi-xin; Zou, Zhen-wei

    2013-08-01

    The purpose of the present study was to observe the structure and functional change of the bone-coating-prosthesis interface in vivo and to evaluate the histocompatibility of self-made prosthetic femoral components in the body and the degree of their bonding with the surrounding bone tissues as well as their stability. Six mature beagle dogs underwent bilateral hip replacement with prosthetic femur components. Three groups were established in terms of different coating of prothesis (four joints in each group): atmosphere (A) plasma-sprayed pure titanium (Ti) prosthetic joint with hydroxyapatite (HA) coating (HA+Ti+A group); vacuum (V) plasma-sprayed pure Ti prosthetic joint with HA coating (HA+Ti+V group); vacuum plasma-sprayed pure Ti prosthetic joint with Ti-HA stepped coating (Ti+HAG+Ti+V group). The hip joints were functionally evaluated, and subjected to X-ray examination, biomechanics inspection, and histological examination. As a result, X-ray imaging revealed all prosthetic joints were in a good location and no dislocation of joint was found. Shear strength of interface was significantly higher in Ti+HAG+Ti+V group than in HA+Ti+V group (P<0.05) and HA+Ti+A group (P<0.05) at 28th week. Histological examination showed the amount of newborn bone in Ti+HAG+Ti+V group was more than in HA+Ti+V group and HA+Ti+A group after 28 weeks. It was suggested that vacuum plasma-sprayed pure Ti prosthetic joint with TI-HA stepped coating could improve the bonding capacity of bone-prosthesis, enhance the stability of prosthesis, and increase the fixion of prosthetic femoral components because of better bone growth. This new type of biological material in prosthetic femoral components holds promises for application in clinical practice. PMID:23904375

  14. 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

  15. 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.

  16. 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.

  17. Effect of Vacuum Annealing on the Characteristics of Plasma Sprayed Al2O3-13wt.%TiO2 Coatings

    NASA Astrophysics Data System (ADS)

    Jingjing, Zhang; Zehua, Wang; Pinghua, Lin; Hongbin, Yuan; Zehua, Zhou; Shaoqun, Jiang

    2012-09-01

    Adhesion strength is one of the critical properties for plasma-sprayed coating. In this study, the plasma-sprayed Al2O3-13wt.%TiO2/NiCrAl coatings were annealed at 300-900 °C for 6 h in vacuum. The tensile bond strength and porosity of the coatings were investigated. The microstructure and the fracture were studied using optical microscopy, scanning electron spectroscopy, and x-ray diffraction. It was found that the tensile bond strength of coatings increased with the increase of annealing temperature until 500 °C, reaching the maximum value of 41.2 MPa, and then decreased as the annealing temperature continues to increase. All coatings presented a brittle fracture and the fracture occurred inside the ceramic coatings except for the coating annealed at 500 °C, which had a brittle-ductile mixed fracture and the fracture occurred at the interface of bond coating and the substrate.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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 resistance but also the simultaneous coverage of multiple air foils.

  7. 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.

  8. 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.

  9. Characterization of Plasma Sprayed Beryllium ITER First Wall Mockups

    SciTech Connect

    Castro, Richard G.; Vaidya, Rajendra U.; Hollis, Kendall J.

    1997-12-31

    ITER first wall beryllium mockups, which were fabricated by vacuum plasma spraying the beryllium armor, have survived 3000 thermal fatigue cycles at 1 MW/sq m without damage during high heat flux testing at the Plasma Materials Test Facility at Sandia National Laboratory in New Mexico. The thermal and mechanical properties of the plasma sprayed beryllium armor have been characterized. Results are reported on the chemical composition of the beryllium armor in the as-deposited condition, the through thickness and normal to the through thickness thermal conductivity and thermal expansion, the four-point bend flexure strength and edge-notch fracture toughness of the beryllium armor, the bond strength between the beryllium armor and the underlying heat sink material, and ultrasonic C-scans of the Be/heat sink interface.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. Plastic flow of plasma sprayed ceramics

    NASA Technical Reports Server (NTRS)

    Padovan, J.; Chung, B. T. F.; Braun, M. J.; Mcdonald, G.; Hendricks, R. C.; Mullen, R. L.

    1984-01-01

    The plastic flow of plasma-sprayed ZrO2-8Y2O3 ceramic has been measured at temperatures up to 1250 C and compared to the plastic flow of pressed and sintered ZrO2-8Y2O3. Plasma spraying of binary oxide ceramics is found to result in a metastable state which is inelastic at high temperature but can also be stabilized or devitrified through heat treating so as to decrease plastic properties. The mechanical properties of the as-plasma sprayed and devitrified ceramic sheet material was measured. An improved algorithm that incorporates the inherently nonlinear thermomechanical field equations was used to determine the influence of inelastic material behavior on the thermomechanical response of ceramic coated seal components. Significant creep was found during the thermal shock and steady heating periods with insufficient time during thermal quench to reverse the process, thereby inducing significant residual stresses into the components.

  18. High power plasma spraying of oxide ceramics

    SciTech Connect

    Lugscheider, E.; Jungklaus, H.; Schwier, G.; Mathesius, H.; Heinrich, P.

    1995-12-31

    New developed high power plasma spray (HPPS) systems offer opportunities for generating both high thermal as well as high kinetic energy transfer to the powder particles. The operation level can be elevated up to 250 kW for continuous processing. PLCs and mass flow controls support high power processing under production conditions. The process is designed for applying large quantities even of high melt materials, such as oxide ceramics. High power plasma processing may result in enhanced coating characteristics. The work in this paper shows first conclusions for processing commercial powders such as alumina, alumina-titania, chromia and a recently developed multicomponent oxide with a HPPS system. Particle velocities were measured after optimizing spraying parameters. Coatings were evaluated by optical microscopy (microstructure and porosity), microhardness and pin-on-disc abrasive wear tests. Powder types and sizes as well as the systems configuration are considered for a general discussion of the capability and limitation in high power plasma spraying.

  19. 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.

  20. 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.

  1. 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.

  2. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    NASA Astrophysics Data System (ADS)

    Cai, Yuxuan

    Superhydrophobic surfaces exhibit superior water repellent properties, and they have remarkable potential to improve current energy infrastructure. Substantial research has been performed on the production of superhydrophobic coatings. However, superhydrophobic coatings have not yet been adopted in many industries where potential applications exist due to the limited durability of the coating materials and the complex and costly fabrication processes. Here presented 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 and strong mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The as-sprayed coating demonstrated a hierarchically structured coating topography, which closely resembles superhydrophobic surfaces in nature. Compared to smooth REO surfaces, the SPPS superhydrophobic coating improved the water contact angle by as much as 65° after vacuum treatment at 1 Pa for 48 hours.

  3. 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.

  4. Influence of Plasma Instabilities in Ceramic Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Etchart-Salas, R.; Rat, V.; Coudert, J. F.; Fauchais, P.; Caron, N.; Wittman, K.; Alexandre, S.

    2007-12-01

    Direct current Suspension Plasma Spraying (SPS) allows depositing finely structured coatings. This article presents an analysis of the influence of plasma instabilities on the yttria-stabilized suspension drops fragmentation. A particular attention is paid to the treatment of suspension jet or drops according to the importance of voltage fluctuations (linked to those of the arc root) and depending on the different spray parameters such as the plasma forming gas mixture composition and mass flow rate and the suspension momentum. By observing the suspension drops injection with a fast shutter camera and a laser flash sheet triggered by a defined transient voltage level of the plasma torch, the influence of plasma fluctuations on jet or drops fragmentation is studied through the deviation and dispersion trajectories of droplets within the plasma jet.

  5. 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.

  6. Behavior of plasma-sprayed coatings

    NASA Technical Reports Server (NTRS)

    Berndt, Christopher C.

    1984-01-01

    The microstructural development of plasma sprayed oxide coatings is described with particualr reference to aluminum oxide coatings and thermal barrier coatings of yttria stabilized zirconia (YSZ). The microstructural features of these coatings, observed by optical and electron microscopy, are related to their mechanical behavior. The adhesion of the coatings is also investigated using fracture toughness and tensile tests. It is noted that acoustic emission is valuable in formulating possible fracture mechanisms for YSZ coatings.

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

    NASA Astrophysics Data System (ADS)

    Mohanty, Mahesh

    Titanium carbide-reinforced metallic coatings, produced by plasma spraying, can be used for sliding wear resistant applications. The sliding wear properties of such coatings are governed to a large extent by the strength, structure and stability of the bond interface between the carbide and the metallic phases. In the present investigation, the microstructure and sliding wear properties of plasma sprayed metal-bonded TiC coatings containing up to 90 v/o carbide have been studied. It was shown that alloying of the metallic phase improved carbide retention in TiC cermets due to better interface bonding, and increased wear resistance and lowered sliding coefficient of friction. TiC-based coatings were produced from both physically blended and synthesized feed powders. It was observed that the precursor TiC-based powder morphology and structure greatly affected the plasma sprayed coating microstructures and the resultant physical and mechanical characteristics. Physical blending of powders induced segregation during spraying, leading to somewhat lower deposit efficiencies and coating uniformity, while synthesized and alloyed titanium carbide/metal composite powders reduced problems of segregation and reactions associated with plasma spraying of physically blended powders where the TiC was in direct contact with the plasma jet. To understand oxidation effects of the environment, Ti and TiC-based coatings were produced under low pressure (VPS), air plasma (APS) and shrouded plasma sprayed conditions. APS Ti and TiC-based powders with reactive matrices suffered severe oxidation decomposition during flight, leading to poor deposition efficiencies and oxidized microstructures. High particle temperatures and cold air plasma spraying. Coating oxidation due to reactions of the particles with the surrounding air during spraying reduced coating hardness and wear resistance. TiC-with Ti or Ti-alloy matrix coatings with the highest hardness, density and wear resistance was 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.

  8. 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.

  9. 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.

  10. Plasma spraying of beryllium and beryllium-aluminum-silver alloys

    SciTech Connect

    Castro, R.G.; Stanek, P.W.; Elliott, K.E.; Jacobson, L.A.

    1993-12-31

    A preliminary investigation on plasma-spraying of beryllium and a beryllium-aluminum 4% silver alloy was done at the Los Alamos National Laboratory`s Beryllium Atomization and Thermal Spray Facility (BATSF). Spherical Be and Be-Al-4%Ag powders, which were produced by centrifugal atomization, were used as feedstock material for plasma-spraying. The spherical morphology of the powders allowed for better feeding of fine (<38 {mu}m) powders into the plasma-spray torch. The difference in the as-deposited densities and deposit efficiencies of the two plasma-sprayed powders will be discussed along with the effect of processing parameters on the as-deposited microstructure of the Be-Al-4%Ag. This investigation represents ongoing research to develop and characterize plasma-spraying of beryllium and beryllium-aluminum alloys for magnetic fusion and aerospace applications.

  11. 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.

  12. 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.

  13. Characteristic of a triple-cathode vacuum arc plasma source

    SciTech Connect

    Xiang, W.; Li, M.; Chen, L.

    2012-02-15

    In order to generate a better ion beam, a triple-cathode vacuum arc plasma source has been developed. Three plasma generators in the vacuum arc plasma source are equally located on a circle. Each generator initiated by means of a high-voltage breakdown between the cathode and the anode could be operated separately or simultaneously. The arc plasma expands from the cathode spot region in vacuum. In order to study the behaviors of expanding plasma plume generated in the vacuum arc plasma source, a Langmuir probe array is employed to measure the saturated ion current of the vacuum arc plasma source. The time-dependence profiles of the saturated current density of the triple vacuum arc plasma source operated separately and simultaneously are given. Furthermore, the plasma characteristic of this vacuum arc plasma source is also presented in the paper.

  14. 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.

  15. 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.

  16. Anisotropic microstructure of plasma-sprayed deposits

    NASA Astrophysics Data System (ADS)

    Ilavsky, J.; Long, G. G.; Allen, A. J.; Leblanc, L.; Prystay, M.; Moreau, C.

    1999-09-01

    The microstructure of plasma sprayed deposits (PSD) is dominated by two void systems—interlamellar pores and intralamellar cracks—each with a different anisotropy. Anisotropy of these void systems and varying crack-to-pore ratios within PSDs are responsible for the anisotropic properties observed within deposits. While it is difficult to apply standard porosity measurement techniques to the assessment of anisotropic microstructures, novel techniques utilizing different approaches have recently emerged. Image analysis (IA) of impregnated PSD samples is the most direct technique. The structure is stabilized by impregnation and then polished and imaged. The limitations of IA lie in the impregnation process and in the subsequent polishing. Also, the images produced from anisotropic materials can be difficult to interpret quantitatively. The technique of small-angle neutron scattering (SANS) has recently been applied to the study of PSDs. The major advantages of SANS are that it does not require sample preparation and that quantitative information can be obtained concerning the separate crack and pore systems, including their distinctive anisotropies. However, the relationship between the SANS results and the underlying structure is more complex and less intuitive than for IA, and the availability of the SANS technique is limited by the need to have access to a powerful neutron source, such as a reactor. Also, the two techniques present different views of the microstructure because of the different sensitivities in different parts of the size range. This article compares results from IA and SANS for a set of thick plasma-sprayed ceramic deposits possessing a range of crack/pore microstructures and discusses how the two techniques might complement one another.

  17. Comparison of plasma sprayed alumina and zirconia coatings by RF and DC plasma spraying

    SciTech Connect

    Bianchi, L.; Blein, F.; Lucchese, P.; Grimaud, A.; Fauchais, P.

    1994-12-31

    Low velocity plasma torches allow to spray bigger particles than conventional (CPT) dc plasma torches. For example, with fused and crushed alumina which size distribution is {minus}90 + 45 {micro}m, the deposition efficiency is about 40% with a CPT which nozzle internal diameter (i.d.) is 7 mm against more than 60% when using a 10 mm i.d. torch adapted to work with the same parameters. With the 10 mm i.d. nozzle the particle velocity is only 90 m/s against 130 m/s with the 7 mm i.d. nozzle. RF plasma torches allow to reach even low particle velocities (in the range 20--60 m/s). This paper compares plasma sprayed alumina and zirconia coatings realized with a RF plasma torch, a low velocity CPT and a CPT. Coating characterization (adhesion/cohesion, microhardness, density) are given for two substrate temperatures (75 C and 300 C) and for the three torches. It discusses the influence of particle velocity and substrate temperature on coatings thermomechanical properties.

  18. 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.

  19. Reactive plasma spraying of Al-Ti alloys

    SciTech Connect

    Entezarian, M.; Shanker, K.; Tsantrizos, P.G.; Allaire, F.; Immarigeon, J.P.; Drew, R.A.L.

    1995-12-31

    Reactive plasma spraying was used to synthesize Al alloys containing a dispersion of TiAl{sub 3} intermetallics. Either Al powder or Al wire and TiCl{sub 4} were the raw materials used. The size, distribution, and morphology of the intermetallic phase were a function of the injection manner of the starting materials, the plasma process parameters, and the molar ratio of the reactants (TiCl{sub 4}/Al). Under optimum conditions, a fine dispersion of micron sized intermetallics was obtained. Investigation of the reaction mechanism showed that the particle`s temperature was a critical factor in producing a fine dispersion of TiAl{sub 3} phase in an Al matrix. Materials produced at temperatures below the melting point of TiAl{sub 3} resulted in a microstructure containing an Al core with a TiAl{sub 3} shell. In contrast, materials produced at higher temperatures resulted in a fine TiAl{sub 3} phase precipitating from the Al-Ti melt during the solidification process. Products were collected as porous deposited layers whose surface was contaminated with chlorides. The products were subjected to purification followed by hot rolling for further consolidation. The effectiveness of vacuum thermal treatment on the removal of Cl was investigated. Al chlorides could be removed by thermal treatments at temperatures below the melting point of Al, while some of the Ti subchlorides required higher temperatures. The mechanical properties of the consolidated materials were also determined and are reported.

  20. Cathodic Vacuum Arc Plasma of Thallium

    SciTech Connect

    Yushkov, Georgy Yu.; Anders, Andre

    2006-10-02

    Thallium arc plasma was investigated in a vacuum arc ionsource. As expected from previous consideration of cathode materials inthe Periodic Table of the Elements, thallium plasma shows lead-likebehavior. Its mean ion charge state exceeds 2.0 immediately after arctriggering, reaches the predicted 1.60 and 1.45 after about 100 microsecand 150 microsec, respectively. The most likely ion velocity is initially8000 m/s and decays to 6500 m/s and 6200 m/s after 100 microsec and 150microsec, respectively. Both ion charge states and ion velocities decayfurther towards steady state values, which are not reached within the 300microsec pulses used here. It is argued that the exceptionally high vaporpressure and charge exchange reactions are associated with theestablishment of steady state ion values.

  1. 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.

  2. Creep of plasma sprayed zirconia. Final Report

    SciTech Connect

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

    1982-11-01

    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.

  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. 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.

  5. Characterization of YSZ solid oxide fuel cells electrolyte deposited by atmospheric plasma spraying and low pressure plasma spraying

    NASA Astrophysics Data System (ADS)

    Zhang, C.; Liao, H. L.; Li, W. Y.; Zhang, G.; Coddet, C.; Zhang, C.; Li, C. J.; Li, C. X.; Ning, X. J.

    2006-12-01

    Yttria doped zirconia has been widely used as electrolyte materials for solid oxide fuel cells (SOFC). Plasma spraying is a cost-effective process to deposit YSZ electrolyte. In this study, the 8 mol% Y2O3 stabilized ZrO2 (YSZ) layer was deposited by low pressure plasma spraying (LPPS) and atmospheric plasma spraying (APS) with fused-crushed and agglomerated powders to examine the effect of spray method and particle size on the electrical conductivity and gas permeability of YSZ coating. The microstructure of YSZ coating was characterized by scanning electron microscopy and x-ray diffraction analysis. The results showed that the gas permeability was significantly influenced by powder structure. The gas permeability of YSZ coating deposited by fused-crushed powder is one order lower in magnitude than that by agglomerated powder. Moreover, the gas permeability of YSZ deposited by LPPS is lower than that of APS YSZ. The electrical conductivity of the deposits through thickness direction was measured by potentiostat/galvanostat based on three-electrode assembly approach. The electrical conductivity of YSZ coating deposited by low pressure plasma spraying with fused-crushed powder of small particle size was 0.043 S cm-1 at 100 °C, which is about 20% higher than that of atmospheric plasma spraying YSZ with the same powder.

  6. 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.

  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. 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.

  9. Slurry and Plasma-spray Coating of Selective Emitting Rare-earth Oxides on High Temperature Resistant Substrates

    NASA Astrophysics Data System (ADS)

    Tobler, W. J.; Durisch, W.

    2007-02-01

    Selective emitting coatings of the rare-earth oxides Yb2O3 and Yb-doped garnet have been applied on SiC by slurry coating and on the high refractory intermetallic compound MoSi2 by vacuum plasma-spraying. The TPV emitters produced are fully operable in oxygen atmosphere at high temperatures > 1500 °C. The novel technique of pairing MoSi2 substrate with plasma-sprayed rare-earth oxide results in highly thermal shock stable emitters due to an ideal match of the thermal expansion coefficients of intermetallic compound and ceramics.

  10. Plasma sprayed Fe(76)Nd(16)B(8) permanent magnets

    NASA Technical Reports Server (NTRS)

    Overfelt, R. A.; Anderson, C. D.; Flanagan, W. F.

    1986-01-01

    Thin coatings (0.16 mm) and thick coatings (0.50 mm) of Fe(76)Nd(16)B(8) were deposited on stainless-steel substrates by low pressure plasma spraying. Microscopic examination of the coatings in a light microscope revealed excessive porosity, but good bonding to the substrate. Fracture cross sections examined in a scanning electron microscope showed the grains to be equiaxed and approximately 1 micron or less in diameter in the as-sprayed condition. The intrinsic coercivities of the as-sprayed coatings varied from 5.8 to 10.9 kOe. The effects of postspray heat treatments on the intrinsic coercivity are also given.

  11. 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.

  12. 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.

  13. 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.

  14. 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).

  15. 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.

  16. Properties of plasma-sprayed freestanding ceramic parts

    NASA Astrophysics Data System (ADS)

    Neufuss, K.; Chráska, P.; Kolman, B.; Sampath, S.; Trávnícek, Z.

    1997-12-01

    Plasma spraying can be used for the production of freestanding parts, such as plates, pipes, and crucibles. However, published data on the properties of such freestanding bodies are scarce. White alumina, gray alumina, zircon, and their combinations were plasma sprayed on metallic mandrels using a water-stabi-lized plasma gun and then stripped off. The resulting tubes were tested for gas permeability, porosity, and elastic properties. Pipes also were made from a mixture of ceramic and aluminum metal powders, and from “sandwich” bodies consisting of ceramic/metal/ceramic layers. Comparison of as-sprayed samples and samples after various posttreatments showed that posttreatments (i.e., sealing with organic and in-organic compounds or with metals, sol-gel technique, calcination, etc.) generally decreases gas perme-ability and increases elastic properties.

  17. Plasma spray synthesis from precursors: Progress, issues, and considerations

    NASA Astrophysics Data System (ADS)

    Ravi, B. G.; Sampath, S.; Gambino, R.; Parise, J. B.; Devi, P. S.

    2006-12-01

    Precursor plasma spray synthesis is an innovative and rapid method for making functional oxide ceramic coatings by starting from solution precursors and directly producing inorganic films. This emerging method utilizes molecularly mixed precursor liquids, which essentially avoids the handling and selection of powders, opening up new avenues for developing compositionally complex functional oxide coatings. Precursor plasma spray also offers excellent opportunities for exploring the nonequilibrium phase evolution during plasma spraying of multicomponent oxides from inorganic precursors. Although there have been efforts in this area since the 1980s and early 1990s with the goal of synthesizing nanoparticles, only recently has the work progressed in the area of functional systems. At the Center for Thermal Spray Research an integrated investigative strategy has been used to explore the benefits and limits of this synthesis strategy. Water- and alcohol-based sol/solution precursors derived from various chemical synthesis methods were used as feedstocks to deposit thin/thick films of spherical and nanostructured coatings of yttrium aluminum garnet (YAG), yttrium iron garnet, lanthanum strontium manganate and Zr-substituted yttrium titanates, and compositions of Y2O3-Al2O3 and their microstructural space centered around stoichiometric YAG. A detailed discussion of the salient features of the radiofrequency induction plasma spraying approach, the results obtained in the investigations to develop various functional oxide coatings, and process issues and challenges are presented.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. Plasma spray gun having gas vortex producing nozzle

    SciTech Connect

    Smyth, R.T.; Zatorski, R.A.

    1985-03-19

    A plasma flame spray gun suitable for being constructed physically smaller than comparable power prior art plasma flame spray guns. The gun includes a nozzle having a tapering portion on the inlet side thereof. A cathode with a flat tip is positioned to at least partially extend into the tapering portion of the nozzle. A gas distribution ring is located around the cathode for creating a vortex around the cathode tip. This causes the arc formed between the tip and the nozzle to have a root which spins around the perimeter of the nozzle tip resulting in less wear and, therefore, extended part life.

  3. 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)

    Mat?j?ek, J.; Kavka, T.; Bertolissi, G.; Ctibor, P.; Vilmov, M.; Mulek, R.; Nevrl, 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.

  4. 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

  5. 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

  6. 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 plasma spray jet.

  7. 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.

  8. 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.

  9. 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.

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

    SciTech Connect

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

    1983-09-01

    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.

  11. 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.

  12. 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.

  13. 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.

  14. 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

  15. 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.

  16. 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.

  17. 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.

  18. Functionally Graded Materials using Plasma Spray with Nano Structured Ceramic

    NASA Astrophysics Data System (ADS)

    Sioh, E. L.; Tok, A. I. Y.

    2013-03-01

    In this paper, nano structured FGM was fabricated using DC plasma spray technique. Nano structured and micro structured powder were used as the feeding powder with steel substrate. The spray parameters was optimized and characterisation of nano-ceramic FGM and micro-ceramic FGM were done using bending test and micro-hardness test. Experimental results have shown that the nano-structured FGM exhibit 20% improvement flexure strength and 10% in hardness. A comparison was made between sintered micro ceramic tile and nano ceramic FGM using simple drop test method.

  19. The properties and fracture behavior of ion plasma sprayed TiN coating on stainless steel substrate

    NASA Astrophysics Data System (ADS)

    Orlova, Dina V.; Goncharenko, Igor M.; Danilov, Vladimir I.; Lobach, Maxim I.; Danilova, Lidiya V.; Shlyakhova, Galina V.

    2015-10-01

    The wear resistance and fracture behavior of ion plasma sprayed TiN coating were studied; the results are presented. The coating was applied to the stainless steel substrate using a vacuum arc method. The samples were tested by active loading. With varying coating thickness, its characteristics were found to change. Multiple cracking would occur in the deformed sample, with fragment borders aligned normal to the extension axis.

  20. Simulation of Motion, Heating, and Breakup of Molten Metal Droplets in the Plasma Jet at Plasma-Arc Spraying

    NASA Astrophysics Data System (ADS)

    Kharlamov, M. Yu.; Krivtsun, I. V.; Korzhyk, V. N.; Ryabovolyk, Y. V.; Demyanov, O. I.

    2015-04-01

    The mathematical model for the process of plasma-arc wire spraying is proposed, which describes behavior of molten metal droplets in the plasma jet, allowing for the processes of their deformation and gas-dynamic breakup. Numerical analysis of the processes of motion, heating, and breakup of molten metal droplets, detached from the sprayed wire at plasma-arc spraying of coatings, was performed. It is shown that during molten droplets movement in the plasma jet their multiple breakup takes place, leading to formation of sprayed particles with dimensions much smaller than dimensions of initial droplets, detached from the sprayed wire tip.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. Suspension Plasma Spraying of YPSZ Coatings: Suspension Atomization and Injection

    NASA Astrophysics Data System (ADS)

    Rampon, Régine; Filiatre, Claudine; Bertrand, Ghislaine

    2008-03-01

    Among processes evaluated to produce some parts of or the whole solid-oxide fuel cell, Suspension Plasma Spraying (SPS) is of prime interest. Aqueous suspensions of yttria partially stabilized zirconia atomized into a spray by an internal-mixing co-axial twin-fluid atomizer were injected into a DC plasma jet. The dispersion and stability of the suspensions were enhanced by adjusting the amount of dispersant (ammonium salt of polyacrylic acid, PAA). A polyvinyl alcohol (PVA) was further added to the suspension to tailor its viscosity. The PVA also improved the dispersion and stability of the suspensions. The atomization of optimized formulations is described implementing Weber and Ohnesorge dimensionless numbers as well as gas-to-liquid mass ratio (ALR) value. Drop size distributions changed from monomodal distributions at low We to multimodal distributions when We number increases. The viscosity of the suspensions has a clear influence on the drop size distribution and suspension spray pattern. The secondary fragmentation of the drops due to the plasma jet was evidenced and the final size of the sheared drops was shown to depend on the characteristics of the suspension. Rather dense zirconia coatings have been prepared, which is a promising way to produce electrolyte.

  8. 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.

  9. 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.

  10. 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.

  11. Residual stress in plasma sprayed ceramic turbine tip and gas path seal specimens

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

    The residual stresses in a ceramic sheet material used for turbine blade tip gas path seals, were estimated. These stresses result from the plasma spraying process which leaves the surface of the sheet in tension. To determine the properties of plasma sprayed ZrO2-Y2O3 sheet material, its load deflection characteristics were measured. Estimates of the mechanical properties for sheet materials were found to differ from those reported for plasma sprayed bulk materials.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. 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.

  19. 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.

  20. The measurement of single particle temperature in plasma sprays

    SciTech Connect

    Fincke, J.R.; Swank, W.D. ); Bolsaitis, P.P.; Elliott, J.F. )

    1990-01-01

    A measurement technique for simultaneously obtaining the size, velocity, temperature, and relative number density of particles entrained in high temperature flow fields is described. In determining the particle temperature from a two-color pyrometery technique, assumptions about the relative spectral emissivity of the particle are required. For situations in which the particle surface undergoes chemical reactions the assumption of grey body behavior is shown to introduce large Temperature measurement uncertainties. Results from isolated, laser heated, single particle measurements and in-flight data from the plasma spraying of WC-Co are presented. 10 refs., 5 figs.

  1. Plasma-sprayed lead zirconate titanate-glass composites

    SciTech Connect

    Sherrit, S.; Savin, C.R.; Wiederick, H.D.; Mukherjee, B.K. . Dept. of Physics); Prasad, S.E. )

    1994-07-01

    A plasma-spray process was used to produce piezoelectric lead zirconate titanate (PZT)-glass composite thick films. The films were found to have the same crystal structure as the PZT (Navy-type V) and lead-based glass starting powder mixture. The films showed good adhesion to stainless steel and silver-coated glass slides and poor adhesion to aluminum substrates. The dielectric constant of the films varied between 58 and 20 with dissipations between 0.019 and 0.032. The films were poled, and their piezoelectric charge coefficient, d[sub 33], was 1.1 pC/N.

  2. 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.

  3. An interchangeable-cathode vacuum arc plasma source.

    PubMed

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

    2010-01-01

    A simplified vacuum arc design [based on metal vapor vacuum arc (MeVVA) concepts] is employed as a plasma source for a study of a (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(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. PMID:20113100

  4. Titanium oxide thin film deposition by pulsed arc vacuum plasma

    NASA Astrophysics Data System (ADS)

    Zhirkov, I. S.; Paternoster, C.; Delplancke-Ogletree, M. P.

    2011-01-01

    The experimental study of effects of deposition conditions and plasma parameters on the structure of titanium oxide films is presented. The films are deposited by reactive deposition from a plasma generated by a pulsed cathodic vacuum arc source. The effects of deposition time and substrate bias voltage are studied, the films being deposited at different substrate temperatures. Bragg-Brentano X-ray diffraction and electron microscopy were used to investigate the structure of deposited films. Correlation between plasma parameters, deposition conditions and structure of synthesized films are established.

  5. Optimizing the thermal conductivity of plasma-sprayed beryllium coatings for fusion applications

    SciTech Connect

    Castro, R.G.; Stanek, P.W.; Cotton, J.D.

    1994-12-31

    Plasma-spraying of beryllium is currently under investigation as a potential coating technique for regenerating damaged beryllium surfaces in the divertor region of ITER. Investigations to optimize the thermal conductivity of plasma-sprayed beryllium coatings are currently being performed at the Los Alamos National Laboratory`s Beryllium Atomization and Thermal Spray Facility (BATSF). Parametric studies are being done to evaluate the effects of processing conditions to minimize the splat morphology present in the beryllium plasma-sprayed deposits. Earlier investigations have shown that this splat morphology, which is characteristic of plasma-sprayed coatings, contains incomplete bonding between individual splat layers which reduces the thermal conductivity of the beryllium spray deposits. Thermal conductivity of plasma-sprayed beryllium which is on the order of 70 W/m{sm_bullet}K is only one-third that of hot pressed beryllium block. Results will be presented on the effects of hydrogen gas addition to the plasma spray torch, higher substrate temperatures and the use of a low velocity laminar flow nozzle to improve the as-deposited density and thermal conductivity of the beryllium plasma-sprayed deposits.

  6. Characterization of the WC coatings deposited by plasma spraying

    NASA Astrophysics Data System (ADS)

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

    2015-06-01

    Tungsten monocarbide (WC) is deposited using a plasma jet on the martensitic noncorrosive steel support (Z12CNDV12), in three different thicknesses.The characteristics of the coatings are determined by: its chemical composition, optical microscopy, RX analysis, tensile adhesion strength, Vickers hardness, the nature and the processing degree of the substrate and the deposition conditions.The method used for determining the behaviour in a corrosive environment of the WC coatings deposited by plasma spraying consists in measuring the electrochemical potential difference between the coating and the substrate, which are immersed in a solution containing NaCl as a corrosive agent. The experimental results are then mathematically processed in order to determine a law and the mechanisms involved.

  7. 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

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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

  13. 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

  14. Observations of plasma dynamics in the vacuum spark

    SciTech Connect

    Chuaqui, H.; Favre, M.; Wyndham, E.S.; Aliaga Rossel, R.; Mitchell, I.; Soto, L.

    1995-10-01

    Experimental observations are presented of a vacuum spark driven by a low impedance pulse forming line delivering 100 kA to the load. A pulsed laser is used to form a preionizing plasma on the cathode. The combination of axial and radial optical streak camera observations, together with the time and space resolved soft x-ray emission, permit the evolution of the plasma dynamics, density and temperature to be measured. Three kinds of behavior are observed according to axial position. A close correlation is found between the x-ray and the optical emission, with the observation of micropinch formation. A discussion is presented in which the behavior of the vacuum spark under differing operating conditions is compared. {copyright} {ital 1995} {ital American} {ital Institute} {ital of} {ital Physics}.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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 scratching.

  20. 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.

  1. Residual stresses determination in textured substrates for plasma sprayed coatings

    NASA Astrophysics Data System (ADS)

    Capek, J.; Pala, Z.; Kovarik, O.

    2015-04-01

    In this contribution, we have striven to respond to the desire of obtaining the residual stress tensor in the both cold-rolled and hot-rolled substrates designated for deposition of thermal coatings by plasma spraying. Residual stresses play an important role in the coating adhesion to the substrate and, as such, it is a good practice to analyse them. Prior to spraying, the substrate is often being grit blasted. Residual stresses and texture were quantitatively assessed in both virgin and grit blasted sample employing three attitudes. Firstly without taking preferred orientation into account, secondly from measurements of interplanar lattice spacings of planes with high Miller indices using MoKα radiation. And eventually, by calculating anisotropic elastic constants as a weighted average between single-crystal and X-ray elastic constants with weighting being done according to the amount of textured and isotropic material in the irradiated volume. In the ensuing verification analyses, it was established that the latter approach is suitable for materials with either very strong or very weak presence of texture.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. Electron beam melting at high pressures with a vacuum separator/plasma lens

    SciTech Connect

    Hershcovitch, A.

    1995-12-31

    Plasmas can be used to provide a vacuum-atmosphere interface or separation between vacua regions as an alternative to differential pumping. Vacuum-atmosphere interface utilizing a cascade arc discharge was successfully demonstrated and a 175 keV electron beam was successfully propagated from vacuum through such a plasma interface and out into atmospheric pressure. This plasma device also functions as an effective plasma tens. Such a device can be adopted for use in electron beam melting.

  7. Plasma Spray-CVD: A New Thermal Spray Process to Produce Thin Films from Liquid or Gaseous Precursors

    NASA Astrophysics Data System (ADS)

    Gindrat, M.; Höhle, H.-M.; von Niessen, K.; Guittienne, Ph.; Grange, D.; Hollenstein, Ch.

    2011-06-01

    New dedicated coating processes which are based on the well-known LPPS™ technology but operating at lower work pressure (100 Pa) are being actively developed. These hybrid technologies contribute to improve the efficiencies in the turbine industry such as aero-engines and land-based gas turbines. They also have a great potential in the domain of new energy concepts in applications like Solid Oxide Fuel Cells, membranes, and photovoltaic with the adoption of new ways of producing coatings by thermal spray. Such processes include Plasma Spray-Thin Film (PS-TF) which gives the possibility to coat thin and dense layers from splats through a classical thermal spray approach but at high velocities (400-800 m/s) and enthalpy (8000-15000 kJ/kg). Plasma Spray-PVD (PS-PVD) which allows producing thick columnar-structured Thermal Barrier Coatings (100-300 μm) from the vapor phase with the employment of the high enthalpy gun and specific powder feedstock material. On the other hand, the Plasma Spray-CVD (PS-CVD) process uses modified conventional thermal spray components operated below 100 Pa which allows producing CVD-like coatings (<1-10 μm) at higher deposition rates using liquid or gaseous precursors as feedstock material. The advantages of such thermal spray-enhanced CVD processes are the high ionization degree and high throughput for the deposition of thin layers. In this article, we present an overview of the possibilities and limitations encountered while producing thin film coatings using liquid and gaseous precursors with this new type of low pressure plasma spray equipment and point out the challenges faced to obtain efficient injection and mixing of the precursors in the plasma jet. In particular, SiO x thin films from Hexamethyldisiloxane (HMDSO or C6H18OSi2) can be deposited on wafers at deposition rates of up to 35 nm/s at an efficiency of about 50%. The process was also used for producing metal oxide coatings (Al2O3, ZnO, and SnO2) by evaporating different metals in combination with an oxygen gas flow. The effect of process parameters on the deposition rate, coating build up, uniformity, and quality of the coatings are discussed. An overview of different potential applications of this new technology will be also presented.

  8. Residual stress in plasma-sprayed ceramic turbine tip and gas-path seal specimens

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

    The residual stresses in a ceramic sheet material used for turbine blade tip gas path seals, were estimated. These stresses result from the plasma spraying process which leaves the surface of the sheet in tension. To determine the properties of plasma sprayed ZrO2-Y2O3 sheet material, its load deflection characteristics were measured. Estimates of the mechanical properties for sheet materials were found to differ from those reported for plasma sprayed bulk materials. Previously announced in STAR as N83-28380

  9. Metal supported tubular solid oxide fuel cells fabricated by suspension plasma spray and suspension high velocity oxy-fuel spray

    NASA Astrophysics Data System (ADS)

    Yoo, Yeong; Wang, Youliang; Deng, Xiaohua; Singh, Devinder; Legoux, Jean-Gabriel

    2012-10-01

    Low temperature (LT) metal supported solid oxide fuel cells (SOFCs) have many advantages in comparison to conventional electrode or electrolyte supported type SOFCs. NRC has demonstrated high performance LT metal supported planar SOFCs fabricated by either wet colloidal spray/sintering or suspension thermal spray. The combination of tubular configuration and metal supported SOFCs may produce more unique and very attractive advantages such as easy and inexpensive sealing method and materials, high specific and volumetric power density, cost-effective fabrication, enhanced robustness, rapid start up, red-ox cycle tolerance and potential use for a pressurized integrated system. In this paper, thin film solid electrolyte of Sm0.2Ce0.8O1.90 (SDC) and NiO-SDC composite anode on sintered porous tubular metal supports were deposited by suspension HVOF spray and suspension plasma spray, respectively on sintered porous tubular metal support. La0.6Sr0.4Co0.2Fe0.8O3-δ (LSCF) cathode on the SDC electrolyte was formed by wet colloidal spray and subsequent sintering process as the final fabrication step. The detailed investigation of suspension and process-related parameters for suspension thermal spray was performed in order to produce thin and crack-free SDC thin film coatings. The electrochemical performance of single cells was demonstrated.

  10. Liquid Precursor Plasma Spraying of Functional Materials: A Case Study for Yttrium Aluminum Garnet (YAG)

    NASA Astrophysics Data System (ADS)

    Ravi, B. G.; Gandhi, Ashutosh S.; Guo, X. Z.; Margolies, J.; Sampath, S.

    2008-03-01

    RF precursor plasma spray synthesis (RFPPS) is an innovative and rapid technique to deposit functional oxide coatings by starting from liquid inorganic precursors and directly producing ceramic coatings. RFPPS offers excellent opportunities in exploring the nonequilibrium phase evolution during plasma spraying of molecularly mixed precursors to form multicomponent oxides. A detailed discussion of progress, critical issues and consideration in precursor development, RF plasma spraying, coating development, and phase evolution of yttrium aluminum garnet (YAG) is presented as a case study. Appropriate selection of precursors and proper tuning of spray parameters resulted in amorphous or crystalline coatings in the as-sprayed condition. YAG phase selection has also been investigated using a discrete, low-density combinatorial synthesis approach.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. Diagnostic Development and Process Correlation of the Plasma Spray Process for Magnetic Confinement Fusion Applications.

    NASA Astrophysics Data System (ADS)

    Hollis, Kendall Jon

    1995-01-01

    The need in present and future nuclear fusion reactors for a method of fabricating and repairing plasma facing components has been a significant problem slowing the progress of research in the fusion community. The plasma spraying technique has been proposed for first wall and divertor fabrication and/or repair. However, consistently producing coatings with thermal conductivities suited for fusion applications requires further research and development. Methods for modeling heat transfer through plasma-sprayed coatings and measuring the temperature of plasma-sprayed particles in flight have been developed. The effect of particle temperature, particle velocity, and substrate temperature on the pore structure of plasma-sprayed coatings was also studied. The effect of pores on the thermal conductivity of plasma-sprayed coatings was investigated. Finite element models of the actual pore structure observed in the coatings gave estimates of the coating thermal conductivity. Comparison of the calculated thermal properties to measured thermal properties of the same coatings show that the pore structure is the major factor decreasing the thermal conductivity of the plasma-sprayed coatings investigated. The use of optical pyrometry for particle surface temperature measurement has inherent uncertainties due to non-thermal emission signals in the plasma/particle plume. Measurements of the non-thermal signals present have been made. The measurements help to define a method for subtracting the non-thermal signal from the raw data to improve the accuracy of particle temperature calculations. The effect of particle temperature, velocity, and substrate temperature on the long thin type of porosity in plasma-sprayed coatings was investigated. The particle temperature and velocity were found to change very little over the range investigated leading to the conclusion that they have little effect on the coating pore structure. However, the substrate temperature during spraying was found to decrease the amount of long thin porosity as substrate temperatures increased. The tools developed for this work can be used for future investigations to increase the fundamental knowledge of plasma spraying and plasma-sprayed coatings. Such future work is critical to the success of plasma-sprayed coatings for use in fusion energy applications.

  17. Dynamic Model of the Wire Dispersion Process in Plasma-Arc Spraying

    NASA Astrophysics Data System (ADS)

    Kharlamov, M. Yu.; Krivtsun, I. V.; Korzhyk, V. N.

    2014-02-01

    The dynamic mathematical model is suggested, describing the jet flow of a molten wire material and formation of droplets, i.e. spraying particles, under conditions of plasma-arc wire spraying. Numerical analysis of the processes of formation and detachment of droplets was carried out, and the effect of spraying parameters on the above processes was investigated. It was shown that the size and interval of detachment of the droplets strongly depend on the diameter and feed speed of the anode wire being sprayed, as well as on the plasmatron operation mode.

  18. 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.

  19. 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.

  20. Visual and Electrical Evidence Supporting a Two-Plasma Mechanism of Vacuum Breakdown Initiation

    SciTech Connect

    Castano-Giraldo, C.; Aghazarian, Maro; Caughman, John B; Ruzic, D. N.

    2012-01-01

    The energy available during vacuum breakdown between copper electrodes at high vacuum was limited using resistors in series with the vacuum gap and arresting diodes. Surviving features observed with SEM in postmortem samples were tentatively correlated with electrical signals captured during breakdown using a Rogowski coil and a high-voltage probe. The visual and electrical evidence is consistent with the qualitative model of vacuum breakdown by unipolar arc formation by Schwirzke [1, 2]. The evidence paints a picture of two plasmas of different composition and scale being created during vacuum breakdown: an initial plasma made of degassed material from the metal surface, ignites a plasma made up of the electrode material.

  1. 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-speed videos captured cathode spot motion showing that the cathode spot had preferred attachment points at the cathode edge. Photographs show uneven cathode erosion at the edge, a deposited layer of cathode material on the anode and insulator, and large macroparticles.

  2. 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.

  3. 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.

  4. The spray-drying process is sufficient to inactivate infectious porcine epidemic diarrhea virus in plasma.

    PubMed

    Gerber, Priscilla F; Xiao, Chao-Ting; Chen, Qi; Zhang, Jianqiang; Halbur, Patrick G; Opriessnig, Tanja

    2014-11-01

    Porcine epidemic diarrhea virus (PEDV) is considered an emergent pathogen associated with high economic losses in many pig rearing areas. Recently it has been suggested that PEDV could be transmitted to naïve pig populations through inclusion of spray-dried porcine plasma (SDPP) into the nursery diet which led to a ban of SDPP in several areas in North America and Europe. To determine the effect of spray-drying on PEDV infectivity, 3-week-old pigs were intragastrically inoculated with (1) raw porcine plasma spiked with PEDV (RAW-PEDV-CONTROL), (2) porcine plasma spiked with PEDV and then spray dried (SD-PEDV-CONTROL), (3) raw plasma from PEDV infected pigs (RAW-SICK), (4) spray-dried plasma from PEDV infected pigs (SD-SICK), or (5) spray-dried plasma from PEDV negative pigs (SD-NEG-CONTROL). For the spray-drying process, a tabletop spray-dryer with industry-like settings for inlet and outlet temperatures was used. In the RAW-PEDV-CONTROL group, PEDV RNA was present in feces at day post infection (dpi) 3 and the pigs seroconverted by dpi 14. In contrast, PEDV RNA in feces was not detected in any of the pigs in the other groups including the SD-PEDV-CONTROL group and none of the pigs had seroconverted by termination of the project at dpi 28. This work provides direct evidence that the experimental spray-drying process used in this study was effective in inactivating infectious PEDV in the plasma. Additionally, plasma collected from PEDV infected pigs at peak disease did not contain infectious PEDV. These findings suggest that the risk for PEDV transmission through commercially produced SDPP is minimal. PMID:25281254

  5. Suspension and solution plasma spraying of finely structured layers: potential application to SOFCs

    NASA Astrophysics Data System (ADS)

    Fauchais, P.; Etchart-Salas, R.; Delbos, C.; Tognonvi, M.; Rat, V.; Coudert, J. F.; Chartier, T.

    2007-04-01

    Suspension direct current plasma spraying allows achieving finely structured coatings whose thickness is between few tens and few hundreds of micrometres. Drops (200-300 µm in diameter) or liquid jets are mechanically injected in the plasma jet. With radial injection they are rapidly (a few µs) fragmented into droplets (a few µm in diameter). The latter are vaporized (in a few µs) and the solid particles contained in suspension droplets are accelerated and melted by the plasma jet. As in conventional plasma spraying (CPS), much smaller splats (with diameters between 0.2 and 3 µm and thicknesses between 30 and 200 nm) are arranged in layers up to form the coating. The low inertia of particles requires spray distances between 40 and 60 mm which induces plasma heat fluxes up to 22 MW m-2 participating in coating densification. Even more than in CPS, the plasma jet fluctuations, particularly for plasmas containing di-atomic gases, perturb drops penetration and fragmentation. It has been chosen to illustrate difficulties and possibilities of this new method, through the spraying of the three layers of an element of solid oxide fuel cells. Indeed, it requires a dense stabilized zirconia electrolyte, if possible thin (15-20 µm) with two porous electrodes: cathode made of perovskite prone to decomposing upon spraying and anode made of two materials (nickel and zirconia) with very different melting points. These components were obtained by spraying ethanol suspensions, with, first, LaMnO3 perovskite particles doped with 10 mol% of MnO2 and 3 µm in mean diameter sprayed with pure argon to limit their decomposition and achieve porous coatings, second, Yttria (13 wt%) stabilized zirconia (YSZ) with two different particle size distributions and morphologies for which plasma compositions were adapted, producing in both cases 15 µm thick and fully dense coatings, third, porous Raneigh nickel by co-spraying the YSZ suspension and solution of nickel nitrate.

  6. 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.

  7. 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.

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

    NASA Astrophysics Data System (ADS)

    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.

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

    PubMed

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

    2012-02-01

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

  11. Making NiTi intermetallic compound coating using laser plasma complex spraying

    SciTech Connect

    Hiraga, Hitoshi; Inoue, Takashi; Matsunawa, Akira

    1996-12-31

    To improve the erosion resistance of the Ti-alloys, surface modification technique using complex spraying system coupled with a high power CO{sub 2} laser and a DC plasma gun was applied. The laser plasma complex spraying system (LPCS) was constructed with 5kW CO{sub 2} laser and low pressure DC plasma spraying unit. In this system, the plasma spray coated layer was remelted and rapidly solidified by the CO{sub 2} laser irradiation. So, it is possible to synthesize intermetallic compound coatings from the simply mixed powder. NiTi intermetallic compound is known as a high cavitation erosion resistant material. In a case of only plasma spraying process, Ti and Ni layer were separated mutually in the coatings, but by the laser plasma complex spraying, NiTi, NiTi{sub 2}, and Ni{sub 3}Ti intermetallic compounds were formed in the coatings. And the coatings were joined metallurgically with substrate and contained few defect. The ratio of phases such as NiTi, NiTi{sub 2}, and Ni{sub 3}Ti was varied with the laser irradiation conditions and powder mixed ratio. To evaluate the erosion resistance of the coatings, vibratory cavitation erosion tests were carried out. The cavitation erosion resistance of the coatings were about 20 times as much as Ti6Al4V substrate due to NiTi phase.

  12. 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.

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

    SciTech Connect

    Lee, K.N.; Miller, R.A.; Jacobson, N.S.

    1995-03-01

    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.

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. Application of plasma spray deposited coatings for seawater activated batteries

    NASA Astrophysics Data System (ADS)

    Tamulevičius, S.; Dargis, R.

    Seawater activated batteries based on Mg and Ni/Al electrodes were constructed and investigated at different electrolyte temperatures. The Ni/Al coatings which were applied as the cathodes for seawater activated batteries were produced by plasma spray deposition. Voltage-time ( U= E- IR( t)) dependence was measured for the galvanic pair Mg-Ni/Al, where I was constant current, E the electromotive force of the galvanic pair and R( t) the variable resistance. It was found that U( t) inclination depends on the anode corrosion rate, and the mass of the anode is the only parameter that restricts the life time of the seawater activated cell. The current density of this cell was found to be a linear function of the temperature of the seawater. Output power density dependence on the spacing between electrodes and number of cells was investigated for cells with different electrode area. A maximum output power density of 3×10 4 W/m 3 was obtained for these cells.

  19. 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.

  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. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. Ion energy distribution functions of vacuum arc plasmas

    SciTech Connect

    Byon, Eungsun; Anders, Andre

    2002-09-16

    The velocity distribution function of vacuum arc ions can be measured by a time-of-flight technique similar to a method originally proposed by Yushkov. The measuring principle makes use of the well-justified assumption that the ion drift velocity from the cathode spot region to a collector is approximately constant. It is shown that the negative time derivative of the collector current is directly proportional to the ion distribution function provided that the time-averaged source intensity (i.e., emission of ions from cathode spots) is constant until the arc is rapidly switched off. In the experiment, arc termination took about 700 ns, which is much faster than the decay of the ion current measured at the collector placed in more than 2 meters distance from the cathode. The experimental distribution functions for most cathode materials show one large peak with a tail and one or more small peaks at higher ion velocities. The distribution functions for some other materials exhibit several peaks. No conclusive answer can be given about the nature of these peaks. Arguments are presented that the peaks are not caused by different charge states or plasma contamination but rather due to insufficiently averaged source fluctuations and/or acceleration by plasma instabilities.

  9. 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.

  10. Control of interparticle cohesion in PS304 plasma spray deposited solid lubricant coating powder feedstock

    NASA Astrophysics Data System (ADS)

    Stanford, Malcolm Keith

    The effects of eutectic barium fluoride - calcium fluoride particle morphology, particle size, size distribution and relative humidity level on PS304 powder feedstock flowability have been investigated in an effort to optimize the plasma spray deposition process. The eutectic fluorides were fabricated by comminution (angular particle morphology) and by gas atomization (spherical particle morphology). The angular fluorides were classified by screening to obtain 38--45mum, 45--106mum, 63--106mum, 45--53mum, 63--75mum and 90--106mum particle size distributions and the spherical fluorides were screened to obtain 45--106mum particles. The fluorides were added incrementally to the other powder constituents of the PS304 feedstock: nichrome, chromia, and silver powders. A linear relationship between feedstock flow rate and concentration of the fluorides was found from 0--10wt% using a Hall flowmeter. For the angular fluorides, the flow rate of the feedstock decreased linearly with increasing fluoride concentration. Flow of feedstock containing spherical fluorides was independent of fluoride concentration. Flow was degraded with decreasing fluoride particle size and with increasing particle size distribution due to interparticle friction. The angle of repose was distinct with respect to physical properties of the fluorides. The Hausner Ratio was less sensitive, though these data behaved predictably. Feedstock containing 10wt% 45--53mum and 90--106mum angular fluorides and 45--106mum angular and spherical fluorides were dried in a vacuum oven and cooled to room temperature under dry nitrogen. The flow of these powders was studied from 2--100% relative humidity (RH). The flow rate was only slightly degraded with increasing humidity below 66%RH, and a greater effect was apparent above 66%RH. No flow was observed above 88%RH for feedstock containing 45--106mum fluorides. The feedstock with narrower fluoride particle size distributions allowed flow up to 95%RH. These results offer guidance that enhances the efficiency of the plasma spray deposition process and the commercial potential for this material system and may have applicability to other powders that do not flow easily, such as cohesive ceramics.

  11. 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.

  12. Bond Characterization of Plasma Sprayed Zirconium on Uranium Alloy by Microcantilever Testing

    NASA Astrophysics Data System (ADS)

    Hollis, K. J.; Mara, N. A.; Field, R. D.; Wynn, T. A.; Crapps, J. M.; Dickerson, P. O.

    2013-03-01

    The future production of low enriched uranium nuclear fuel for test reactors requires a well-adhered diffusion barrier coating of zirconium (Zr) on the uranium/molybdenum (U-Mo) alloy fuel. In this study, the interfacial bond between plasma sprayed Zr coatings and U-Mo fuel was characterized by microcantilever beam testing. Test results revealed the effect of specific flaws such as cracks and pores on the bonding of interfaces with a sampling area of approximately 20 μm2. TEM examination showed the Zr/U-Mo interface to contain rows of very fine grains (5-30 nm) with the Zr in contact with UO2. Bond characteristics of plasma sprayed samples were measured that are similar to those of roll bonded samples showing the potential for plasma sprayed Zr coatings to have high bond strength.

  13. 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.

  14. 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.

  15. Mechanical Properties and Microstructure of Plasma Sprayed Ni-Based Metallic Glass Coating

    NASA Astrophysics Data System (ADS)

    Kobayashi, Akira; Kuroda, Toshio; Kimura, Hisamichi; Inoue, Akihisa

    2010-10-01

    Various developmental research works on the metallic glass have been conducted in order to broaden its application field. Thermal spraying method is one of the potential techniques to enhance the excellent properties such as high toughness and corrosion resistance of the metallic glass material. The gas tunnel type plasma spraying is useful to obtain high quality ceramic coatings such as Al2O3 and ZrO2 coatings. In this study, the Ni-based metallic glass coatings were produced by the gas tunnel type plasma spraying under various experimental conditions, and their microstructure and mechanical properties were investigated. At the plasma current of 200-300 A, the Ni-based metallic glass coatings of more than 200 μm in thickness were formed densely with Vickers hardness of about Hv = 600.

  16. 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.

  17. Mechanical Properties and Microstructure of Plasma Sprayed Ni-Based Metallic Glass Coating

    SciTech Connect

    Kobayashi, Akira; Kuroda, Toshio; Kimura, Hisamichi; Inoue, Akihisa

    2010-10-13

    Various developmental research works on the metallic glass have been conducted in order to broaden its application field. Thermal spraying method is one of the potential techniques to enhance the excellent properties such as high toughness and corrosion resistance of the metallic glass material. The gas tunnel type plasma spraying is useful to obtain high quality ceramic coatings such as Al{sub 2}O{sub 3} and ZrO{sub 2} coatings. In this study, the Ni-based metallic glass coatings were produced by the gas tunnel type plasma spraying under various experimental conditions, and their microstructure and mechanical properties were investigated. At the plasma current of 200-300 A, the Ni-based metallic glass coatings of more than 200 {mu}m in thickness were formed densely with Vickers hardness of about Hv = 600.

  18. 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.

  19. Plasma-sprayed, self-lubricating coatings for use from cryogenic temperatures to 870 deg C (1600 deg F)

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1975-01-01

    A plasma-sprayed coating is described with good lubricating properties over a wide temperature range. The coating, designated NASA LUBE PS101, contains silver, nichrome, calcium fluoride, and an oxidation protective glass. Oscillating tests were conducted of self-aligning, plain cylindrical bearings, in which the bore was lined with 0.025 cm (0.010 in.) thick coatings of PS101; these were conducted at a radial load of 3.5 x 10 to the 7th power N/sq m (5000 psi) in nitrogen gas at -107 C (-160 F), in vacuum at room temperature, and in air from room temperature to 870 C (1600 F). Friction coefficients were less than 0.25 in all cases and wear rates were low. The coating is not brittle, and it has adequate oxidation resistance in air to at least 870 C.

  20. Generation of the first layers of a zirconia plasma sprayed coating: Correlation between splat layering and spraying parameters

    SciTech Connect

    Haddadi, A.; Nardou, F.; Grimaud, A.; Fauchais, P.

    1995-12-31

    Fused and crushed partially stabilized zirconia particles (8 wt % Y{sub 2}O{sub 3}) were plasma sprayed with an Ar-H{sub 2} plasma jet (45 slm Ar, 15 slm H{sub 2}, 600 A, nozzle i.d. 7 mm, internal injection). The study was devoted to the splat, beads and passes (maximum 8 passes) formation. The particles were sprayed on cast iron or stainless steel substrates at which temperature was kept as constant as possible either at 75 or at 350 C with the help of air jets either blown orthogonally to the plasma jet or to the substrate surface. The splat shape and morphology was examined by OM and image analysis, the beads and passes cross sections as well as fractured sections were examined by SEM and their phases determined by XRD. These examinations have shown the drastic influence of the substrate temperature on the splat shapes and contacts with underlying layers, columnar structure growth within one bead or one pass and macrocracks network within the beads and passes.

  1. Technical note - Plasma-sprayed ceramic thermal barrier coatings for smooth intermetallic alloys

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Doychak, J.

    1992-01-01

    A new approach for plasma spray deposition of ceramic thermal barrier coatings directly to smooth substrates is described. Ceramic thermal barrier coatings were directly applied to substrates that had been coated with low-pressure plasma sprayed NiCrAlY bond coats and then centerless ground to simulate a smooth oxidation-resistant substrate. As the high-temperature oxidation behavior of NiAl+Zr is superior to that of MCrALY alloy, the bond coat is not required for oxidation resistance.

  2. Plasma-Sprayed Ceramic Coatings for Barrier Applications Against Molten Uranium Corrosion

    NASA Astrophysics Data System (ADS)

    Ananthapadmanabhan, P. V.; Chakravarthy, Y.; Chaturvedi, Vandana; Thiyagarajan, T. K.; Pragatheeswaran, A.

    2015-07-01

    Ceramic coatings are applied on engineering components for protecting them from large thermal load and hot corrosion. Choices of coating material for protection against hot corrosion by uranium are few, because of its high reactivity. Yttrium oxide has a high melting temperature and is inert towards uranium. Therefore, yttrium oxide coatings are effective as a barrier against hot corrosion by uranium and its alloys. This paper gives a summary of the developmental work on plasma-sprayed yttria coatings for corrosion barrier applications against molten uranium. Results show that plasma-sprayed yttria coatings offer a long-term solution to hot corrosion problems.

  3. Atmosphere corrosion behavior of plasma sprayed and laser remelted coatings on copper

    NASA Astrophysics Data System (ADS)

    Liang, Gongying; Wong, T. T.; An, Geng; MacAlpine, J. M. K.

    2006-01-01

    Nickel and chromium coatings were produced using plasma spraying and laser remelting on the copper sheet. The corrosion test was carried out in an acidic atmosphere, and the corrosive behaviors of both coatings and original copper samples were investigated by using an impedance comparison method. Experimental results show that nickel and chromium coatings display better corrosion resistance properties relative to the original pure copper sample. The corrosion rate of chromium coating is less than that of nickel coating, and corrosion resistances of laser remelted nickel and chromium samples are better than those of plasma sprayed samples. The corrosion deposit film of copper is loose compared with nickel and chromium.

  4. Deflection, spraying, and induced scattering of intense laser beams in plasmas

    SciTech Connect

    Kruer, W.L.

    1996-09-01

    Investigations into laser beam spraying, deflection, and induced scattering in plasmas are presented. Recent calculations and experiments on beam spraying due to filamentation are discussed. A simple model is presented for an enhanced beam deflection associated with nearly sonic plasma flow transverse to the beam. This model provides useful insights on the laser beam deflection, its scaling and the importance of self-consistent profile modifications. Finally, some discussion is given of recent experiments demonstrating the interplay between stimulated.Raman and Brillouin scattering.

  5. Deposition of Lanthanum Strontium Cobalt Ferrite (LSCF) Using Suspension Plasma Spraying for Oxygen Transport Membrane Applications

    NASA Astrophysics Data System (ADS)

    Fan, E. S. C.; Kesler, O.

    2015-08-01

    Suspension plasma spray deposition was utilized to fabricate dense lanthanum strontium cobalt ferrite oxygen separation membranes (OSMs) on porous metal substrates for mechanical support. The as-sprayed membranes had negligible and/or reversible material decomposition. At the longer stand-off distance (80 mm), smooth and dense membranes could be manufactured using a plasma with power below approximately 81 kW. Moreover, a membrane of 55 μm was observed to have very low gas leakage rates desirable for OSM applications. This thickness could potentially be decreased further to improve oxygen diffusion by using metal substrates with finer surface pores.

  6. 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.

  7. Development of a plasma sprayed ceramic gas path seal for high pressure turbine application

    NASA Technical Reports Server (NTRS)

    Shiembob, L. T.

    1978-01-01

    Development of the plasma sprayed graded, layered ZRO2/CoCrAlY seal system for gas turbine engine blade tip seal applications up to 1589 K (2400 F) surface temperature was continued. The effect of changing ZRO2/CoCrAlY ratios in the intermediate layers on thermal stresses was evaluated analytically with the goal of identifying the materials combinations which would minimize thermal stresses in the seal system. Three methods of inducing compressive residual stresses in the sprayed seal materials to offset tensile thermal stresses were analyzed. The most promising method, thermal prestraining, was selected based upon potential, feasibility and complexity considerations. The plasma spray equipment was modified to heat, control and monitor the substrate temperature during spraying. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capability of the thermal prestrain method to develop compressive residual stresses in the sprayed structure and (2) define the effect of spraying on a heated substate on abradability, erosion and thermal shock characteristics of the seal system. Thermal stress analysis, including residual stresses and material properties variations, was performed and correlated with thermal shock test results. Seal system performance was assessed and recommendations for further development were made.

  8. The abrasive wear of plasma sprayed nanoscale tungsten carbide-cobalt (WC-Co)

    NASA Astrophysics Data System (ADS)

    Tewksbury, Graham Alfred

    Thermal spray coatings composed of a variety of carbide sizes and cobalt contents were sprayed with a high energy plasma spray system. The size of the carbides used fell into three rough groupings, micrometer scale carbides (1--2 mum), submicrometer (700--300 nm), and nanoscale (≈100 nm). The feedstock powder was evaluated in terms of their size distribution, external morphology, internal morphology, and initial carbide size. Two different fixtures were used in spraying to evaluate the effect of cooling rate on the wear resistance of the coatings. The microstructures of the sprayed coatings were examined using optical metallography, SEM, FESEM, TEM, XRD and chemical analysis. The coatings were evaluated in low stress abrasive wear by the ASTM G-65 Dry Sand Rubber Wheel test. Furthermore, the porosity and hardness of the coatings were evaluated. The cobalt content was found to be the predominant influence on the wear rate of the coatings. The decrease in the carbide size was not found to effect the wear rate of the coatings. Coatings sprayed on the 'hot' fixture were found to have slightly improved wear resistance as compared to coatings sprayed on the 'cold' fixture. The wear rates of the coatings were found to be a function of the WC/Co volume ratio.

  9. Spraying Powder Materials by the High-Enthalpy Laminar Plasma Flow

    SciTech Connect

    Khutsishvili, M.; Kikvadze, L.

    2008-03-19

    One of the most promising engineering solutions of the problem of spraying powder materials is the proposed method of plasma spraying by the laminar plasma jet. Laminar plasma flow is characterized by small jet angle divergence; the powder particles are penetrated and accelerated mainly in the axial direction. The molten powder particles are transported almost to the surface of a treated work-piece inside the laminar plasma flow in an atmosphere of the plasma-forming gas with the acceleration on the entire transfer area, which leads to an increase in the particles velocity, a decrease of their oxidability, an increase in the powder deposition efficiency, density, adhesion strength with the surface to be coated.

  10. Spraying Powder Materials by the High-Enthalpy Laminar Plasma Flow

    NASA Astrophysics Data System (ADS)

    Khutsishvili, M.; Kikvadze, L.

    2008-03-01

    One of the most promising engineering solutions of the problem of spraying powder materials is the proposed method of plasma spraying by the laminar plasma jet. Laminar plasma flow is characterized by small jet angle divergence; the powder particles are penetrated and accelerated mainly in the axial direction. The molten powder particles are transported almost to the surface of a treated work-piece inside the laminar plasma flow in an atmosphere of the plasma-forming gas with the acceleration on the entire transfer area, which leads to an increase in the particles velocity, a decrease of their oxidability, an increase in the powder deposition efficiency, density, adhesion strength with the surface to be coated.

  11. Development of a plasma sprayed ceramic gas path seal for high pressure turbine applications

    NASA Technical Reports Server (NTRS)

    Shiembob, L. T.; Hyland, J. F.

    1979-01-01

    Development of the plasma sprayed graded, layered ZrO2/CoCrAlY seal system for gas turbine engine blade tip seal application up to 1589 K (2400 F) surface temperature was continued. Methods of improvement of the cyclic thermal shock resistance of the sprayed zirconia seal system were investigated. The most promising method, reduction of the ceramic thickness and metallic substrate stiffness were selected based upon potential and feasibility. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capacity of the geometry changes to reduce operating stresses in the sprayed structure; and (2) define the abradability, erosion, thermal shock and physical property characteristic for the sprayed ceramic seal system. Thermal stress analysis was performed and correlated with thermal shock test results.

  12. Behavior of plasma-sprayed TiC coatings under electron beam thermal shocks

    SciTech Connect

    Brunet, C.; Dallaire, S.; St-Jacques, R.G.

    1985-11-01

    Within the framework of a research program on materials for fusion machine, plasma-sprayed TiC coatings over Inconel 625 substrates were investigated. In order to evaluate the potential of these coatings in fusion environment, the existing thermal flux conditions on limiters of tokamaks are simulated with an electron beam thermal shock experiment. TiC coatings sprayed in air show severe damages when exposed to 2.5 kW cm/sup -2/, 1.0 s, heat pulses. Coatings sprayed in an inert gas enclosure withstood 3.0 kW cm/sup -2/, 1.0 s, heat pulses without melting. Surface melting and subsurface crystal growth are observed in the case of coatings sprayed in air.

  13. Mechanical, In Vitro Antimicrobial and Biological Properties of Plasma Sprayed Silver-Doped Hydroxyapatite Coating

    PubMed Central

    Roy, Mangal; Fielding, Gary A.; Beyenal, Haluk; Bandyopadhyay, Amit; Bose, Susmita

    2012-01-01

    Implant related infection is one of the key concerns in total joint hip arthroplasties. In order to reduce bacterial adhesion, silver (Ag) / silver oxide (Ag2O) doping was used in plasma sprayed hydroxyapatite (HA) coating on titanium substrate. HA powder was doped with 2.0, 4.0 and 6.0 wt% Ag, heat treated at 800 °C and used for plasma spray coating using a 30 kW plasma spray system, equipped with supersonic nozzle. Application of supersonic plasma nozzle significantly reduced phase decomposition and amorphous phase formation in the HA coatings as evident by X-ray diffraction (XRD) study and Fourier transformed infrared spectroscopic (FTIR) analysis. Adhesive bond strength of more than 15 MPa ensured the mechanical integrity of the coatings. Resistance against bacterial adhesion of the coatings was determined by challenging them against Pseudomonas Aeruginosa (PAO1). Live/Dead staining of the adherent bacteria on the coating surfaces indicated a significant reduction in bacterial adhesion due to the presence of Ag. In vitro cell-material interactions and alkaline phosphatase (ALP) protein expressions were evaluated by culturing human fetal osteoblast cells (hFOB). Present results suggest that the plasma sprayed HA coatings doped with an optimum amount of Ag can have excellent antimicrobial property without altering mechanical property of the Ag doped HA coatings. PMID:22313742

  14. Modeling of Micro- and Nanoparticle Characteristics in DC Suspension Plasma Spray

    NASA Astrophysics Data System (ADS)

    Shao, Xue-ming; Zhang, Kai; Xiong, Hong-bing

    2015-02-01

    Suspension plasma spray is a promising technology for surface coatings. In this work, a comprehensive numerical model was developed to investigate the multiphase flow of suspension droplets and nanoparticles in direct-current (DC) plasma spraying. A three-dimensional computational model was developed to describe the plasma jet flow fields coupled with the axial injection of suspension droplets in which the zirconia micro- and nanoparticles were dispersed. The suspension droplets were tracked using Lagrangian coordinates, considering particle heating, melting, and evaporation. After evaporation of the solvent surrounding the particle, the nanoparticles were discharged into the plasma flow. In addition to the viscous force exerted by the flow on the micrometer-sized particles, the Brownian force and the Saffman lift force were taken into account. The effects of the noncontinuum on particle momentum transfer and evaporation on heat transfer were also considered. The numerical predictions of gas flow temperature were compared with experimental data and numerical data obtained with a different computational fluid dynamics code. The agreement was reasonable. The trajectories, velocity, and temperature of nanoparticles were calculated, and compared with those of microparticles. The results showed that the Brownian force plays a major role in acceleration and heating of nanoparticles. Compared with the conventional plasma spray process with micrometer-sized feedstock, the nanoparticles in suspension plasma spraying were found to have a wider spatial distribution and higher temperature. The effects of operating parameters, such as the power input to the plasma gas and plasma gas composition, on the gas velocity and temperature were investigated. The parameters that have a significant effect on the heat and momentum transfer to the particles injected in the plasma jet were identified.

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

    SciTech Connect

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

    1993-10-01

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

  16. Plasma spraying of hard magnetic coatings based on Sm-Co alloys

    NASA Astrophysics Data System (ADS)

    Saunin, V. N.; Telegin, S. V.

    2015-01-01

    Our research is focused on the formation of hard magnetic coatings by plasma spraying an arc-melted Sm-Co powder. We have studied basic magnetic characteristics depending on the components ratio in the alloy. A sample with a 40 wt.% Sm coating exhibits the highest coercive force (63 kOe) as compared to near-to-zero coercive force in the starting powder. X-ray structure analysis of the starting alloy and the coating reveals that the amount of SmCo5 phase in the sprayed coating increases occupying up to 2/3 of the sample. We have also studied temperature dependence of the coating and have been able to obtain plasma sprayed permanent magnets operating within the temperature range from -100 to +500 °C. The technique used does not involve any additional thermal treatment and allows a coating to be formed right on the magnetic conductor surface irrespective of the conductor geometry.

  17. Improvement in mechanical properties of plasma sprayed hydroxyapatite coatings by Al2O3 reinforcement.

    PubMed

    Mittal, Manoj; Nath, S K; Prakash, Satya

    2013-07-01

    Thermal sprayed hydroxyapatite coatings suffer from poor mechanical properties like tensile strength, wear resistance, hardness, toughness and fatigue. The mechanical properties of hydroxyapatite coatings can be enhanced via incorporation of secondary bioinert reinforcement material. In this study an attempt has been made to improve the mechanical properties of plasma sprayed hydroxyapatite by reinforcing it with 10, 20 and 30% Al2O3. The plasma sprayed coatings have been characterized using FE-SEM/EDAX, XRD, AFM and FTIR spectroscopy. Corrosion studies have been done in simulated body fluid and abrasive wear studies have been performed on flat specimens on a disk wear tester. Microhardness, tensile strength and wear resistance are found to be increased with increasing Al2O3 content. All types of coatings show superior resistance against corrosion in simulated body fluid. PMID:23623104

  18. Limiter/vacuum system for plasma impurity control and exhaust in tokamaks

    SciTech Connect

    Abdou, M.; Brooks, J.; Mattas, R.

    1980-01-01

    A detailed design of a limiter/vacuum system for plasma impurity control and exhaust has been developed for the STARFIRE tokamak power plant. It is shown that the limiter/vacuum concept is a very attractive option for power reactors. It is relatively simple and inexpensive and deserves serious experimental verification.

  19. Al2O3-ZrO2 Finely Structured Multilayer Architectures from Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Tingaud, Olivier; Montavon, Ghislain; Denoirjean, Alain; Coudert, Jean-François; Rat, Vincent; Fauchais, Pierre

    2010-01-01

    Suspension plasma spraying (SPS) is an alternative to conventional atmospheric plasma spraying (APS) aiming at manufacturing thinner layers (i.e., 10-100 μm) due to the specific size of the feedstock particles, from a few tens of nanometers to a few micrometers. The staking of lamellae and particles, which present a diameter ranging from 0.1 to 2.0 μm and an average thickness from 20 to 300 nm, permits to manufacture finely structured layers. Moreover, it appears as a versatile process able to manufacture different coating architectures according to the operating parameters (suspension properties, injection configuration, plasma properties, spray distance, torch scan velocity, scanning step, etc.). However, the different parameters controlling the properties of the coating, and their interdependences, are not yet fully identified. Thus, the aim of this paper is, on the one hand, to better understand the influence of operating parameters on the coating manufacturing mechanisms (in particular, the plasma gas mixture effect) and, on the other hand, to produce Al2O3-ZrO2 finely structured layers with large varieties of architectures. For this purpose, a simple theoretical model was used to describe the plasma torch operating conditions at the nozzle exit, based on experimental data (mass enthalpy, arc current intensity, thermophysical properties of plasma forming gases, etc.) and the influences of the spray parameters were determined by mean of the study of sizes and shapes of spray beads. The results enabled then to reach a better understanding of involved phenomena and their interactions on the final coating architectures permitting to manufacture several types of microstructures.

  20. A Novel Plasma-Sprayed Nanostructured Coating with Agglomerated-Unsintered Feedstock

    NASA Astrophysics Data System (ADS)

    Gao, Yang; Zhao, Yan; Yang, Deming; Gao, Jianyi

    2016-01-01

    In this article, an unusual agglomerated powder of Y2O3-stabilized ZrO2 (YSZ) that did not undergo calcination was introduced as a feedstock for thermal spray deposition using internal injection atmospheric plasma spray (APS) and the very-low-pressure plasma spray (VLPPS) methods at an ambient pressure of 100-150 Pa. The results show that the microstructure of the coating is influenced not only by the spray parameters (such as arc gas composition, ambient pressure, and arc current) but also by the manufacture process of the agglomerates particularly the sintering process. The microstructure of the coating exhibited a bimodal structure if the APS method was used; in this case, the microstructure resembles that of other nanostructured coatings using regular agglomerated-sintered feedstock. A coating having a novel fully nano-equiaxed structure with a microporosity of 10-15% was first successfully deposited using VLPPS with 20Ar-30He SLPM plasma gas flows at a current of 500 A. The experimental results suggest that the nano-scale equiaxed structure in the coating is directly formed from original nanoparticles that had undergone melting, while inside the nozzle they were subsequently solidified on the substrate. The VLPPS method, which offers some unique advantages over the conventional plasma spray process, is generic in nature and can potentially be used to deposit a wide variety of ceramic coatings for diverse applications. The thermal conductivity values of the fully nanostructured and bimodal structured coatings were measured, and the microstructures of the coating both in the as-sprayed state and after heat treatment for 10 h at 1300 °C were investigated.

  1. Accuracy and Roughness of TiN Coatings Deposited by Vacuum Arc Plasma

    NASA Astrophysics Data System (ADS)

    Budilov, V.; Ramazanov, K.; Yagafarov, I.; Vafin, R.

    2015-11-01

    Nitride coatings were deposited by vacuum arc plasma in an atmosphere of argon and nitrogen using different deposition conditions of part location and configuration, angle between plasma flow and processing surface. The coating thickness, part dimensions and surface roughness were measured before and after coating deposition. The type of part poor shape precision after coating deposition by vacuum arc plasma was defined. An impact of coating deposition by vacuum arc discharge on the part dimensional and form accuracy was revealed. The effect of parts location on dimensional and radial surfaces form accuracy was induced. The effect of coating surface polythickness on part dimensional and form accuracy for parts with different stiffness was defined. The impact of part location area and parts quantity on coating thickness, surface roughness, dimensional and form accuracy of part was revealed. The coating thickness distribution law, parts quality class and accuracy degree after vacuum ion plasma coating deposition were assigned.

  2. Plasma spray joining of Al-matrix particulate reinforced composites

    SciTech Connect

    Itsukaichi, T.; Eagar, T.W.; Unemoto, M.; Okane, I.

    1996-09-01

    Aluminum matrix composite joints have been produced on both aluminum alloy and metal matrix composite (MMC) substrates using powders containing SiC and Al{sub 2}O{sub 3} particulates. Most of the composite powders were produced by ball milling, but the most effective joints were produced using Osprey composite powders. The results of preliminary joining experiments indicate that the substrate should be preheated to 200 C and a very wide bevel angle should be provided in order to obtain the highest strength joints. Silicon alloy additions to the matrix significantly improved strength but titanium additions had no effect. Heat treatment after spraying significantly improved the bond strength and restored precipitation hardening in the matrix. Significant amounts of Mg were lost from the deposit during spraying while some free silicon was produced by pyrolysis of the SiC powder; hence, further efforts must develop powder compositions that produce the optimum matrix composition in the sprayed deposit. Hot isostatic pressing of the samples to eliminate porosity had only a small effect on the final strength of the joints. No significant amount of Al{sub 4}C{sub 3} was detected in deposits which contained SiC.

  3. 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

    The development of plasma-sprayed yttria stabilized zirconia (YSZ) ceramic turbine blade tip seal components is discussed. The YSZ layers are quite thick (0.040 to 0.090 in.). The service potential of seal components with such thick ceramic layers is cyclic thermal shock limited. The most usual failure mode is ceramic layer delamination at or very near the interface between the plasma sprayed YSZ layer and the NiCrAlY bondcoat. Deposition of a thin RF sputtered YSZ primer to the bondcoat prior to deposition of the thick plasma sprayed YSZ layer was found to reduce laminar cracking in cyclic thermal shock testing. The cyclic thermal shock life of one ceramic seal design was increased by a factor of 5 to 6 when the sputtered YSZ primer was incorporated. A model based on thermal response of plasma sprayed YSZ particles impinging on the bondcoat surface with and without the sputtered YSZ primer provides a basis for understanding the function of the primer.

  4. Effect of Plasma Nitriding and Nitrocarburizing on HVOF-Sprayed Stainless Steel Coatings

    NASA Astrophysics Data System (ADS)

    Park, Gayoung; Bae, Gyuyeol; Moon, Kyungil; Lee, Changhee

    2013-12-01

    In this work, the effects of plasma nitriding (PN) and nitrocarburizing on HVOF-sprayed stainless steel nitride layers were investigated. 316 (austenitic), 17-4PH (precipitation hardening), and 410 (martensitic) stainless steels were plasma-nitrided and nitrocarburized using a N2 + H2 gas mixture and the gas mixture containing C2H2, respectively, at 550 °C. The results showed that the PN and nitrocarburizing produced a relatively thick nitrided layer consisting of a compound layer and an adjacent nitrogen diffusion layer depending on the crystal structures of the HVOF-sprayed stainless steel coatings. Also, the diffusion depth of nitrogen increased when a small amount of C2H2 (plasma nitrocarburizing process) was added. The PN and nitrocarburizing resulted in not only an increase of the surface hardness, but also improvement of the load bearing capacity of the HVOF-sprayed stainless steel coatings because of the formation of CrN, Fe3N, and Fe4N phases. Also, the plasma-nitrocarburized HVOF-sprayed 410 stainless steel had a superior surface microhardness and load bearing capacity due to the formation of Cr23C6 on the surface.

  5. Fatigue testing of plasma-sprayed thermal barrier coatings, volume 2

    NASA Technical Reports Server (NTRS)

    Cruse, T. A.; Nagy, A.; Popelar, C. F.

    1990-01-01

    A plasma sprayed thermal barrier coating for diesel engines were fatigue tested. Candidate thermal barrier coating materials were fatigue screened and a data base was generated for the selected candidate material. Specimen configurations are given for the bend fatigue tests, along with test setup, specimen preparation, test matrix and procedure, and data analysis.

  6. Numerical simulations of stable explosive-emission center plasma expansion in vacuum

    SciTech Connect

    Nefedtsev, E. V. Batrakov, A. V.

    2015-10-15

    We present the results of our numerical simulations of the stable cathode-flare expansion stage in the vacuum-breakdown switching period. We used the model of two-fluid hydrodynamics with corrections that allowed it to be applied to a consistent description of the electron and ion transport in plasma and the electron transport in a plasma-anode vacuum gap without imposing any joining conditions at the expanding plasma boundary. We have analyzed the dynamics of the density, directed velocity, and temperature profiles for both components and the influence of various factors on the plasma-cloud expansion velocity.

  7. Specific Measurements of In-Flight Droplet and Particle Behavior and Coating Microstructure in Suspension and Solution Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Fauchais, P.; Vardelle, M.; Goutier, S.; Vardelle, A.

    2015-12-01

    The plasma spraying of suspensions of sub-micro- or nano-sized particles and of solutions of chemicals precursors produces finely structured coatings that have generally enhanced properties compared to conventional plasma-sprayed coatings. However, most techniques used in conventional plasma spraying are no more adapted to experimentally observe the behavior of the liquid feedstock in the plasma jet and investigate the effect of the operating conditions on liquid fragmentation in droplets, solid particles released by solvent evaporation or formed from the chemical precursors. Also, specific techniques have to be used to study the coating formation and characterize its microstructure. This paper aims to present the main techniques developed or adapted, up to now, to study the plasma-liquid feedstock interactions and characterize the coatings achieved by suspension and solution plasma spraying.

  8. Enhancement of Functional Ceramic Coating Performance by Gas Tunnel Type Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Kobayashi, Akira

    2016-02-01

    A high-precision plasma system has been pursued for advanced thermal processing. The gas tunnel type plasma jet device developed by the author exhibits high energy density and also high efficiency. Among its various applications is the plasma spraying of ceramics such as Al2O3 and ZrO2. The performance of these ceramic coatings is superior to conventional ones. Properties such as the mechanical and chemical properties of the zirconia coatings were reported in previous studies. In this study, the enhancement of the performance of functional ceramic coatings by the gas tunnel type plasma spraying method was carried out using different powders. Results show that the alumina/zirconia composite system exhibited improvements of mechanical properties and corrosion resistance. The alumina/zirconia composite coating has the potential for use as a high functionally graded thermal barrier coating. Another application of the gas tunnel type plasma is for surface modification of metals. As an example, TiN films were formed in 5 s and, thick TiN coatings were easily obtained by gas tunnel type plasma reactive spraying.

  9. High Anatase Rate Titanium Dioxide Coating Deposition by Low Power Microwave Plasma Spray

    NASA Astrophysics Data System (ADS)

    Redza, Ahmad; Kondo, Toshiki; Yasui, Toshiaki; Fukumoto, Masahiro

    2016-02-01

    Titanium dioxide is a promising photocatalyst material because of the magnificent properties of this material where it is able to remove the air pollution substance and the deodorizing function. Generally, the deposition method of a titanium dioxide coating is carried out by an organic system binder but the powerful photocatalytic reaction will degrades the binder. Therefore, thermal spray is considered to be the alternative method but this method will induce crystallization transformation of titanium dioxide from anatase phase with high photocatalytic activity to rutile phase with low photocatalyst which caused by high heat input. Since our microwave plasma spraying device is operable at low power comparing with conventional high power plasma spray, the reduce effect of the heat input onto the particles at the time of spraying can be achieved and coating deposition with high rate of anatase phase is expected. Therefore, in this research, the coating deposition by controlling the heat input into the spray particle which can be resulted in high rate of anatase phase with high photocatalytic activity was conducted. By controlled condition, coating with optimum anatase rate of 83% is able to be fabricated by this method.

  10. Suspension Plasma Spraying of Sub-micron Silicon Carbide Composite Coatings

    NASA Astrophysics Data System (ADS)

    Mubarok, F.; Espallargas, N.

    2015-06-01

    Thermal spraying of silicon carbide (SiC) material is a challenging task since SiC tends to decompose during atmospheric spraying process. The addition of metal or ceramic binders is necessary to facilitate the bonding of SiC particles, allowing SiC composite coating to be deposited. In the conventional procedures, the binders are added through mechanical mixing of powder constituents, making it difficult to achieve homogeneous distribution. In the new procedure proposed in this work, the binder is delivered as a nano-film of the surface of the individual SiC particles through co-precipitation treatment. Suspension plasma spray (SPS) coating technique has been used with the aim at avoiding the decomposition of SiC typically expected with atmospheric techniques, such as atmospheric plasma spray. The deposited SiC coatings by SPS showed identical SiC phase peak as identified in the suspension feedstock, indicating that the nano-film binder was able to protect SiC particles from decomposition. Further analysis by XPS revealed that SiC particles underwent some minor oxidation. Unfortunately, all the SiC coatings exhibited poor mechanical performance due to low cohesive strength, high porosity, and powdery structure making the coatings vulnerable to grain pull-out. This was due to the absence of sintering process during the spraying process contributing to the low performance of SiC SPS coatings.

  11. Development of a plasma sprayed ceramic gas path seal for high pressure turbine applications

    NASA Technical Reports Server (NTRS)

    Shiembob, L. T.

    1977-01-01

    The plasma sprayed graded layered yittria stabilized zirconia (ZrO2)/metal(CoCrAlY) seal system for gas turbine blade tip applications up to 1589 K (2400 F) seal temperatures was studied. Abradability, erosion, and thermal fatigue characteristics of the graded layered system were evaluated by rig tests. Satisfactory abradability and erosion resistance was demonstrated. Encouraging thermal fatigue tolerance was shown. Initial properties for the plasma sprayed materials in the graded, layered seal system was obtained, and thermal stress analyses were performed. Sprayed residual stresses were determined. Thermal stability of the sprayed layer materials was evaluated at estimated maximum operating temperatures in each layer. Anisotropic behavior in the layer thickness direction was demonstrated by all layers. Residual stresses and thermal stability effects were not included in the analyses. Analytical results correlated reasonably well with results of the thermal fatigue tests. Analytical application of the seal system to a typical gas turbine engine application predicted performance similar to rig specimen thermal fatigue performance. A model for predicting crack propagation in the sprayed ZrO2/CoCrAlY seal system was proposed, and recommendations for improving thermal fatigue resistance were made. Seal system layer thicknesses were analytically optimized to minimize thermal stresses in the abradability specimen during thermal fatigue testing. Rig tests on the optimized seal configuration demonstrated some improvement in thermal fatigue characteristics.

  12. Vacuum arc plasma thrusters with inductive energy storage driver

    NASA Technical Reports Server (NTRS)

    Krishnan, Mahadevan (Inventor)

    2009-01-01

    A plasma thruster with a cylindrical inner and cylindrical outer electrode generates plasma particles from the application of energy stored in an inductor to a surface suitable for the formation of a plasma and expansion of plasma particles. The plasma production results in the generation of charged particles suitable for generating a reaction force, and the charged particles are guided by a magnetic field produced by the same inductor used to store the energy used to form the plasma.

  13. Optimization of Atmospheric Plasma Spray Process Parameters using a Design of Experiment for Alloy 625 coatings

    NASA Astrophysics Data System (ADS)

    Azarmi, F.; Coyle, T. W.; Mostaghimi, J.

    2008-03-01

    Alloy 625 is a Ni-based superalloy which is often a good solution to surface engineering problems involving high temperature corrosion, wear, and thermal degradation. Coatings of alloy 625 can be efficiently deposited by thermal spray methods such as Air Plasma Spraying. As in all thermal spray processes, the final properties of the coatings are determined by the spraying parameters. In the present study, a D-optimal experimental design was used to characterize the effects of the APS process parameters on in-flight particle temperature and velocity, and on the oxide content and porosity in the coatings. These results were used to create an empirical model to predict the optimum deposition conditions. A second set of coatings was then deposited to test the model predictions. The optimum spraying conditions produced a coating with less than 4% oxide and less than 2.5% porosity. The process parameters which exhibited the most important effects directly on the oxide content in the coating were particle size, spray distance, and Ar flow rate. The parameters with the largest effects directly on porosity were spray distance, particle size, and current. The particle size, current, and Ar flow rate have an influence on particle velocity and temperature but spray distance did not have a significant effect on either of those characteristics. Thus, knowledge of the in-flight particle characteristics alone was not sufficient to control the final microstructure. The oxidation index and the melting index incorporate all the parameters that were found to be significant in the statistical analyses and correlate well with the measured oxide content and porosity in the coatings.

  14. Plasma spraying of porous Ni/ZRO{sub 2}-cermet anodes for the solid oxide fuel cells

    SciTech Connect

    Fendler, E.; Henne, R.; Lang, M.

    1995-07-01

    Fuel cells convert the reaction energy of gaseous fuels directly into electrical energy. In the case of solid oxide fuel cells (SOFC) the reaction educts and products are transported to and removed from the electrode/electrolyte interfaces through the porous electrodes. The gas-tight electrolyte consisting of Yttria Stabilized Zirconia (YSZ) with an ionic conductivity separates the electrodes. The materials conventionally used for the anode and the cathode are a Ni/YSZ-cermet and a La{sub 0.8}Sr{sub 0.2}MnO{sub 3} (LSM), respectively. Therefore the multilayer structure Positive electrode - Electrolyte - Negative electrode (PEN) consists of ceramic and metallic components in dense and porous manner. Vacuum plasma spraying (VPS) promises a great potential to meet the economic requirements as well as the demanded technical specifications of the PEN production. Compared with conventional production processes the number of production steps and the production time can be reduced if the whole PEN was manufactured by VPS in a consecutive spray process. Furthermore, application of thermal spray methods avoids reactions between the cathode and electrolyte during the manufacturing due to the rapid and independent solidification of each particle on the substrate surface. Using conventional shaping plus sintering processes for PEN fabrication undesired phases may conventional shaping plus sintering processes for PEN fabrication undesired phases may occur at the cathode/electrolyte interface. Another advantage of the VPS process is the possibility to build up layers with graded composition and porosity. This work is focused on the production of porous electrodes.

  15. Plasma modeling of MFTF-B and the sensitivity to vacuum conditions

    SciTech Connect

    Porter, G.D.; Rensink, M.

    1984-09-12

    The Mirror Fusion Test Facility (MFTF-B) is a large tandem mirror device currently under construction at Lawrence Livermore National Laboratory. The completed facility will consist of a large variety of components. Specifically, the vacuum vessel that houses the magnetic coils is basically a cylindrical vessel 60 m long and 11 m in diameter. The magnetics system consists of some 28 superconducting coils, each of which is located within the main vacuum vessel. Twenty of these coils are relatively simple solenoidal coils, but the remaining eight are of a more complicated design to provide an octupole component to certain regions of the magnetic field. The vacuum system is composed of a rough vacuum chain, used to evacuate the vessel from atmospheric pressure, and a high vacuum system, used to maintain good vacuum conditions during a plasma shot. High vacuum pumping is accomplished primarily by cryogenic panels cooled to 4.5/sup 0/K. The MFTF-B coil set is shown together with typical axial profiles of magnetic field (a), electrostatic potential (b), and plasma density (c). The plasma is divided into nine regions axially, as labelled on the coil set in Figure 1. The central cell, which is completely azimuthally symmetric, contains a large volume plasma that is confined by a combination of the magnetic fields and the electrostatic potentials in the yin-yang cell.

  16. Circularly polarized waves in a plasma with vacuum polarization effects

    SciTech Connect

    Lundin, J.; Stenflo, L.; Brodin, G.; Marklund, M.; Shukla, P. K.

    2007-06-15

    The theory for large amplitude circularly polarized waves propagating along an external magnetic field is extended in order to also include vacuum polarization effects. A general dispersion relation, which unites previous results, is derived.

  17. Absorption and Decomposition of CO2 by Active Ferrites Prepared by Atmospheric Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Li, Shaowei; He, Zhida; Zheng, Yanjun; Chen, Changfeng

    2015-12-01

    Active ferrites, which play an important role in the catalytic decomposition of CO2, have been fabricated by atmospheric plasma spraying to incorporate FeO and anoxic iron oxide [Fe3O4-δ (0 < δ < 1)]. The complexity of phase composition, especially the presence of FeO, gives the resulting powder a greater ability to decompose CO2 when compared to hydrogen-reduced Fe3O4 or Fe2O3 particles. Spraying distance is found to play an important role in modulating the decomposition ability of the powders, while elevated temperatures can also enhance the catalytic decomposition of CO2.

  18. An electron microscopy study of the effect of Ce on plasma sprayed bronze coatings

    NASA Astrophysics Data System (ADS)

    Wensheng, Li; Wang, S. C.; Ma, Chao; Zhiping, Wang

    2012-07-01

    The Cu-Al eutectoid alloy is an excellent material for mould due to its superior low friction. The conventional sand casting technique, however, is not feasible to fabricate high Al bronze because of high hardness and brittleness. Plasma arc spray has been used to produce high Al/Fe bronze coatings for mould. The inherent impurities such as H, O, N, S during the spray, however, may affect the coating's mechanical strength. One approach is to utilise the active rare earth Ce to clean up these impurities. The study is to investigate the effect of Ce on the microstructure, which has few reported in the literature.

  19. An Insight into Suspension Plasma Spray: Injection of the Suspension and Its Interaction with the Plasma Flow

    NASA Astrophysics Data System (ADS)

    Marchand, O.; Girardot, L.; Planche, M. P.; Bertrand, P.; Bailly, Y.; Bertrand, G.

    2011-12-01

    Yttria Stabilized Zirconia (YSZ) suspensions were injected in an atmospheric plasma jet using two designs of a home-made two-fluid atomizing nozzle. The sprays of drops were visualized and the behavior of the suspension in the plasma jet was investigated by implementing the Particle Image Velocimetry (PIV) method. The effects of the suspension formulation (surface tension, liquid viscosity, and relative gas-to-liquid mass ratio, GLR) on the distribution and median value of the drop size as well as on the velocity maximum value were evaluated. The interactions between the sprays and the plasma jet were studied. The differences in the behavior of the particle velocity along and radial to the torch axis were pointed out. The validity of PIV measurements was finally demonstrated by the relation established between the in-flight particle velocity and the coating structure.

  20. Carbon Nanotubes Reinforced Al-11 wt% Si Alloy via Plasma Spray

    NASA Astrophysics Data System (ADS)

    Moosa, Ahmed A.; Mohamed, Mohamed I.; Ismael, Mustafa K.

    2015-10-01

    In this work, multi-walled carbon nanotubes (MWCNTs) with different portions (0.5, l, 2, 4) wt% were added to a gas atomized Al-ll wt% Si powder. The Al-ll wt% /MWCNTS nanocomposite powder was examined by FESEM, Raman spectroscopy, X-ray diffraction (XRD). Air plasma spraying (APS) was used to spray Al-ll wt% Si/MwCNTs nanocomposite powder on aluminum alloy AA6082-T6 substrates. Al-ll wt% Si/MWCNTs nanocomposite coating layer was examined using FESEM/EDS, Raman spectroscopy, XRD and HRTEM. SEM/EDS showed that Al4C3 is formed at the interface e between the coating layer and the substrate in Al-ll wt% Si/4 wt% MWCNTs plasma spray coating. The adhesion test showed good adhesion in the ranges 5-l5 MPa between the coating layer and the substrate. Microhardness test of the air plasma sprayed (APS) Al-ll wt% Si/MWNTs nanocomposite layer is increased with the MWCNTs wt%.

  1. Comparison of Physical-chemical and Mechanical Properties of Chlorapatite and Hydroxyapatite Plasma Sprayed Coatings

    PubMed Central

    Demnati, Imane; Grossin, David; Marsan, Olivier; Bertrand, Ghislaine; Collonges, Gérard; Combes, Christèle; Parco, Maria; Braceras, Inigo; Alexis, Joel; Balcaen, Yannick; Rey, Christian

    2015-01-01

    Chlorapatite can be considered a potential biomaterial for orthopaedic applications. Its use as plasma-sprayed coating could be of interest considering its thermal properties and particularly its ability to melt without decomposition unlike hydroxyapatite. Chlorapatite (ClA) was synthesized by a high-temperature ion exchange reaction starting from commercial stoichiometric hydroxyapatites (HA). The ClA powder showed similar characteristics as the original industrial HA powder, and was obtained in the monoclinic form. The HA and ClA powders were plasma-sprayed using a low-energy plasma spraying system with identical processing parameters. The coatings were characterized by physical-chemical methods, i.e. X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and Raman spectroscopy, including distribution mapping of the main phases detected such as amorphous calcium phosphate (ACP), oxyapatite (OA), and HA or ClA. The unexpected formation of oxyapatite in ClA coatings was assigned to a side reaction with contaminating oxygenated species (O2, H2O). ClA coatings exhibited characteristics different from HA, showing a lower content of oxyapatite and amorphous phase. Although their adhesion strength was found to be lower than that of HA coatings, their application could be an interesting alternative, offering, in particular, a larger range of spraying conditions without formation of massive impurities. PMID:25893015

  2. What Do We Know, What are the Current Limitations of Suspension Plasma Spraying?

    NASA Astrophysics Data System (ADS)

    Fauchais, P.; Vardelle, M.; Vardelle, A.; Goutier, S.

    2015-10-01

    Nano-structured coatings should exhibit better properties than micro-structured coatings because of a high volume fraction of internal interfaces. Since the mid-nineties a large body of works have been devoted to suspension and solution plasma spraying for the deposition of finely and even nanometer-structured coatings. The aim of this paper is to take stock of our present knowledge in the field of suspension plasma spraying that is, at the moment, essentially used for oxide ceramic coatings. It will first tackle the injection of the suspension in the plasma jet and the behavior of nano or sub-micro-meter particles processed in the plasma jet core involving the liquid breakup and vaporization that releases the solid particles from the solvent droplets. It will, then, deal with the plasma torches and liquid feeding systems available to suspension spraying. It will finally discuss the key characteristics of suspensions (solvent, dispersant, and particle morphologies), designing of coating microstructure, and potential industrial applications, with the developments requested to cope with these applications.

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

    NASA Astrophysics Data System (ADS)

    Mawdsley, Jennifer Renee

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

  4. Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Elam, Sandra; Ellis, David L.; McKechnie, Timothy; Hickman, Robert; Rose, M. Franklin (Technical Monitor)

    2001-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.

  5. Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Elam, Sandra; McKechnie, Timothy; Hickman, Robert; Stinson, Thomas N. (Technical Monitor)

    2002-01-01

    Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshal Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100 mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.03 in. NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200 F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650 C (1200 F) than NARloy-Z does at 538 C (1000 F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed.

  6. Robust Low Cost Aerospike/RLV Combustion Chamber by Advanced Vacuum Plasma Process

    NASA Technical Reports Server (NTRS)

    Holmes, Richard; Ellis, David; McKechnie

    1999-01-01

    Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. At the same time, fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of a shrinking NASA budget. In recent years, combustion chambers of equivalent size to the Aerospike chamber have been fabricated at NASA-Marshall Space Flight Center (MSFC) using innovative, relatively low-cost, vacuum-plasma-spray (VPS) techniques. Typically, such combustion chambers are made of the copper alloy NARloy-Z. However, current research and development conducted by NASA-Lewis Research Center (LeRC) has identified a Cu-8Cr-4Nb alloy which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. In fact, researchers at NASA-LeRC have demonstrated that powder metallurgy (P/M) Cu-8Cr-4Nb exhibits better mechanical properties at 1,200 F than NARloy-Z does at 1,000 F. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost, VPS process to deposit Cu-8Cr-4Nb with mechanical properties that match or exceed those of P/M Cu-8Cr-4Nb. In addition, oxidation resistant and thermal barrier coatings can be incorporated as an integral part of the hot wall of the liner during the VPS process. Tensile properties of Cu-8Cr-4Nb material produced by VPS are reviewed and compared to material produced previously by extrusion. VPS formed combustion chamber liners have also been prepared and will be reported on following scheduled hot firing tests at NASA-Lewis.

  7. Effect of Starting Microstructure on Thermal Properties forAs-Sprayed and Thermally Exposed Plasma-Sprayed YSZ Coatings

    SciTech Connect

    Wang, Hsin; Tan, Y; Longtin, J P; Sampath, S

    2009-01-01

    Thermal barrier coatings (TBCs) experience thermal gradients, excessive temperature, and high heat flux from hot gases in turbines during service. These extended thermal effects induce sin-tering and significant microstructure changes, which alter the resulting thermal conductivity within the TBCs. In this study plasma-sprayed Yttria Stabilized Zirconia (YSZ) TBCs using dif-ferent starting powders and process parameters were subjected to thermal aging at several tem-peratures and time intervals, after which their thermal conductivity was measured at room tem-perature. The thermal conductivity results are analyzed by introducing the Larson-Miller pa-rameter describing the creep behavior of thermal conductivity increase with annealing tempera-ture and time. One set of selected coatings was also annealed under the same conditions and the thermal conductivity was measured at elevated temperatures. The temperature-dependent ther-mal conductivity data is analyzed and used to predict long-term thermal behavior for general YSZ coating design.

  8. Generation of uniform electron beam plasma in a dielectric flask at fore-vacuum pressures

    NASA Astrophysics Data System (ADS)

    Zolotukhin, D. B.; Burdovitsin, V. A.; Oks, E. M.

    2016-02-01

    We describe a system for the generation of spatially uniform and homogeneous dense plasma in a dielectric flask using a forevacuum-pressure plasma-cathode electron beam source. At optimum beam energy and gas pressure, the non-uniformity in plasma density distribution along the length of the flask is less than 10%, and the plasma density and electron temperature in the flask are greater than for the plasma produced in the vacuum chamber with no flask. The measured parameters of the beam plasma in the flask are compared to the predictions of a model based on balance equations.

  9. Measurement of residual stresses within alumina coatings plasma sprayed on XC38 steel

    SciTech Connect

    Mellali, M.; Leger, A.C.; Vardelle, M; Grimaud, A.; Fauchais, P.

    1995-12-31

    Sand blasting, preheating and plasma spraying induce residual stresses within coatings and substrates. To better understand their evolution during the different steps of spraying, a method based on radius of curvature of coated test beams ({approximately} 100 x 10 x 1 mm{sup 3}) was used. It was quite easy to set up the experiments to determine the strains, the Young`s moduli of coatings and substrate were determined to compute the corresponding stresses (the values of the Poisson`s coefficient being usually low). The residual stresses of alumina coatings on XC38 steel were studied for different Ra of substrate surface and different preheating and spraying temperatures and coating thicknesses.

  10. Development of an environmentally acceptable volatile organic compounds recovery and reuse system based on vacuum spray flash with dibasic acid esters as absorbents.

    PubMed

    Koyama, Toshiyuki; Shirakawa, Yoichi; Kuwahata, Kenichi; Yajima, Tatsuhiko

    2009-01-01

    We used dibasic acid esters as the absorbent for a volatile organic compounds (VOC) recovery and reuse system geared mainly toward VOCs from painting and presswork. The system consists of three elements: absorption using dibasic acid esters, separation by vacuum spray flash method, and recovery by condensation. The concentration of both ethyl acetate (EtAc) and isopropyl alcohol (IPA) decreased around 90% at room temperature. Vacuum spray flash was found as a useful process for cost-effective and energy-effective VOC removal system. The difference in the dissolubility parameters (Hansen constant) between dibasic acid esters and VOCs and the boiling point of VOCs was the main contributor to the separation behavior. PMID:25084416

  11. Multiple Ionization Of Metal Ions By ECR Heating Of Electrons In Vacuum Arc Plasmas

    SciTech Connect

    Vodopyanov, A.V.; Golubev, S.V.; Mansfeld, D.A.; Razin, S.V.; Nikolaev, A.G.; Oks, E.M.; Savkin, K.P.

    2005-03-15

    A joint research and development effort has been initiated, whose ultimate goal is the enhancement the mean ion charge states in vacuum arc metal plasmas by a combination of a vacuum arc discharge and an electron cyclotron resonance (ECR) heating. Metal plasma was generated by a special vacuum arc mini-gun and injected into mirror magnetic trap. Plasma was pumped by high frequency gyrotron-generated microwave radiation (frequency 37.5 GHz, max power 100 kW, pulse duration 1.5 ms). Using of powerful microwaves makes it possible to sustain sufficient temperature of electrons needed for multiple ionizations at high plasma density (more then 1013 cm-3). Parameter of multiple ionization efficiency Ne{tau}i, where Ne is plasma density, {tau}i, is ion lifetime, in such a case could reach rather high value {approx}109 cm-3-s. In our situation {tau}i = Ltrap/Vi, where Ltrap is trap length, Vi is plasma gun flow velocity. The results have demonstrated substantial multiple ionization of metal ions (including metals with high melting temperature). For a metal (lead, platinum) plasma, ECR heating shifted the average ion charge up to 5+. Further increase of the ion charge states will be attained by increasing the vacuum arc plasma density and optimizing the ECR heating conditions.

  12. Fabrication of High-Temperature Heat Exchangers by Plasma Spraying Exterior Skins on Nickel Foams

    NASA Astrophysics Data System (ADS)

    Hafeez, P.; Yugeswaran, S.; Chandra, S.; Mostaghimi, J.; Coyle, T. W.

    2016-05-01

    Thermal-sprayed heat exchangers were tested at high temperatures (750 °C), and their performances were compared to the foam heat exchangers made by brazing Inconel sheets to their surface. Nickel foil was brazed to the exterior surface of 10-mm-thick layers of 10 and 40 PPI nickel foam. A plasma torch was used to spray an Inconel coating on the surface of the foil. A burner test rig was built to produce hot combustion gases that flowed over exposed face of the heat exchanger. Cooling air flowed through the foam heat exchanger at rates of up to 200 SLPM. Surface temperature and air inlet/exit temperature were measured. Heat transfer to air flowing through the foam was significantly higher for the thermally sprayed heat exchangers than for the brazed heat exchangers. On an average, thermally sprayed heat exchangers show 36% higher heat transfer than conventionally brazed foam heat exchangers. At low flow rates, the convective resistance is large (~4 × 10-2 m2 K/W), and the effect of thermal contact resistance is negligible. At higher flow rates, the convective resistance decreases (~2 × 10-3 m2 K/W), and the lower contact resistance of the thermally sprayed heat exchanger provides better performance than the brazed heat exchangers.

  13. Plasma and magnetohydrodynamic problems in vacuum consumable arc remelting

    SciTech Connect

    Bertram, L.A.; Zanner, F.J.

    1982-01-01

    Production of large homogeneous ingots of macrosegregation sensitive reactive alloys by the vacuum consumable arc remelting process depends on reliable control of the furnace. Such control is possible only when the normal operation is understood. A tightly coupled theoretical-experimental-numerical program has been under way for some time at Sandia in conjunction with other DOE and private facilities, aimed at achieving this understanding. The furnace arc and electrode surfaces have been studied by high speed cinematography, showing that basic arc behavior is similar to that reported in the arc physics literature for vacuum breaker switches with cold (unmelted) electrodes.

  14. Plasma Spray Synthesis Of Nanostructured V2O5 Films For Electrical Energy Storage

    SciTech Connect

    Nanda, Jagjit

    2011-01-01

    We demonstrate for the first time, the synthesis of nanostructured vanadium pentoxide (V2O5) films and coatings using plasma spray technique. V2O5 has been used in several applications such as catalysts, super-capacitors and also as an electrode material in lithium ion batteries. In the present studies, V2O5 films were synthesized using liquid precursors (vanadium oxychloride and ammonium metavanadate) and powder suspension. In our approach, the precursors were atomized and injected radially into the plasma gun for deposition on the substrates. During the flight towards the substrate, the high temperature of the plasma plume pyrolyzes the precursor particles resulting into the desired film coatings. These coatings were then characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), Transmission electron microscopy (TEM) and Differential Scanning Calorimetry (DSC). Among the precursors, vanadium oxychloride gave the best results in terms of nanocrystalline and monophasic films. Spraying of commercial powder suspension yielded multi-phasic mixture in the films. Our approach enables deposition of large area coatings of high quality nanocrystalline films of V2O5 with controllable particle morphology. This has been optimized by means of control over precursor composition and plasma spray conditions. Initial electrochemical studies of V2O5 film electrodes show potential for energy storage studies.

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

    NASA Astrophysics Data System (ADS)

    Mihm, Sebastian; Duda, Thomas; Gruner, Heiko; Thomas, Georg; Dzur, Birger

    2012-06-01

    Over the last few years, global economic growth has triggered a dramatic increase in the demand for resources, resulting in steady rise in prices for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened potential of savings and form the basis for securing future competitive advantages in the market. In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the optimization of the APS coating process is the use of the existing coating equipment. Furthermore, the current coating quality and characteristics must not change so as to avoid new qualification and testing. Using experience in APS and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow-rate, the electrical power, the arrangement and angle of the powder injectors in relation to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedures such as spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity and temperature), powder injection conditions (injection point, injection speed, grain size and distribution) and the coating lamination (coating pattern and spraying distance) are examined. The optimized process and resulting coating were compared to the current situation using several diagnostic methods. The improved process significantly reduces costs and achieves the requirement of comparable coating quality. Furthermore, a contribution was made towards better comprehension of the APS of ceramics and the definition of a better method for future process developments.

  16. MCrAlY Bondcoats by High-Velocity Atmospheric Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Sebold, D.; Vaßen, R.

    2014-01-01

    MCrAlY bondcoats (M = Co, Ni) are used to protect metallic substrates from oxidation and to improve adhesion of ceramic thermal barrier coatings for high temperature applications, such as in land-based and aviation turbines. Since MCrAlYs are prone to take up oxygen during thermal spraying, bondcoats often are manufactured under inert gas conditions at low pressure. Plasma spraying at atmospheric conditions is a cost-effective alternative if it would be possible to limit the oxygen uptake as well as to obtain sufficiently dense microstructures. In the present work, high-velocity spray parameters were developed for the TriplexPro 210 three-cathode plasma torch using MCrAlY powders of different particle size fractions to achieve these objectives. The aims are conflictive since the former requires cold conditions, whereas the latter is obtained by more elevated particle temperatures. High particle velocities can solve this divergence as they imply shorter time for oxidation during flight and contribute to coating densification by kinetic rather than thermal energy. Further aims of the experimental work were high deposition efficiencies as well as sufficient surface roughness. The oxidation behavior of the sprayed coatings was characterized by thermal gravimetric analyses and isothermal heat treatments.

  17. Fabrication and Characterization of Amorphous Alumina-Yttria-Stabilized Zirconia Coatings by Air Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Song, Xuemei; Suhonen, Tomi; Varis, Tommi; Huang, Liping; Zheng, Xuebin; Zeng, Yi

    2014-12-01

    Almost fully amorphous coatings of near-eutectic alumina-yttria-stabilized zirconia (Al2O3-YSZ) were prepared by air plasma spraying using Al2O3 and 8 mol.% YSZ crystalline-mixed powders. The coatings consist of mostly an amorphous phase with a small amount of nanocrystals. Various characterization techniques were used to understand coating formation and the origins of the different phases within the coatings. The formation of the mostly amorphous structure is attributed to the high glass-forming ability of Al2O3-YSZ and the appropriate plasma spraying conditions. A small number of nanocrystals are produced during crystallization of the incoming molten droplets or by recrystallization of the solidified splats by accumulated heat. Scanning electron microscopy shows that the coatings have a dense, layered structure with low porosity, and bright-field transmission electron microscopy images indicate sharp interface rather than grit-blasted wavy surface between splats and substrates in the coatings. The as-sprayed amorphous coatings crystallized at around 920 °C and micro-hardness of the as-sprayed amorphous coatings was 8.12 GPa.

  18. Mechanical Properties of Yttria- and Ceria-Stabilized Zirconia Coatings Obtained by Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Łatka, Leszek; Cattini, Andrea; Chicot, Didier; Pawłowski, Lech; Kozerski, Stefan; Petit, Fabrice; Denoirjean, Alain

    2013-03-01

    Plasma generated by the SG-100 torch was applied to spray suspension formulated with the use of ZrO2 + 8 wt.% Y2O3 (8YSZ) and ZrO2 + 24 wt.% CeO2 + 2.5 wt.% Y2O3 (24CeYSZ) as solid phases. The suspensions were formulated with the use of 20 wt.% solid phase, 40 wt.% water, and 40 wt.% ethanol. The plasma spray parameters were optimized by keeping constant: (a) the electric power of 40 kW and (b) the working gas compositions of 45 slpm for Ar and 5 slpm for H2. On the other hand, the spray distance was varied from 40 to 60 mm and the torch linear speed was varied from 300 to 500 mm/s. The coatings were sprayed onto stainless steel substrates, and their thicknesses were in the range from 70 to 110 μm. The coating microstructures were analyzed with a scanning electron microscope. Mechanical properties were tested with the different methods including the indentation and scratch tests. The indentation test, carried out with various loads ranging from 100 to 10,000 mN, enabled to determine elastic modulus and Martens microhardness. Young's modulus of the coatings was in the range of 71-107 GPa for 8YSZ and 68-130 GPa for 24CeYSZ coatings. The scratch test enabled the authors to find the scratch macrohardness.

  19. Parametric study of Al and Al 2O 3 ceramic coatings deposited by air plasma spray onto polymer substrate

    NASA Astrophysics Data System (ADS)

    Guanhong, Sun; Xiaodong, He; Jiuxing, Jiang; Yue, Sun

    2011-06-01

    Aluminum and ceramic (Al 2O 3) coatings were deposited onto the polymer substrate by air plasma spray (APS) to improve the mechanical properties of the polymer surface. The effect of spray parameters (current and spray distance in this paper) on the phase composition, microstructure and mechanical properties was investigated. Shear adhesion strength between the coatings and the substrates was also examined. The results indicate that the deposition parameters have a significant effect on the phase composition, microstructure and mechanical properties of as-spayed coatings. The maximum shear adhesion strength of the bond coats was 5.21 MPa with the current of 180 A and 190 mm spray distance.

  20. The effects of plasma spray parameters and atmosphere on the properties and microstructure of WC-Co coatings

    NASA Astrophysics Data System (ADS)

    Ghosh, D.; Lamy, D.; Sopkow, T.; Smuga-Otto, I.

    Wear- and corrosion-resistant coatings deposited by plasma spray process are increasingly used in severe environments in resource industries, such as oil and gas, oil sands, mining, pulp and paper, etc. While there is a large volume of literature in the area of plasma spray coatings, comparatively few papers deal with the co-relation between coating properties and microstructure as a function of plasma spray processing parameters. In this study, the effect of some plasma spray processing variables and atmosphere (air or inert gas) on the microstructure and the properties of WC-Co coatings were studied. The properties of the coatings measured include: microhardness, porosity by image analysis, wear resistance by dry sand/rubber wheel abrasion test (ASTM G 65-91) and corrosion properties by AC impedance technique. Phase analyses of the coatings were also performed by X-ray diffraction. From the above, optimized coatings were developed for oil and gas industry applications.

  1. Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines

    NASA Technical Reports Server (NTRS)

    Sumner, I. E.; Ruckle, D. L.

    1980-01-01

    As part of a NASA program to reduce fuel consumption of current commercial aircraft engines, methods were investigated for improving the durability of plasma sprayed ceramic coatings for use on vane platforms in the JT9D turbofan engine. Increased durability concepts under evaluation include use of improved strain tolerant microstructures and control of the substrate temperature during coating application. Initial burner rig tests conducted at temperatures of 1010 C (1850 F) indicate that improvements in cyclic life greater than 20:1 over previous ceramic coating systems were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 100-cycle JT9D engine endurance test with only minor damage occurring to the coatings.

  2. The structure, properties and performance of plasma-sprayed beryllium for fusion applications

    SciTech Connect

    Castro, R.G.; Stanek, P.W.; Elliott, K.E.

    1995-09-01

    Plasma-spray technology is under investigation as a method for producing high thermal conductivity beryllium coatings for use in magnetic fusion applications. Recent investigations have focused on optimizing the plasma-spray process for depositing beryllium coatings on damaged beryllium surfaces. Of particular interest has been optimizing the processing parameters to maximize the through-thickness thermal conductivity of the beryllium coatings. Experimental results will be reported on the use of secondary H{sub 2} gas additions to improve the melting of the beryllium powder and transferred-arc cleaning to improve the bonding between the beryllium coatings and the underlying surface. Information will also be presented on thermal fatigue tests which were done on beryllium coated ISX-B beryllium limiter tiles using 10 sec cycle times with 60 sec cooldowns and an International Thermonuclear Experimental Reactor (ITER) relevant divertor heat flux slightly in excess of 5 MW/m{sup 2}.

  3. High Performance MoxN Electrode Fabricated by Solution Precursor Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Gazman, Yakov

    Changing climate and decreasing availability of fossil fuels stimulate the use of alternative energy sources and energy storage devices such as electrochemical capacitors The current study investigates the implementation of SPPS (Solution Precursor Plasma Spraying) for the deposition of high surface area electrochemical capacitor electrodes. A high performance MoxN electrochemical capacitor electrode was produced by solution precursor plasma spraying for the first time. The best electrode exhibited an initial capacitance of 62.4 mF cm-2 at a scan rate of 100 mV sec-1. The capacitance decreased by 22% after the first 1000 cycles, but the performance then stabilized, decreasing by only 0.15% over cycles 4000 to 5000 and exhibiting a capacitance of 30mF cm-2 after 5000 cycles. SPPS is a novel deposition method, thus further understanding and optimization of the process is required to improve the performance and manufacturability, but a clear potential was proven.

  4. Self-lubricating plasma-sprayed composites for sliding contact bearings to 900 C

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1974-01-01

    Plasma-sprayed composites which have good oxidation-resistance and self-lubricating characteristics to 900 C were developed. The composites are a Nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication. They are applied to bearing surfaces in layers about 0.050 cm thick by plasma-spraying; the layers are then machined to a thickness of 0.025 cm. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 3.5 times 10 to the 7th power Newtons per square meter (5000 psi) and a thrust load of 1960 Newtons (440 lb). Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated bearing temperature cycles between 25 and 900 C.

  5. Preparation and in vitro evaluation of plasma-sprayed bioactive akermanite coatings.

    PubMed

    Yi, Deliang; Wu, Chengtie; Ma, Xubing; Ji, Heng; Zheng, Xuebin; Chang, Jiang

    2012-12-01

    Bioactive ceramic coatings on titanium (Ti) alloys play an important role in orthopedic applications. In this study, akermanite (Ca(2)MgSi(2)O(7)) bioactive coatings are prepared through a plasma spraying technique. The bonding strength between the coatings and Ti-6Al-4V substrates is around 38.7-42.2 MPa, which is higher than that of plasma sprayed hydroxyapatite (HA) coatings reported previously. The prepared akermanite coatings reveal a distinct apatite-mineralization ability in simulated body fluid. Furthermore, akermanite coatings support the attachment and proliferation of rabbit bone marrow mesenchymal stem cells (BMSCs). The proliferation rate of BMSCs on akermanite coatings is obviously higher than that on HA coatings. PMID:23159958

  6. A design of experiment study of plasma sprayed alumina-titania coatings

    SciTech Connect

    Steeper, T.J. and Co., Aiken, SC . Savannah River Lab.); Varacalle, D.J. Jr.; Wilson, G.C. ); Riggs, W.L. II ); Rotolico, A.J.; Nerz, J.E. )

    1992-01-01

    An experimental study of the plasma spraying of alumina-titania powder is presented in this paper. This powder system is being used to fabricate heater tubes that emulate nuclear fuel tubes for use in thermal-hydraulic testing. Coating experiments were conducted using a Taguchi fractional-factorial design parametric study. Operating parameters were varied around the typical spray parameters in a systematic design of experiments in order to display the range of plasma processing conditions and their effect on the resultant coating. The coatings were characterized by hardness and electrical tests, image analysis, and optical metallography. Coating qualities are discussed with respect to dielectric strength, hardness, porosity, surface roughness, deposition efficiency, and microstructure. The attributes of the coatings are correlated with the changes in operating parameters.

  7. Mechanical property measurements of plasma-sprayed thermal-barrier coatings subjected to oxidation

    NASA Technical Reports Server (NTRS)

    Berndt, C. C.; Miller, R. A.

    1984-01-01

    Techniques have been developed for measuring the tensile properties of plasma-sprayed coatings which are used in thermal barrier applications. The measurements have included the average Young's modulus, bond strength and elongation at failure. The oxidation behavior of the bond coat plays an important role in the integrity and adhesion of plasma-sprayed thermal barrier coatings. This work studies the nature of the high temperature degradation on the mechanical properties of the coating. Furnace tests have been carried out on U-700 alloy with bond coats of NiCrAlY or NiCrAlZr and an overlay of ZrO2-8 percent Y2O3. Weight gain measurements on the coatings have been examined with relation to the adhesion strength and failure observations. The results from an initial study are reported in this work.

  8. Mechanical property measurements of plasma-sprayed thermal-barrier coatings subjected to oxidation

    SciTech Connect

    Berndt, C.C.; Miller, R.A.

    1984-07-01

    Techniques have been developed for measuring the tensile properties of plasma-sprayed coatings which are used in thermal barrier applications. The measurements have included the average Young's modulus, bond strength and elongation at failure. The oxidation behavior of the bond coat plays an important role in the integrity and adhesion of plasma-sprayed thermal barrier coatings. This work studies the nature of the high temperature degradation on the mechanical properties of the coating. Furnace tests have been carried out on U-700 alloy with bond coats of NiCrAlY or NiCrAlZr and an overlay of ZrO2-8 percent Y2O3. Weight gain measurements on the coatings have been examined with relation to the adhesion strength and failure observations. The results from an initial study are reported in this work. 13 references.

  9. A design of experiment study of plasma sprayed alumina-titania coatings

    SciTech Connect

    Steeper, T.J.; Varacalle, D.J. Jr.; Wilson, G.C.; Riggs, W.L. II; Rotolico, A.J.; Nerz, J.E.

    1992-08-01

    An experimental study of the plasma spraying of alumina-titania powder is presented in this paper. This powder system is being used to fabricate heater tubes that emulate nuclear fuel tubes for use in thermal-hydraulic testing. Coating experiments were conducted using a Taguchi fractional-factorial design parametric study. Operating parameters were varied around the typical spray parameters in a systematic design of experiments in order to display the range of plasma processing conditions and their effect on the resultant coating. The coatings were characterized by hardness and electrical tests, image analysis, and optical metallography. Coating qualities are discussed with respect to dielectric strength, hardness, porosity, surface roughness, deposition efficiency, and microstructure. The attributes of the coatings are correlated with the changes in operating parameters.

  10. Mechanical Properties of Plasma-Sprayed ZrO2-8 wt% Y2O3 Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

    2004-01-01

    Mechanical behavior of free standing, plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings, including strength, fracture toughness, fatigue, constitutive relation, elastic modulus, and directionality, has been determined under various loading-specimen configurations. This report presents and describes a summary of mechanical properties of the plasma-sprayed coating material to provide them as a design database.

  11. Reactive Plasma-Sprayed Aluminum Nitride-Based Coating Thermal Conductivity

    NASA Astrophysics Data System (ADS)

    Shahien, Mohammed; Yamada, Motohiro; Fukumoto, Masahiro; Egota, Kazumi; Okamoto, Kenji

    2015-12-01

    Recently, thick aluminum nitride/alumina (AlN/Al2O3) composite coatings were successfully fabricated through the reactive plasma spraying of fine Al2O3/AlN mixture in the N2/H2 atmospheric plasma. The coatings consist of AlN, Al5O6N, γ-Al2O3, and α-Al2O3 phases. This study will evaluate the thermal conductivity of these complicated plasma-sprayed coatings and optimize the controlling aspects. Furthermore, the influence of the process parameters on the coatings thermal conductivity will be investigated. The fabricated coatings showed very low thermal conductivity (2.43 W/m K) compared to the AlN sintered compacts. It is attributed to the phase composition of the fabricated coatings, oxide content, and porosity. The presence of Al2O3, Al5O6N and the high coating porosity decreased its thermal conductivity. The presence of oxygen in the AlN lattice creates Al vacancies which lead to phonon scattering and therefore suppressed the thermal conductivity. The formation of γ-Al2O3 phase in the coating leads to further decrease in its conductivity, due to its lower density compared to the α-phase. Moreover, the high porosity of the coating strongly suppressed the conductivity. This is due to the complicated microstructure of plasma spray coatings (splats, porosity, and interfaces, particularly in case of reactive spray process), which obviously lowered the conductivity. Furthermore, the measured coating density was lower than the AlN value and suppressed the coating conductivity. In addition, the spraying parameter showed a varied effect on the coating phase composition, porosity, density, and therefore on its conductivity. Although the N2 gas flow improved the nitride content, it suppressed the thermal conductivity gradually. It is attributed to the further increase in the porosity and further decrease in the density of the coatings with the N2 gas. Furthermore, increasing the arc did not show a significant change on the coating thermal conductivity. On the other hand, the influence of spray parameters was optimized by investigating the effect of simple heat treatment (at 1100 °C) as a function of the arc current and N2 gas flow. The heat treatment improved the coating thermal conductivity at the different spray parameters. Thus, after heat treatment, the coating porosity, γ-Al2O3, Al5O6N strongly decreased and therefore the conductivity improved. On the other hand, the N2 gas flow and/or arc current did not show any difference on the conductivity after heat treatment. Therefore, using higher N2 gas flow and higher arc current is economically useless. Finally, although the obtained conductivity of the coating was not so high (compared to the AlN value), the main factors that govern the conductivity of such complicated plasma-spraying composite coating was realized. Herein, in order to fabricate high thermal conductivity AlN plasma spray coating, adjusting the phase composition, oxide content, porosity, and microstructure (at low N2 gas flow rate and low arc current) through the post-heat treatment is the key factor.

  12. COMPARISON OF THERMAL PROPERTIES OF THERMAL BARRIER COATING DEPOSITED ON IN738 USING STANDARD AIR PLASMA SPRAY WITH 100HE PLASMA SPRAY SYSTEM

    SciTech Connect

    Uppu, N.; Mensah, P.F.; Ofori, D.

    2006-07-01

    A typical blade material is made of Nickel super alloy and can bear temperatures up to 950°C. But the operating temperature of a gas turbine is above the melting point of super alloy nearly at 1500°C. This could lead to hot corrosions, high temperature oxidation, creep, thermal fatigue may takes place on the blade material. Though the turbine has an internal cooling system, the cooling is not adequate to reduce the temperature of the blade substrate. Therefore to protect the blade material as well as increase the efficiency of the turbine, thermal barrier coatings (TBCs) must be used. A TBC coating of 250 μm thick can reduce the temperature by up to 200° C. Air Plasma Spray Process (APS) and High Enthalpy Plasma Spray Process (100HE) were the processes used for coating the blades with the TBCs. Because thermal conductivity increases with increase in temperature, it is desired that these processes yield very low thermal conductivities at high temperatures in order not to damage the blade. An experiment was carried out using Flash line 5000 apparatus to compare the thermal conductivity of both processes.The apparatus could also be used to determine the thermal diffusivity and specific heat of the TBCs. 75 to 2800 K was the temperature range used in the experimentation. It was found out that though 100HE has high deposition efficiency, the thermal conductivity increases with increase in temperatures whiles APS yielded low thermal conductivities.

  13. Miniature pulsed vacuum arc plasma gun and apparatus for thin-film fabrication

    DOEpatents

    Brown, Ian G.; MacGill, Robert A.; Galvin, James E.; Ogletree, David F.; Salmeron, Miquel

    1998-01-01

    A miniature (dime-size in cross-section) vapor vacuum arc plasma gun is described for use in an apparatus to produce thin films. Any conductive material can be layered as a film on virtually any substrate. Because the entire apparatus can easily be contained in a small vacuum chamber, multiple dissimilar layers can be applied without risk of additional contamination. The invention has special applications in semiconductor manufacturing.

  14. Miniature pulsed vacuum arc plasma gun and apparatus for thin-film fabrication

    DOEpatents

    Brown, I.G.; MacGill, R.A.; Galvin, J.E.; Ogletree, D.F.; Salmeron, M.

    1998-11-24

    A miniature (dime-size in cross-section) vapor vacuum arc plasma gun is described for use in an apparatus to produce thin films. Any conductive material can be layered as a film on virtually any substrate. Because the entire apparatus can easily be contained in a small vacuum chamber, multiple dissimilar layers can be applied without risk of additional contamination. The invention has special applications in semiconductor manufacturing. 8 figs.

  15. Monitoring Delamination of Plasma-Sprayed Thermal Barrier Coatings by Reflectance-Enhanced Luminescence

    NASA Technical Reports Server (NTRS)

    Eldridge, Jeffrey I.; Bencic, Timothy J.

    2006-01-01

    Highly scattering plasma-sprayed thermal barrier coatings (TBCs) present a challenge for optical diagnostic methods to monitor TBC delamination because scattering attenuates light transmitted through the TBC and usually degrades contrast between attached and delaminated regions of the TBC. This paper presents a new approach where reflectance-enhanced luminescence from a luminescent sublayer incorporated along the bottom of the TBC is used to identify regions of TBC delamination. Because of the higher survival rate of luminescence reflecting off the back surface of a delaminated TBC, the strong scattering exhibited by plasma-sprayed TBCs actually accentuates contrast between attached and delaminated regions by making it more likely that multiple reflections of luminescence off the back surface occur before exiting the top surface of the TBC. A freestanding coating containing sections designed to model an attached or delaminated TBC was prepared by depositing a luminescent Eu-doped or Er-doped yttria-stabilized zirconia (YSZ) luminescent layer below a plasma-sprayed undoped YSZ layer and utilizing a NiCr backing layer to represent an attached substrate. For specimens with a Eu-doped YSZ luminescent sublayer, luminescence intensity maps showed excellent contrast between unbacked and NiCr-backed sections even at a plasma-sprayed overlayer thickness of 300 m. Discernable contrast between unbacked and NiCr-backed sections was not observed for specimens with a Er-doped YSZ luminescent sublayer because luminescence from Er impurities in the undoped YSZ layer overwhelmed luminescence originating form the Er-doped YSZ sublayer.

  16. In-situ formation of multiphase air plasma sprayed barrier coatings for turbine components

    SciTech Connect

    Subramanian, Ramesh

    2001-01-01

    A turbine component (10), such as a turbine blade, is provided which is made of a metal alloy (22) and a base, planar-grained thermal barrier layer (28) applied by air plasma spraying on the alloy surface, where a heat resistant ceramic oxide overlay material (32') covers the bottom thermal barrier coating (28), and the overlay material is the reaction product of the precursor ceramic oxide overlay material (32) and the base thermal barrier coating material (28).

  17. Finite element analysis of residual stress in plasma-sprayed ceramic

    NASA Technical Reports Server (NTRS)

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

    1985-01-01

    Residual stress in a ZrO2-Y2O3 ceramic coating resulting from the plasma spraying operation is calculated. The calculations were done using the finite element method. Both thermal and mechanical analysis were performed. The resulting residual stress field was compared to the measurements obtained by Hendricks and McDonald. Reasonable agreement between the predicted and measured moment occurred. However, the resulting stress field is not in pure bending.

  18. Finite element analysis of residual stress in plasma-sprayed ceramic

    SciTech Connect

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

    1985-08-01

    Residual stress in a ZrO2-Y2O3 ceramic coating resulting from the plasma spraying operation is calculated. The calculations were done using the finite element method. Both thermal and mechanical analysis were performed. The resulting residual stress field was compared to the measurements obtained by Hendricks and McDonald. Reasonable agreement between the predicted and measured moment occurred. However, the resulting stress field is not in pure bending. 14 references.

  19. A model for residual stress evolution in air-plasma-sprayed zirconia thermal barrier coatings

    SciTech Connect

    Nair, B. G.; Singh, J. P.; Grimsditch, M.

    2000-02-28

    Ruby fluorescence spectroscopy indicates that residual stress in air-plasma-sprayed zirconia thermal barrier coatings is a function of the local interface geometry. The stress profile of a simulated rough interface characterized by ``peaks'' and ``valleys'' was modeled with a finite-element approach that accounted for thermal mismatch, oxide scale growth, and top coat sintering. Dependence of the stress profile on interface geometry and microstructure was investigated, and the results were compared with measured stresses.

  20. High current multicharged metal ion source using high power gyrotron heating of vacuum arc plasma.

    PubMed

    Vodopyanov, A V; Golubev, S V; Khizhnyak, V I; Mansfeld, D A; Nikolaev, A G; Oks, E M; Savkin, K P; Vizir, A V; Yushkov, G Yu

    2008-02-01

    A high current, multi charged, metal ion source using electron heating of vacuum arc plasma by high power gyrotron radiation has been developed. The plasma is confined in a simple mirror trap with peak magnetic field in the plug up to 2.5 T, mirror ratio of 3-5, and length variable from 15 to 20 cm. Plasma formed by a cathodic vacuum arc is injected into the trap either (i) axially using a compact vacuum arc plasma gun located on axis outside the mirror trap region or (ii) radially using four plasma guns surrounding the trap at midplane. Microwave heating of the mirror-confined, vacuum arc plasma is accomplished by gyrotron microwave radiation of frequency 75 GHz, power up to 200 kW, and pulse duration up to 150 micros, leading to additional stripping of metal ions by electron impact. Pulsed beams of platinum ions with charge state up to 10+, a mean charge state over 6+, and total (all charge states) beam current of a few hundred milliamperes have been formed. PMID:18315170

  1. Tailored plasma sprayed MCrAlY coatings for aircraft gas turbine applications

    NASA Technical Reports Server (NTRS)

    Pennisi, F. J.; Gupta, D. K.

    1981-01-01

    Eighteen plasma sprayed coating systems, nine based on the NiCoCrAly chemistry and nine based on the CoCrAly composition, were evaluated to identify coating systems which provide equivalent or superior life to that shown by the electron beam physical vapor deposited NiCoCrAly and CoCrAly coatings respectively. NiCoCrAly type coatings were examined on a single crystal alloy and the CoCrAly based coatings were optimized on the B1900+ Hf alloy. Cyclic burner rig oxidation and hot corrosion and tensile ductility tests used to evaluate the various coating candidates. For the single crystal alloy, a low pressure chamber plasma sprayed NiCoCrAly + Si coating exhibited a 2x oxidation life improvement at 1394 K (2050 F) over the vapor deposited NiCoCrAly material while showing equivalent tensile ductility. A silicon modified low pressure chamber plasma sprayed CoCrAly coating was found to be more durable than the baseline vapor deposited CoCrAly coating on the B1900+ Hf alloy.

  2. Plasma sprayed cast iron coatings containing solid lubricant graphite and h-BN structure

    NASA Astrophysics Data System (ADS)

    Tsunekawa, Y.; Ozdemir, I.; Okumiya, M.

    2006-06-01

    Water-atomized cast iron powder of Fe-2.17 at.%C-9.93at.%Si-3.75at.%Al were deposited onto an aluminum alloy substrate by atmospheric direct current plasma spraying to improve its tribological properties. Preannealing of the cast iron powder allows the precipitation of considerable amounts of graphite structure in the powder. However, significant reduction in graphitized carbon in cast iron coatings is inevitable after plasma spraying in air atmosphere due to the in-flight burning and dissolution into molten iron droplets. Hexagonal boron nitride (h-BN) powders, which have excellent lubricating properties like graphite, were incorporated into the cast iron powder as a solid lubricant by the sintering process (1300°C) to obtain protective coatings with a low friction coefficient. The performance of each coating was evaluated using a ring-on-disk-type wear tester under a paraffin-based oil condition in an air atmosphere. A conventional cast iron liner, which had a flaky graphite embedded in the pearlitic matrix, was also tested under similar conditions for comparison. Sections of worn surfaces and debris were characterized, and the wear behavior of plasma-sprayed coatings was discussed.

  3. The Performances of TiN-TiB2 Coating Prepared by Reactive Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Ma, Jing; Hu, Jianwen; Yan, Dongqing; Mao, Zhengping

    2012-06-01

    Reactive plasma sprayed coatings were prepared on carbon steel substrates with Ti and B4C as starting materials. Two kinds of gases (Ar and N2) were used as feeding gases for powders, respectively. 10 wt.% Cr was added in the powders as binder to increase the bond strength of the coating. The phases, microstructure, micro-hardness and corrosion polarization behavior in 3.5 wt.% NaCl solution of the two coatings were studied. The results show that TiN-TiB2 coatings were prepared under both conditions. The two coatings have typically laminated structure. However, the coating prepared with Ar as feeding gas has higher porosity and some unmelted Cr particles. It also contains certain content of titanium oxides. The microhardness of coating prepared with Ar as feeding gas is lower due to its higher porosity, unmelted Cr particles and some amounts of TiO2. The corrosion resistance of TiN-TiB2 coating prepared with Ar as feeding gas in 3.5 wt.% NaCl solution is worse than that of the coating prepared with N2 as feeding gas. Yet the corrosion resistance of reactive plasma sprayed TiN-TiB2 coating is improved greatly compared with that of carbon steel. The thermodynamic analysis of reactive plasma spraying process is also discussed.

  4. Copper-titanium diboride coatings obtained by plasma spraying reactive micropellets

    NASA Astrophysics Data System (ADS)

    Legoux, J. G.; Dallaire, S.

    1993-09-01

    Electrotribological applications require materials with both high electrical conductivity and wear resisance. For this purpose, a copper- base plasma sprayed coating containing titanium diboride particles was developed. The process for fabricating this CU- TiB2 coating consists of plasma spraying reactive powders that contain a Cu- Ti alloy and boron. The reaction between the copper alloy and boron proceeds in different steps going from solid- state diffusion of titanium and copper to the synthesis of TiB2 in a liquid below 1083 C. Plasma sprayed copper coatings contain finer TiB2 crystals than Cu- TiB2 materials synthesized in a furnace at 1200 C. Coatings with 25 vol% TiB2 have hardnesses that are comparable to Cu- Co- Be and Cu- Ni- Be alloys and to Cu- W and Cu- Mo alloys used in spot welding. Their low electrical resistivity of 52 ?? cm could be increased by lowering the oxygen content with coatings and controlling the formation of TiB2 clusters, the titanium content in solution in copper remaining low after the synthesis reaction.

  5. Microstructure and thermal behaviour of plasma sprayed zirconia/alumina composite coating.

    PubMed

    Kobayashi, A; Ando, Y; Kurokawa, K; Hejwowski, T

    2011-10-01

    In thermal barrier coatings (TBC), failure occurs near or at the interface between the metallic bondcoat and topcoat. On high temperature conditions, an oxide scale which is named thermally grown oxide (TGO) occurs along the bond/topcoat interface. For diminishing the creation of TGO, a dense coating with low residual stress and thermal stress buffer layer was preferable. High hardness ceramic coatings could be obtained by gas tunnel type plasma spraying, and the deposited coating had superior property in comparison with those deposited by conventional type plasma spray method. In this study, the gas tunnel type plasma spraying system was utilized to produce a zirconia/alumina functionally graded thermal barrier coating and discussed its physical and mechanical properties, thermal behavior and high temperature oxidation resistance of the coating are discussed. Consequently, the proposed system exhibited superior mechanical properties and oxidation resistance at the expenses of a slightly lower thermal insulating effect. This interlayer is preferred in order to minimize the detrimental effect of the phase transformation of gamma-Al2O3 to alpha-Al2O3. PMID:22400271

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

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

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

  7. On characterisation of wire-arc-plasma-sprayed Ni on alumina substrate

    SciTech Connect

    Laik, A.; Chakravarthy, D.P.; Kale, G.B. . E-mail: gbkale@apsara.barc.ernet.in

    2005-08-15

    A study was carried out on metal-ceramic bonding produced by the technique of wire-arc-plasma spraying of Ni on Al{sub 2}O{sub 3} substrate. The Ni layer and the Ni/Al{sub 2}O{sub 3} interface were characterised using optical and electro-optic techniques. The plasma-deposited Ni layer shows a uniform lamellar microstructure throughout the cross-section. The metal-ceramic interface was found to be well bonded with no pores, flaws or cracks in the as-sprayed condition. The optical metallography and concentration profiles established with the help of an electron probe microanalyser confirmed the absence of any intermediate phase at the interface. An annealing treatment at 1273 K for 24 h on the plasma-coated samples did not result in formation of any intermetallic compound or spinel at the Ni/Al{sub 2}O{sub 3} interface. This indicates that the oxygen picked up by Ni during the spraying operation is less than the threshold value required to form the spinel NiAl{sub 2}O{sub 4}.

  8. Columnar-Structured Mg-Al-Spinel Thermal Barrier Coatings (TBCs) by Suspension Plasma Spraying (SPS)

    NASA Astrophysics Data System (ADS)

    Schlegel, N.; Ebert, S.; Mauer, G.; Vaßen, R.

    2015-01-01

    The suspension plasma spraying (SPS) process has been developed to permit the feeding of sub-micrometer-sized powder into the plasma plume. In contrast to electron beam-physical vapor deposition and plasma spray-physical vapor deposition, SPS enables the cost-efficient deposition of columnar-structured coatings. Due to their strain tolerance, these coatings play an important role in the field of thermal barrier coatings (TBCs). In addition to the cost-efficient process, attention was turned to the TBC material. Nowadays, yttria partially stabilized zirconia (YSZ) is used as standard TBC material. However, its long-term application at temperatures higher than 1200 °C is problematic. At these high temperatures, phase transitions and sintering effects lead to the degradation of the TBC system. To overcome those deficits of YSZ, Mg-Al-spinel was chosen as TBC material. Even though it has a lower melting point (~2135 °C) and a higher thermal conductivity (~2.5 W/m/K) than YSZ, Mg-Al-spinel provides phase stability at high temperatures in contrast to YSZ. The Mg-Al-spinel deposition by SPS resulted in columnar-structured coatings, which have been tested for their thermal cycling lifetime. Furthermore, the influence of substrate cooling during the spraying process on thermal cycling behavior, phase composition, and stoichiometry of the Mg-Al-spinel has been investigated.

  9. X-ray diffraction characterization of crystallinity and phase composition in plasma-sprayed hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Prevy, Paul S.

    2000-09-01

    Orthopedic and dental implants consisting of a metallic substrate plasma spray coated with hydroxyapatite (HA) are currently used in reconstructive surgery. The crystalline phases present in the calcium phosphate ceramic and the degree of crystallinity must be controlled for medical applications. X-ray diffraction (XRD) is routinely employed to characterize the phase composition and percent crystallinity in both biological and sintered HA. However, application of the same XRD methods to plasma-sprayed coatings is complicated by the potential presence of several crystalline contaminant phases and an amorphous component. To overcome the complexities of characterizing plasma-sprayed HA coatings, an external standard method of XRD quantitative analysis has been developed that can be applied nondestructively. Data collection and reduction strategies allowing separation of intensity diffracted from commonly occurring phases and the amorphous fraction are presented. The method is applied to coating samples, and detection limits and sources of error are discussed. Repeability and accuracy are demonstrated with powder mixtures of known composition.

  10. Eddy currents in a nonperiodic vacuum vessel induced by axisymmetric plasma motion

    SciTech Connect

    DeLucia, J.

    1985-12-01

    A method is described for calculating the two-dimensional trajectory of a vertically or horizontally unstable axisymmetric tokamak plasma in the presence of a resistive vacuum vessel. The vessel is not assumed to have toroidal symmetry. The plasma is represented by a current-filament loop that is free to move vertically and to change its major radius. Its position is evolved in time self-consistently with the vacuum vessel eddy currents. The plasma current, internal inductance, and poloidal beta can be specified functions of time so that eddy currents resulting from a disruption can be modeled. The vacuum vessel is represented by a set of current-filaments whose positions and orientations are chosen to model the dominant eddy current paths. Although the specific application is to TFTR, the present model is of general applicability. 7 refs., 4 figs., 2 tabs.

  11. Use of Polycarbonate Vacuum Vessels in High-Temperature Fusion-Plasma Research

    SciTech Connect

    B. Berlinger, A. Brooks, H. Feder, J. Gumbas, T. Franckowiak and S.A. Cohen

    2012-09-27

    Magnetic fusion energy (MFE) research requires ultrahigh-vacuum (UHV) conditions, primarily to reduce plasma contamination by impurities. For radiofrequency (RF)-heated plasmas, a great benefit may accrue from a non-conducting vacuum vessel, allowing external RF antennas which avoids the complications and cost of internal antennas and high-voltage high-current feedthroughs. In this paper we describe these and other criteria, e.g., safety, availability, design flexibility, structural integrity, access, outgassing, transparency, and fabrication techniques that led to the selection and use of 25.4-cm OD, 1.6-cm wall polycarbonate pipe as the main vacuum vessel for an MFE research device whose plasmas are expected to reach keV energies for durations exceeding 0.1 s

  12. A Seemingly Simple Task: Filling a Solenoid Volume in Vacuum with Dense Plasma

    SciTech Connect

    Anders, Andre; Kauffeldt, Marina; Roy, Prabir; Oks, Efim

    2010-06-24

    Space-charge neutralization of a pulsed, high-current ion beam is required to compress and focus the beam on a target for warm dense matter physics or heavy ion fusion experiments. We described attempts to produce dense plasma in and near the final focusing solenoid through which the ion beam travels, thereby providing an opportunity for the beam to acquire the necessary charge-compensating electrons. Among the options are plasma injection from four pulsed vacuum arc sources located outside the solenoid, and using a high current (> 4 kA) pulsed vacuum arc plasma from a ring cathode near the edge of the solenoid. The plasma distribution is characterized by photographic means and by an array of movable Langmuir probes. The plasma is produced at several cathode spots distributed azimuthally on the ring cathode. Beam neutralization and compression are accomplished, though issues of density, uniformity, and pulse-to-pulse reproducibly remain to be solved.

  13. The spatial and temperature structure of vacuum spark plasmas. [comparison with solar flare spectra

    NASA Technical Reports Server (NTRS)

    Feldman, U.; Goldsmith, S.; Schwob, J. L.; Doschek, G. A.

    1975-01-01

    The spatial and temperature structures of the X-ray emitting components of low-inductance vacuum-spark plasmas are investigated. The plasmas produced by low-inductance vacuum sparks show striking resemblances to solar-flare plasmas. High-resolution photographs show that the spark plasmas are composed of hot (about 30 million K) compact sources (less than 20 microns) and cooler (about 10 million K) larger sources (of the order of 100 microns). Both types of sources may be produced by the same plasma at different times. The differences between the solar flare iron-line spectrum near 1.9 A and the spark iron-line spectrum are discussed and interpreted.

  14. Manufacturing nanostructured YSZ coatings by suspension plasma spraying (SPS): effect of injection parameters

    NASA Astrophysics Data System (ADS)

    Meillot, E.; Vert, R.; Caruyer, C.; Damiani, D.; Vardelle, M.

    2011-05-01

    The suspension plasma spraying process is investigated using shadow imaging techniques to appreciate the different trajectories of the liquid jet interacting with a dc high-energy plasma flow. Then, the modelling of different liquid injections (isolated droplet, train of droplets and continuous jet) helps us to determine which injection type must be preferred. From that, coating depositions have been carried out with yttria zirconia suspension. Trajectory deviations at impact have been measured depending on the injection pressure and injection location. Coatings have been realized under the same operating investigations and their microstructures and mechanical properties have been characterized.

  15. Vacuum-arc plasma-beam motion in curved magnetic fields

    NASA Astrophysics Data System (ADS)

    Gidalevich, Evgeny; Goldsmith, Samuel; Boxman, Raymond

    1994-05-01

    A theoretical model is presented for transport of vacuum arc generated metal vapor plasma through a magnetized quarter-tours duct used for filtering out macroparticles in order to deposit high quality thin films. The model utilizes a two fluid approximation which takes into account collisions among the plasma particles. It is found that centrifugal forces must lead to a charge separation generated field, that determines plasma drift in the centrifugal force direction to the duct wall and give rise to ion loss. Another cause for plasma is the plasma pressure gradient. The plasma output flux is an increasing function of the magnetic field strength. The plasma flux in the output plane is asymmetrically skewed to favor the outside half. A further asymmetry in the flux distribution in the direction of the torroidal axis of symmetry is introduced if ions of different charge states are present in the plasma.

  16. Low-Energy Plasma Spray (LEPS) Deposition of Hydroxyapatite/Poly-?-Caprolactone Biocomposite Coatings

    NASA Astrophysics Data System (ADS)

    Garcia-Alonso, Diana; Parco, Maria; Stokes, Joseph; Looney, Lisa

    2012-01-01

    Thermal spraying is widely employed to deposit hydroxyapatite (HA) and HA-based biocomposites on hip and dental implants. For thick HA coatings (>150 ?m), problems are generally associated with the build-up of residual stresses and lack of control of coating crystallinity. HA/polymer composite coatings are especially interesting to improve the pure HA coatings' mechanical properties. For instance, the polymer may help in releasing the residual stresses in the thick HA coatings. In addition, the selection of a bioresorbable polymer may enhance the coatings' biological behavior. However, there are major challenges associated with spraying ceramic and polymeric materials together because of their very different thermal properties. In this study, pure HA and HA/poly-?-caprolactone (PCL) thick coatings were deposited without significant thermal degradation by low-energy plasma spraying (LEPS). PCL has never been processed by thermal spraying, and its processing is a major achievement of this study. The influence of selected process parameters on microstructure, composition, and mechanical properties of HA and HA/PCL coatings was studied using statistical design of experiments (DOE). The HA deposition rate was significantly increased by the addition of PCL. The average porosity of biocomposite coatings was slightly increased, while retaining or even improving in some cases their fracture toughness and microhardness. Surface roughness of biocomposites was enhanced compared with HA pure coatings. Cell culture experiments showed that murine osteoblast-like cells attach and proliferate well on HA/PCL biocomposite deposits.

  17. Noise power spectra of inductively coupled plasma mass spectrometry using a cooled spray chamber

    NASA Astrophysics Data System (ADS)

    Pollmann, D.; Pilger, C.; Hergenröder, R.; Leis, F.; Tschöpel, P.; Broekaert, J. A. C.

    1994-07-01

    The influence of the spray chamber temperature and the related aerosol water loading on ArO + as typical spectral interference in inductively coupled plasma mass spectrometry (ICP-MS) is studied. Therefore, the noise power spectra for the ArO + have been measured by use of fast Fourier transform (FFT) analysis. A Meinhard nebulizer and a GMK nebulizer were used in connection with a cooled spray chamber at a temperature of 5-25°C. It could be found that the relative standard deviation of the analyte signal in ICP-MS was improved by cooling the spray chamber. The noise power spectra showed that especially the white noise goes down when the spray chamber is cooled. The overall white noise with the GMK nebulizer is shown to be higher in the case of an Al 2O 3 slurry than in the case of an AlCl 3 solution, containing both 400 μg/ml Al. The pumping pulse rates are clearly visible in the noise amplitude spectra, but their amplitudes decrease at the presence of an impactor bead m the GMK nebulizer. Shifts of the noise band around 355 Hz were shown to occur as a result of the power level and the outer gas flow as well.

  18. Thin film synthesis using miniature pulsed metal vapor vacuum arc plasma guns

    SciTech Connect

    Godechot, X.; Salmeron, M.B.; Ogletree, D.F.; Galvin, J.E.; MacGill, R.A.; Dickinson, M.R.; Yu, K.M.; Brown, I.G.

    1990-04-01

    Metallic coatings can be fabricated using the intense plasma generated by the metal vapor vacuum arc. We have made and tested an embodiment of vacuum arc plasma source that operates in a pulsed mode, thereby acquiring precise control over the plasma flux and so also over the deposition rate, and that is in the form of a miniature plasma gun, thereby allowing deposition of metallic thin films to be carried out in confined spaces and also allowing a number of such guns to be clustered together. The plasma is created at the cathode spots on the metallic cathode surface, and is highly ionized and of directed energy a few tens of electron volts. Adhesion of the film to the substrate is thus good. Virtually all of the solid metals of the Periodic Table can be used, including highly refractory metals like tantalum and tungsten. Films, including multilayer thin films, can be fabricated of thickness from Angstroms to microns. We have carried out preliminary experiments using several different versions of miniature, pulsed, metal vapor vacuum arc plasma guns to fabricate metallic thin films and multilayers. Here we describe the plasma guns and their operation in this application, and present examples of some of the thin film structures we have fabricated, including yttrium and platinum films of thicknesses from a few hundred Angstroms up to 1 micron and an yttrium-cobalt multilayer structure of layer thickness about 100 Angstroms. 33 refs., 5 figs.

  19. The expansion of a plasma into a vacuum - Basic phenomena and processes and applications to space plasma physics

    NASA Technical Reports Server (NTRS)

    Wright, K. H., Jr.; Stone, N. H.; Samir, U.

    1983-01-01

    In this review attention is called to basic phenomena and physical processes involved in the expansion of a plasma into a vacuum, or the expansion of a plasma into a more tenuous plasma, in particular the fact that upon the expansion, ions are accelerated and reach energies well above their thermal energy. Also, in the process of the expansion a rarefaction wave propagates into the ambient plasma, an ion front moves into the expansion volume, and discontinuities in plasma parameters occur. The physical processes which cause the above phenomena are discussed, and their possible application is suggested for the case of the distribution of ions and electrons (hence plasma potential and electric fields) in the wake region behind artificial and natural obstacles moving supersonically in a rarefied space plasma. To illustrate this, some in situ results are reexamined. Directions for future work in this area via the utilization of the Space Shuttle and laboratory work are also mentioned.

  20. Conditioning technique for high power RF vacuum transmission line components using multipactor plasma

    NASA Astrophysics Data System (ADS)

    Mishra, Kishore; Rathi, D.; George, Siju; Varia, Atul; Parihar, M.; Jadav, H. M.; Srinivas, Y. S. S.; Singh, Raj; Kumar, Sunil; Kulkarni, S. V.

    2010-02-01

    Multipactor is a low power, electron multiplication based resonance breakdown phenomenon in vacuum often observed in radio frequency (RF) and microwave systems. A multipactor discharge is often undesirable as it can create a reactive component that detunes the resonant cavities, generates noise in communication system and induces gas desorption from the conductor surfaces. Multipactor breakdown on dielectric surface is also a major concern for failure of vacuum window in klystrons, cyclotrons and accelerators. Despite of these, the multipactor discharge is not absolutely undesirable. Its usefulness is being explored in electron gun technology, plasma display technology, ICRH antenna conditioning etc. Since multipactor is a pure electron resonance phenomenon, it can happen without any gas being present in the system. Nevertheless, the massive electron bombardment on conductor surfaces removes substantial amount of adsorbed gas species and increases the neutral pressure. In the presence of neutrals these resonant electrons ionize the gaseous atoms and forms the plasma known as multipactor plasma. Many of the high power RF components used in the vacuum transmission line interface sections of ICRH system are having restricted access to surface condition them especially the inner conductors of transmission line sections and dielectric material of vacuum window. By suitably choosing the operating frequency and a minimum pressure, it is possible to form a multipactor plasma in the above components to condition them. Such a conditioning technique is adopted for conditioning of vacuum window and vacuum transmission line of ICRH system. In this paper, an overview of multipactor plasma, a brief description of the test set up, testing conditions and conditioning results are presented.

  1. Column Formation in Suspension Plasma-Sprayed Coatings and Resultant Thermal Properties

    SciTech Connect

    Van Every, Kent; Krane, Matthew; Trice, Rodney; Wang, Hsin; Porter, Wallace D; Besser, Matthew; Sordelet, Daniel; Ilavsky, Dr. Jan; Almer, Jon

    2011-01-01

    The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 {micro}m and 80 nm. The powder-ethanol suspensions made with 15-{micro}m diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

  2. Column Formation in Suspension Plasma-Sprayed Coatings and Resultant Thermal Properties

    SciTech Connect

    VanEvery, Kent; Krane, Matthew J.M.; Trice, Rodney W; Wang, Hsin; Porter, Wallace; Besser, Matthew; Sordelet, Daniel; Ilavsky, Jan; Almer, Jonathan

    2012-03-19

    The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 {micro}m and 80 nm. The powder-ethanol suspensions made with 15-{micro}m diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k{sub th}) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k{sub th} values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k{sub th} of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k{sub th} increase was less than has been observed in APS coatings.

  3. Column formation in suspension plasma-sprayed coatings and resultant thermal properties.

    SciTech Connect

    Van Every, K.; Krane, M. J. M.; Trice, R. W.; Wang, H.; Porter, W.; Besser, M.; Sordelet, D.; Ilavsky, J.; Almer, J.

    2011-06-01

    The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 {micro}m and 80 nm. The powder-ethanol suspensions made with 15-{micro}m diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

  4. Neutron and X-ray diffraction of plasma-sprayed zirconia-yttria thermal barrier coatings

    NASA Technical Reports Server (NTRS)

    Shankar, N. R.; Herman, H.; Singhal, S. P.; Berndt, C. C.

    1984-01-01

    ZrO2-7.8mol. pct. YO1.5, a fused powder, and ZrO2-8.7mol. pct. YO1.5, a prereacted powder, were plasma-sprayed onto steel substrates. Neutron diffraction and X-ray diffraction of the as-received powder, the powder plasma sprayed into water, as-sprayed coatings, and coatings heat-treated for 10 and 100 h were carried out to study phase transformations and ordering of the oxygen ions on the oxygen sublattice. The as-received fused powder has a much lower monoclinic percentage than does the pre-reacted powder, this resulting in a much lower monoclinic percentage in the coating. Heat treatment increases the percentages of the cubic and monoclinic phases, while decreasing the tetragonal content. An ordered tetragonal phase is detected by the presence of extra neutron diffraction peaks. These phase transformations and ordering will result in volume changes. The implications of these transformations on the performance of partially stabilized zirconia thermal barrier coatings is discussed.

  5. Characterization of Microstructure and Thermal Properties of YSZ Coatings Obtained by Axial Suspension Plasma Spraying (ASPS)

    NASA Astrophysics Data System (ADS)

    Ganvir, Ashish; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per

    2015-10-01

    The paper aims at demonstrating various microstructures which can be obtained using the suspension spraying technique and their respective significance in enhancing the thermal insulation property of a thermal barrier coating. Three different types of coating microstructures are discussed which were produced by the Axial Suspension Plasma Spraying. Detailed characterization of coatings was then performed. Optical and scanning electron microscopy were utilized for microstructure evaluations; x-ray diffraction for phase analysis; water impregnation, image analysis, and mercury intrusion porosimetry for porosity analysis, and laser flash analysis for thermal diffusivity measurements were used. The results showed that Axial Suspension Plasma Spraying can generate vertically cracked, porous, and feathery columnar-type microstructures. Pore size distribution was found in micron, submicron, and nanometer range. Higher overall porosity, the lower density of vertical cracks or inter-column spacing, and higher inter-pass porosity favored thermal insulation property of the coating. Significant increase in thermal diffusivity and conductivity was found at higher temperature, which is believed to be due to the pore rearrangement (sintering and pore coarsening). Thermal conductivity values for these coatings were also compared with electron beam physical vapor deposition (EBPVD) thermal barrier coatings from the literature and found to be much lower.

  6. Atmosphere Plasma-Sprayed Carbon Nanotubes/Cordierite Nanocomposite Coatings for Microwave Absorption Applications

    NASA Astrophysics Data System (ADS)

    Su, Jinbu; Zhou, Wancheng; Liu, Yi; Luo, Fa; Zhu, Dongmei

    2014-10-01

    Multi-walled carbon nanotubes (MWCNTs)/cordierite (MAS) nanocomposite coatings with different MWCNT contents were prepared via atmosphere plasma spraying method. The characteristics of the MWCNTs/MAS powders and as-sprayed coatings, such as microstructure and phase constitution, were observed and measured. The dielectric properties and microwave absorption properties of MWCNTs/MAS powders and nanocomposite coatings have been investigated at the frequency of 8.2-12.4 GHz with different MWCNT contents and sample thicknesses. When the MWCNT content increased to 7%, the nanocomposite coating revealed the highest dielectric constant and optimal microwave absorption property. Further increase in MWCNT content led to severe oxidation of MWCNTs during the plasma spray process, which resulted in lower dielectric constants and poor microwave absorption property. Moreover, the sample thickness has a noticeable influence on the reflection loss (RL) of the MWCNTs/MAS coatings, and the coating of 2.4-mm thickness shows optical microwave absorption with a minimum RL of -15.61 dB and bandwidth of 2.35 GHz.

  7. Fabrication and characterization of plasma-sprayed HA/SiO(2) coatings for biomedical application.

    PubMed

    Morks, M F

    2008-01-01

    Fused silica powder has been mixed with hydroxyapatite (HA) powder and plasma sprayed by using gas tunnel-type plasma jet. The influence of silica content (10 wt% and 20 wt%) on the microstructure and mechanical properties of HA-silica coatings was investigated. For investigating the microstructure and mechanical properties of HA-silica coatings, SUS 304 stainless steel was used as substrate material. The spraying was carried out on roughened substrate in an atmospheric chamber. Scanning electron microscope micrographs of cross-sectioned HA/SiO(2) coatings showed that the sprayed HA coatings with 10 and 20 wt% SiO(2) have dense structure with low porosity compared to the pure HA coatings. On the other hand, as the amount of silica was increased the coatings became denser, harder and exhibited high abrasive wear resistance. The presence of silica significantly improved the adhesive strength of HA/SiO(2) coatings mainly due to the increase in bonding strength of the coating at the interface. PMID:19627776

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

    DOEpatents

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

    1983-01-01

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

  9. Nano Structured Plasma Spray Coating for Wear and High Temperature Corrosion Resistance Applications

    NASA Astrophysics Data System (ADS)

    Ghosh, D.; Shukla, A. K.; Roy, H.

    2014-04-01

    The nano structured coating is a major challenge today to improve the different mechanical properties, wear and high temperature corrosion resistance behaviour of different industrial alloys. This paper is a review on synthesis of nano powder, plasma spraying methods, techniques of nano structured coating by plasma spray method, mechanical properties, tribological properties and high temperature corrosion behaviour of nano structured coating. Nano structured coatings of ceramic powders/composites are being developed for wide variety of applications like boiler, turbine and aerospace industries, which requires the resistance against wear, corrosion, erosion etc. The nano sized powders are subjected to agglomeration by spray drying, after which nano structured coating can be successfully applied over the substrate. Nano structured coating shows improved mechanical wear resistance and high temperature corrosion resistance. The significant improvement of wear and corrosion resistance is mainly attributed to formation of semi molten nano zones in case of nano structured coatings. The future scope of application of nano structured coating has also been highlighted in this paper.

  10. Relation Between Microstructure and Thermal Conductivity of Plasma-Sprayed 8YSZ Coating

    NASA Astrophysics Data System (ADS)

    Li, Yong; Li, Chang-Jiu; Yang, Guan-Jun; Li, Cheng-Xing

    Plasma-sprayed YSZ coatings have been widely employed as thermal insulation coatings in gas turbine for its low thermal conductivity. Thermal conductivity of ceramic coatings is closely related to coating microstructure. In the present study, YSZ coating was deposited on a stainless steel by atmospheric plasma spraying using a fuse-crushed 8wt.%Y2O3-stablized ZrO2 powder at different spray distances from 70 mm and 100 mm. The microstructure of YSZ coatings was quantitatively characterized through visualization of lamellar structure assisted by electroplating Ni and subsequent EDX line analysis. The thermal conductivity of YSZ coatings with different microstructures was tested by a laser flash technique. Results showed that the mean lamellar bonding ratio was 32% and almost kept unchanged for the coatings deposited at 70 mm and 85 mm and it was reduced by 25% when distance was increased to 100 mm. The thermal conductivity of the coatings largely depended on the mean bonding ratio between lamellae and increased with the bonding ratio.

  11. An investigation of particle trajectories and melting in an air plasma sprayed zirconia

    SciTech Connect

    Neiser, R.A.; Roemer, T.J.

    1996-12-31

    The partially stabilized zirconia powders used to plasma spray thermal barrier coatings typically exhibit broad particle-size distributions. There are conflicting reports in the literature about the extent of injection-induced particle-sizing effects in air plasma-sprayed materials. If significant spatial separation of finer and coarser particles in the jet occurs, then one would expect it to play an important role in determining the microstructure and properties of deposits made from powders containing a wide range of particle sizes. This paper presents the results of a study in which a commercially available zirconia powder was fractionated into fine, medium, and coarse cuts and sprayed at the same torch conditions used for the ensemble powder. Diagnostic measurements of particle surface temperature, velocity, and number-density distributions in the plume for each size-cut and for the ensemble powder are reported. Deposits produced by traversing the torch back and forth to produce a raised bead were examined metallographically to study their shape and location with respect to the torch centerline and to look at their internal microstructure. The results show that, for the torch conditions used in this study, the fine, medium, and coarse size-cuts all followed the same mean trajectory. No measureable particle segregation effects were observed. Considerable differences in coatings microstructure were observed. These differences can be explained by the different particle properties measured in the plume.

  12. Electromagnetic loads and structural response of the CIT (Compact Ignition Tokamak) vacuum vessel to plasma disruptions

    SciTech Connect

    Salem, S.L.; Listvinsky, G.; Lee, M.Y.; Bailey, C.

    1987-01-01

    Studies of the electromagnetic loads produced by a variety of plasma disruptions, and the resulting structural effects on the compact Ignition Tokamak (CIT) vacuum vessel (VV), have been performed to help optimize the VV design. A series of stationary and moving plasmas, with disruption rates from 0.7--10.0 MA/ms, have been analyzed using the EMPRES code to compute eddy currents and electromagnetic pressures, and the NASTRAN code to evaluate the structural response of the vacuum vessel. Key factors contributing to the magnitude of EM forces and resulting stresses on the vessel have been found to include disruption rate, and direction and synchronization of plasma motion with the onset of plasma current decay. As a result of these analyses, a number of design changes have been made, and design margins for the present 1.75 meter design have been improved over the original CIT configuration. 1 ref., 10 figs., 4 tabs.

  13. Contamination due to memory effects in filtered vacuum arc plasma deposition systems

    SciTech Connect

    Martins, D.R.; Salvadori, M.C.; Verdonck, P.; Brown, I.G.

    2002-08-13

    Thin film synthesis by filtered vacuum arc plasma deposition is a widely used technique with a number of important emerging technological applications. A characteristic feature of the method is that during the deposition process not only is the substrate coated by the plasma, but the plasma gun itself and the magnetic field coil and/or vacuum vessel section constituting the macroparticle filter are also coated to some extent. If then the plasma gun cathode is changed to a new element, there can be a contamination of the subsequent film deposition by sputtering from various parts of the system of the previous coating species. We have experimentally explored this effect and compared our results with theoretical estimates of sputtering from the SRIM (Stopping and Range of Ions in Matter) code. We find film contamination of order 10-4 - 10-3, and the memory of the prior history of the deposition hardware can be relatively long-lasting.

  14. The impact of vacuum freeze-drying on collagen sponges after gas plasma sterilization.

    PubMed

    Markowicz, M; Koellensperger, E; Steffens, G C M; Frentz, M; Schrage, N; Pallua, N

    2006-01-01

    The sterilization of porous collagen sponges remains a challenging procedure. Gamma irradiation denatures collagen, resulting in dramatic changes to its structure. Ethylene oxide leaves toxic residues requiring weeks to evaporate. This study investigated the impact on cell behavior of gas plasma treatment when combined with vacuum freeze-drying. The goal of this procedure is to eliminate the molecules of hydrogen peroxide remaining after the sterilization process, together with their decomposition products, from the scaffolds. These molecules hinder the immediate use of the porous designs. Collagen and EDC/NHS-heparinized collagen scaffolds were sterilized with gas plasma. H2O2 released by the collagen specimens was measured by peroxidase test both immediately and also 1 week after the plasma treatment. Further measurements were done 24, 36, 48 and 72 h after vacuum freeze-drying. The activity of these scaffolds was further evaluated in relation to the proliferation, migration and differentiation of human umbilical vein endothelial cells (HUVECs). Both immediately after exposure to gas plasma and also 1 week later, the collagen designs contained significantly higher concentrations of H2O2 than scaffolds having also undergone vacuum freeze-drying. This procedure achieved faster decontamination of the remaining H2O2. Following vacuum freeze-drying, sponges already allowed HUVEC proliferation after 48 h, but in non-lyophilized specimens after gas plasma treatment alone, cell death occurred as early as only 1 week later. These data highlight the advantages of carrying out vacuum freeze-drying following gas plasma sterilization. The results show the substantial impact of sterilization of porous materials made for tissue engineering. PMID:16411599

  15. A Three-Dimensional Analysis of the Suspension Plasma Spray Impinging on a Flat Substrate

    NASA Astrophysics Data System (ADS)

    Jadidi, M.; Mousavi, M.; Moghtadernejad, S.; Dolatabadi, A.

    2015-01-01

    Suspension feedstock in plasma spraying is an emerging process for producing coatings with enhanced characteristics. Sub-micron up to few micron-sized particles are suspended in a liquid and injected into the plasma plume. After suspension's breakup and evaporation, molten and semi-molten fine particles are deposited on a substrate. Particle conditions upon impact (i.e., trajectory, velocity, and temperature) as well as substrate location and shape have key influences on the adhesion and quality of the coatings. In the current study, a three-dimensional two-way coupled Eulerian-Lagrangian approach is used to model the plasma jet, droplet/particle trajectory, velocity, and temperature. To model the turbulence and the effect of substrate on the flow field, Reynolds Stress Model is used. In addition, Kelvin-Helmholtz Rayleigh-Taylor breakup model is employed to predict the secondary breakup of the suspension. The focus of this work is on the particles behavior near the substrate. Flat substrates placed at standoff distances ranging from 40 to 60 mm are modeled to provide detailed information on the coating particles upon impact using suspension plasma spraying.

  16. Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings

    NASA Technical Reports Server (NTRS)

    Harder, Bryan J.; Zhu, Dongming

    2011-01-01

    In order to generate advanced multilayer thermal and environmental protection systems, a new deposition process is needed to bridge the gap between conventional plasma spray, which produces relatively thick coatings on the order of 125-250 microns, and conventional vapor phase processes such as electron beam physical vapor deposition (EB-PVD) which are limited by relatively slow deposition rates, high investment costs, and coating material vapor pressure requirements. The use of Plasma Spray - Physical Vapor Deposition (PS-PVD) processing fills this gap and allows thin (< 10 microns) single layers to be deposited and multilayer coatings of less than 100 microns to be generated with the flexibility to tailor microstructures by changing processing conditions. Coatings of yttria-stabilized zirconia (YSZ) were applied to NiCrAlY bond coated superalloy substrates using the PS-PVD coater at NASA Glenn Research Center. A design-of-experiments was used to examine the effects of process variables (Ar/He plasma gas ratio, the total plasma gas flow, and the torch current) on chamber pressure and torch power. Coating thickness, phase and microstructure were evaluated for each set of deposition conditions. Low chamber pressures and high power were shown to increase coating thickness and create columnar-like structures. Likewise, high chamber pressures and low power had lower growth rates, but resulted in flatter, more homogeneous layers

  17. Vapors and Droplets Mixture Deposition of Metallic Coatings by Very Low Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Vautherin, B.; Planche, M.-P.; Bolot, R.; Quet, A.; Bianchi, L.; Montavon, G.

    2014-04-01

    In recent years, the very low pressure plasma-spraying (VLPPS) process has been intensely developed and implemented to manufacture thin, dense and finely structured ceramic coatings for various applications, such as Y2O3 for diffusion barriers, among other examples. This paper aims at presenting developments carried out on metallic coatings. Aluminum was chosen as a demonstrative material due to its "moderate" vaporization enthalpy (i.e., 38.23 KJ cm-3) compared to the one of copper (i.e., 55.33 KJ cm-3), cobalt (i.e., 75.03 KJ cm-3), or even tantalum (i.e., 87.18 KJ cm-3). The objective of this work is primarily to better understand the behavior of a solid precursor injected into the plasma jet leading to the formation of vapors and to better control the factors affecting the coating structure. Nearly dense aluminum coatings were successfully deposited by VLPPS at 100 Pa with an intermediate power plasma torch (i.e., Sulzer Metco F4 type gun with maximum power of 45 kW). Optical emission spectroscopy (OES) was implemented to study and analyze the vapor behavior into the plasma jet. Simplified CFD modeling allowed better understanding of some of the thermo-physical mechanisms. The effect of powder-size distribution, substrate temperature and spray distance were studied. The phase composition and microstructural features of the coatings were characterized by XRD and SEM. Moreover, Vickers microhardness measurements were implemented.

  18. Simulation of Effervescent Atomization and Nanoparticle Characteristics in Radio Frequency Suspension Plasma Spray

    NASA Astrophysics Data System (ADS)

    Xiong, Hong-Bing; Qian, Li-Juan; Lin, Jian-Zhong

    2012-03-01

    In this paper, a comprehensive model was developed to investigate the suspension spray for a radio frequency (RF) plasma torch coupled with an effervescent atomizer. Firstly, the RF plasma is simulated by solving the thermo-fluid transport equations with electromagnetic Maxwell equation. Secondly, primary atomization of the suspension is solved by a proposed one-dimensional breakup model and validated with the experimental data. Thirdly, the suspension droplets and discharged nanoparticles are modeled in Lagrangian manner, to calculate each particle tracking, acceleration, heating, melting and evaporation. Saffman lift force, Brownian force and non-continuum effect are considered for nanoparticle momentum transfer, as well as the effects of evaporation on heat transfer. This model predicts the nanoparticle trajectory, velocity, temperature and size in the RF suspension plasma spray. Effects of the torch and atomizer operating conditions on the particle characteristics are investigated. Such operating conditions include gas-to-liquid flow ratio, atomizer orifice diameter, injection pressure, power input level, plasmas gas flow rate, and powder material. The statistical distributions for the multiple particles are also discussed for different cases.

  19. Method for minimizing decarburization and other high temperature oxygen reactions in a plasma sprayed material

    DOEpatents

    Lenling, William J.; Henfling, Joseph A.; Smith, Mark F.

    1993-06-08

    A method is disclosed for spray coating material which employs a plasma gun that has a cathode, an anode, an arc gas inlet, a first powder injection port, and a second powder injection port. A suitable arc gas is introduced through the arc gas inlet, and ionization of the arc gas between the cathode and the anode forms a plasma. The plasma is directed to emenate from an open-ended chamber defined by the boundary of the anode. A coating is deposited upon a base metal part by suspending a binder powder within a carrier gas that is fed into the plasma through the first powder injection port; a material subject to degradation by high temperature oxygen reactions is suspended within a carrier gas that is fed into the plasma through the second injection port. The material fed through the second injection port experiences a cooler portion of the plasma and has a shorter dwell time within the plasma to minimize high temperature oxygen reactions. The material of the first port and the material of the second port intermingle within the plasma to form a uniform coating having constituent percentages related to the powder-feed rates of the materials through the respective ports.

  20. Characterization of Thermal Diffusion Related Properties in Plasma Sprayed Zirconium Coatings

    NASA Astrophysics Data System (ADS)

    Hollis, K. J.; Hawley, M. E.; Dickerson, P. O.

    2012-06-01

    Zirconium (Zr) metal is of interest for chemical corrosion protection and nuclear reactor core applications. Inert chamber plasma spraying has been used to produce thin Zr coatings on stainless steel (SS) substrates. The coatings were deposited while using transferred arc (TA) cleaning/heating at five different current levels. In order to better understand thermal diffusion governed processes, the coating porosity, grain size and interdiffusion with the substrate were measured as a function of TA current. Low porosity (3.5 to <0.5%), recrystallization with fine equiaxed grain size (3-8 μm diameter) and varying elemental diffusion distance (0-50 μm) from the coating-substrate interface were observed. In addition, the coatings were low in oxygen content compared to the wrought SS substrates. The Zr coatings sprayed under these conditions look promising for highly demanding applications.

  1. Plasma Spray Deposition of Lanthanum Phosphate and Phase Structure of the Resultant Coatings

    NASA Astrophysics Data System (ADS)

    Pragatheeswaran, A.; Ananthapadmanabhan, P. V.; Chakravarthy, Y.; Chaturvedi, Vandana; Bhandari, Subhankar; Ramachandran, K.

    2015-12-01

    Plasma-sprayed lanthanum phosphate coatings were prepared on stainless steel substrates at different input powers from 16 to 24 kW. Coatings were characterized by x-ray diffraction, scanning electron microscopy, and Fourier transformed infrared spectroscopy. Results showed that the as-sprayed coatings consist of lanthanum ortho (LaPO4), poly(La2P4O13), and oxy(La3PO7) phosphates. Subsequent heat treatment of the coatings resulted in the recombination of the La-polyphosphate and La-oxyphosphate to form LaPO4. SEM images of microstructure of the coatings and coating-substrate interface showed micro-cracks, voids, and porosity that were found to decrease with deposition power.

  2. Investigations of Local Corrosion Behavior of Plasma-Sprayed FeCr Nanocomposite Coating by SECM

    NASA Astrophysics Data System (ADS)

    Shi, Xi; Shu, Mingyong; Zhong, Qingdong; Zhang, Junliang; Zhou, Qiongyu; Bui, Quoc Binh

    2016-02-01

    FeCr alloy coating can be sprayed on low-carbon steel to improve the corrosion resistance because of FeCr alloy's high anti-corrosion capacity. In this paper, Fe microparticles/Cr nanoparticles coating (NFC) and FeCr microparticles coating (MFC) were prepared by atmospheric plasma spraying and NFC was heat-treated under hydrogen atmosphere at 800 °C (HNFC). EDS mapping showed no penetration of Ni in MFC and NFC while penetration of Ni occurred in HNFC. X-ray diffraction results indicated the form of the NiCrFe (bcc) solid solution in HNFC. SECM testing in 3.5 (wt.%) NaCl revealed that the anti-corrosion capacity of NFC improved compared with MFC, while HNFC improved further.

  3. Microwave absorption property of plasma spray W-type hexagonal ferrite coating

    NASA Astrophysics Data System (ADS)

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

    2015-03-01

    In order to enhance the adhesion strength of microwave absorbing materials, W-type hexagonal ferrite coating is fabricated by plasma spray. The feedstock of ferrite powders is synthesized by solid-state reaction and spray dried process. Microstructures of the coating are analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectra (EDS). Hexagonal ferrite coating is successfully deposited on the substrate with adhesion strength of 28 MPa. The magnetic property of ferrite samples is measured using vibrating sample magnetometer (VSM). Saturation magnetization of the ferrite coating is lower than ferrite powder. Reflection loss of the hexagonal ferrite coating is measured in frequency of 2-18 GHz. The result shows that the coating is suitable for electromagnetic wave absorbers in Ku-band.

  4. Investigations of Local Corrosion Behavior of Plasma-Sprayed FeCr Nanocomposite Coating by SECM

    NASA Astrophysics Data System (ADS)

    Shi, Xi; Shu, Mingyong; Zhong, Qingdong; Zhang, Junliang; Zhou, Qiongyu; Bui, Quoc Binh

    2016-01-01

    FeCr alloy coating can be sprayed on low-carbon steel to improve the corrosion resistance because of FeCr alloy's high anti-corrosion capacity. In this paper, Fe microparticles/Cr nanoparticles coating (NFC) and FeCr microparticles coating (MFC) were prepared by atmospheric plasma spraying and NFC was heat-treated under hydrogen atmosphere at 800 C (HNFC). EDS mapping showed no penetration of Ni in MFC and NFC while penetration of Ni occurred in HNFC. X-ray diffraction results indicated the form of the NiCrFe (bcc) solid solution in HNFC. SECM testing in 3.5 (wt.%) NaCl revealed that the anti-corrosion capacity of NFC improved compared with MFC, while HNFC improved further.

  5. Controlling of Nitriding Process on Reactive Plasma Spraying of Al Particles

    NASA Astrophysics Data System (ADS)

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

    2011-10-01

    Reactive plasma spraying (RPS) has been considered as a promising technology for in-situ formation of aluminum nitride (AlN) thermally sprayed coatings. To fabricate thick A lN coatings in RPS process, controlling and improving the in-flight nitriding reaction of Al particles is required. In this study, it was possible to control the nitriding reaction by using ammonium chloride (NH4Cl) powders. Thick and dense AlN coating (more than 300 μm thickness) was successfully fabricated with small addition of NH4Cl powders. Thus, addition of NH4Cl prevented the Al aggregation by changing the reaction pathway to a mild way with no explosive mode (relatively low heating rates) and it acts as a catalyst, nitrogen source and diluent agent.

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

    NASA Astrophysics Data System (ADS)

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

    2015-08-01

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

  7. Ideal plasma response to vacuum magnetic fields with resonant magnetic perturbations in non-axisymmetric tokamaks

    NASA Astrophysics Data System (ADS)

    Kim, Kimin; Ahn, J.-W.; Scotti, F.; Park, J.-K.; Menard, J. E.

    2015-10-01

    Ideal plasma shielding and amplification of resonant magnetic perturbations in non-axisymmetric tokamak is presented by field line tracing simulation with full ideal plasma response, compared to measurements of divertor lobe structures. Magnetic field line tracing simulations in NSTX with toroidal non-axisymmetry indicate the ideal plasma response can significantly shield/amplify and phase shift the vacuum resonant magnetic perturbations. Ideal plasma shielding for n   =   3 mode is found to prevent magnetic islands from opening as consistently shown in the field line connection length profile and magnetic footprints on the divertor target. It is also found that the ideal plasma shielding modifies the degree of stochasticity but does not change the overall helical lobe structures of the vacuum field for n   =   3. Amplification of vacuum fields by the ideal plasma response is predicted for low toroidal mode n   =   1, better reproducing measurements of strong striation of the field lines on the divertor plate in NSTX.

  8. Thermal-Cycling Behavior of Plasma-Sprayed Partially Stabilized Zirconia Coatings on High-Density Graphite Substrate

    NASA Astrophysics Data System (ADS)

    Sure, Jagadeesh; Thyagarajan, K.; Mallika, C.; Mudali, U. Kamachi

    2015-08-01

    The thermal cycling behavior of partially stabilized zirconia (PSZ)-coated by plasma-spray process on NiCrAlY bond-coated high-density (HD) graphite substrate was investigated. Thermal cycling was carried out at 600 and 750 °C under vacuum, up to 200 cycles. Each cycle comprised a 10-min heating followed by forced air cooling for 10 min down to room temperature. Characterization of the microstructure and the phase analysis of thermal-cycled PSZ coatings by scanning electron microscopy, energy dispersive x-ray spectroscopy, x-ray diffraction (XRD), and Raman spectroscopy revealed the correlation between the microstructural/crystallographic phases and the mechanical integrity of the coating up to 200 cycles. Segmented and vertical cracks generated on the coating during thermal cycling were observed to propagate with increase in the number of cycles. Macrocracks and variations in elemental compositions were not observed until 200 cycles at 600 and 750 °C. XRD and Raman spectroscopic analysis confirmed the presence of nontransformable tetragonal phase only in all the thermal-cycled PSZ coatings, irrespective of temperature up to 200 cycles.

  9. Simulation on change of generic satellite radar cross section via artificially created plasma sprays

    NASA Astrophysics Data System (ADS)

    Chung, Shen Shou Max; Chuang, Yu-Chou

    2016-06-01

    Recent advancements in antisatellite missile technologies have proven the effectiveness of such attacks, and the vulnerability of satellites in such exercises inspires a new paradigm in RF Stealth techniques suitable for satellites. In this paper we examine the possibility of using artificially created plasma sprays on the surface of the satellite’s main body to alter its radar cross section (RCS). First, we briefly review past research related to RF Stealth using plasma. Next, we discuss the physics between electromagnetic waves and plasma, and the RCS number game in RF Stealth design. A comparison of RCS in a generic satellite and a more complicated model is made to illustrate the effect of the RCS number game, and its meaning for a simulation model. We also run a comparison between finite-difference-time-domain (FDTD) and multilevel fast multipole method (MLFMM) codes, and find the RCS results are very close. We then compare the RCS of the generic satellite and the plasma-covered satellite. The incident radar wave is a differentiated Gaussian monopulse, with 3 dB bandwidth between 1.2 GHz and 4 GHz, and we simulate three kinds of plasma density, with a characteristic plasma frequency ω P  =  0.1, 1, and 10 GHz. The electron-neutral collision frequency ν en is set at 0.01 GHz. We found the RCS of plasma-covered satellite is not necessarily smaller than the originally satellite. When ω P is 0.1 GHz, the plasma spray behaves like a dielectric, and there is minor reduction in the RCS. When ω P is 1 GHz, the X-Y cut RCS increases. When ω P is 10 GHz, the plasma behaves more like a metal to the radar wave, and stronger RCS dependency to frequency appears. Therefore, to use plasma as an RCS adjustment tool requires careful fine-tuning of plasma density and shape, in order to achieve the so-called plasma stealth effect.

  10. The structure and thermal properties of plasma-sprayed beryllium for the International Thermonuclear Experimental Reactor (ITER)

    SciTech Connect

    Castro, R.G.; Bartlett, A.; Elliott, K.E.; Hollis, K.J.

    1996-09-01

    Plasma spraying is being studied for in situ repair of damaged Be and W plasma facing surfaces for ITER, the next generation magnetic fusion energy device, and is also being considered for fabricating Be and W plasma-facing components for the first wall of ITER. Investigators at LANL`s Beryllium Atomization and Thermal Spray Facility have concentrated on investigating the structure-property relation between as-deposited microstructures of plasma sprayed Be coatings and resulting thermal properties. In this study, the effect of initial substrate temperature on resulting thermal diffusivity of Be coatings and the thermal diffusivity at the coating/Be substrate interface (interface thermal resistance) was investigated. Results show that initial Be substrate temperatures above 600 C can improve the thermal diffusivity of the Be coatings and minimize any thermal resistance at the interface between the Be coating and Be substrate.

  11. Thermal Shock Properties of Yttria-Stabilized Zirconia Coatings Deposited Using Low-Energy Very Low Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Zhu, Lin; Zhang, Nannan; Bolot, Rodolphe; Liao, Hanlin; Coddet, Christian

    2015-08-01

    Yttria-stabilized zirconia (YSZ) coatings have been frequently used as a thermal protective layer on the metal or alloy component surfaces. In the present study, ZrO2-7%Y2O3 thermal barrier coatings (TBCs) were successfully deposited by DC (direct current) plasma spray process under very low pressure conditions (less than 1 mbar) using low-energy plasma guns F4-VB and F100. The experiments were performed to evaluate the thermal shock resistance of different TBC specimens which were heated to 1373 K at a high-temperature cycling furnace and held for 0.5 h, followed by air cooling at room temperature for 0.2 h. For comparison, a corresponding atmospheric plasma spray (APS) counterpart was also elaborated to carry out the similar experiments. The results indicated that the very low pressure plasma spray (VLPPS) coatings displayed better thermal shock resistance. Moreover, the failure mechanism of the coatings was elucidated.

  12. Laser Cladding to Improve Oxidation Behavior of Air Plasma-Sprayed Ni-20Cr Coating on Stainless Steel Substrate

    NASA Astrophysics Data System (ADS)

    Rauf, M. Mudassar; Shahid, Muhammad; Nusair Khan, A.; Mehmood, K.

    2015-09-01

    Air plasma-sprayed Ni-20Cr coating on stainless steel (AISI-304) substrate was re-melted using CO2 laser to remove the inherent defects, i.e., porosity, splat boundaries, and oxides of air plasma-sprayed coating. The (1) uncoated, (2) air plasma-sprayed, and (3) laser-re-melted specimens were exposed to cyclic oxidation at 900 °C for a hundred cycles run. The oxidation products were characterized using XRD and SEM. Weight changes were determined after every 4th cycle; Uncoated samples showed severe oxidation indicated by substantial weight loss, whereas air plasma-coated samples demonstrated noticeable weight gain. However, oxidation resistance of laser-cladded samples was found to be significantly improved as the samples showed negligible weight change; porosity within the coating was minimized with an improvement in interface quality causing reduction in delamination damage.

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

    SciTech Connect

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

    2005-05-15

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

  14. Modeling the Influence of Injection Modes on the Evolution of Solution Sprays in a Plasma Jet

    NASA Astrophysics Data System (ADS)

    Shan, Y.; Coyle, T. W.; Mostaghimi, J.

    2010-01-01

    Solution precursor plasma spraying (SPPS) is a novel technology with great potential for depositing finely structured ceramic coatings with nano- and sub-micrometric features. The solution is injected into the plasma jet either as a liquid stream or gas atomized droplets. Solution droplets or the stream interact with the plasma jet and break up into fine droplets. The solvent vaporizes very fast as the droplets travel downstream. Solid particles are finally formed, and the particle are heated up and accelerated to the substrate to generate the coating. The deposition process and the properties of coatings obtained are extremely sensitive to the process parameters, such as torch operating conditions, injection modes, injection parameters, and substrate temperatures. This article numerically investigates the effect of injection modes, a liquid stream injection and a gas-blast injection, on the size distribution of injected droplets. The particle/droplet size, temperature, and position distributions on the substrate are predicted for different injection modes.

  15. Evaluation of human osteoblastic cell response to plasma-sprayed silicon-substituted hydroxyapatite coatings over titanium substrates.

    PubMed

    Gomes, Pedro S; Botelho, Cláudia; Lopes, Maria A; Santos, José D; Fernandes, Maria H

    2010-08-01

    Silicon-substituted hydroxyapatite (Si-HA) coatings have been plasma sprayed over titanium substrates (Ti-6Al-4V) aiming to improve the bioactivity of the constructs for bone tissue repair/regeneration. X-ray diffraction analysis of the coatings has shown that, previous to the thermal deposition, no secondary phases were formed due to the incorporation of 0.8 wt % Si into HA crystal lattice. Partial decomposition of hydroxyapatite, which lead to the formation of the more soluble phases of alpha- and beta-tricalcium phosphate and calcium oxide, and increase of amorphization level only occurred following plasma spraying. Human bone marrow-derived osteoblastic cells were used to assess the in vitro biocompatibility of the constructs. Cells attached and grew well on the Si-HA coatings, putting in evidence an increased metabolic activity and alkaline phosphatase expression comparing to control, i.e., titanium substrates plasma sprayed with hydroxyapatite. Further, a trend for increased differentiation was also verified by the upregulation of osteogenesis-related genes, as well as by the augmented deposition of globular mineral deposits within established cell layers. Based on the present findings, plasma spraying of Si-HA coatings over titanium substrates demonstrates improved biological properties regarding cell proliferation and differentiation, comparing to HA coatings. This suggests that incorporation of Si into the HA lattice could enhance the biological behavior of the plasma-sprayed coating. PMID:20574971

  16. Effect of Powder Injection on the Interfacial Fracture Toughness of Plasma-Sprayed Zirconia

    NASA Astrophysics Data System (ADS)

    Okajima, Yoshifumi; Nakamura, Toshio; Sampath, Sanjay

    2013-03-01

    Adhesive strength of the plasma-sprayed thermal barrier coating is one of the most important parameters which influence their durability and reliability during service. While many methods exist to measure the adhesive strength, in general, they require cumbersome and time-consuming specimen preparation. Furthermore, considerations of the adhesion strength from the point-of-view of fracture toughness or for that matter, their systematic correlation to both processing variances are limited. Consequently, there is an opportunity to both simplify the measurement procedure and establish correlations among methods and linkages between processing parameters and interfacial fracture toughness. In this paper, we report results on adhesion strength of plasma-sprayed yttria-stabilized zirconia (YSZ) coating on aluminum substrates based on both interfacial indentation test (to measure interfacial fracture toughness) and the modified tensile adhesive test. Carrier gas flow for powder injection into the plasma torch was systematically varied to introduce variances in particle melting with concomitant impact on the measured adhesive strength. The results indicate the correlation between the particle melting index and the measured interfacial fracture toughness.

  17. Evaluation of plasma pressure of high current low inductance vacuum spark on cathode surface

    NASA Astrophysics Data System (ADS)

    Sarantsev, S. A.

    2016-01-01

    This paper presents evaluation of the plasma pressure in a high current, low inductance vacuum spark on the cathode surface (the electrode material is steel). Calculations are provided for the first half period of the discharge, wherein the cathode surface is subjected to the most severe impacts (micropinches are created resulting in high-energy plasma beams). The evaluations were made using the experimental data obtained on the Pion device. The data of electrical measurements of the discharge current, the average plasma flow values obtained with the multi-grid probe and the data from a cathode macrostructure study were used. The results are given for different values of the discharge current.

  18. Theory of coherent transition radiation generated at a plasma-vacuum interface

    SciTech Connect

    Schroeder, Carl B.; Esarey, Eric; van Tilborg, Jeroen; Leemans, Wim P.

    2003-06-26

    Transition radiation generated by an electron beam, produced by a laser wakefield accelerator operating in the self-modulated regime, crossing the plasma-vacuum boundary is considered. The angular distributions and spectra are calculated for both the incoherent and coherent radiation. The effects of the longitudinal and transverse momentum distributions on the differential energy spectra are examined. Diffraction radiation from the finite transverse extent of the plasma is considered and shown to strongly modify the spectra and energy radiated for long wavelength radiation. This method of transition radiation generation has the capability of producing high peak power THz radiation, of order 100 (mu)J/pulse at the plasma-vacuum interface, which is several orders of magnitude beyond current state-of-the-art THz sources.

  19. Theory of coherent transition radiation generated at a plasma-vacuum interface.

    PubMed

    Schroeder, C B; Esarey, E; Van Tilborg, J; Leemans, W P

    2004-01-01

    Transition radiation generated by an electron beam, produced by a laser wakefield accelerator operating in the self-modulated regime, crossing the plasma-vacuum boundary is considered. The angular distributions and spectra are calculated for both the incoherent and the coherent radiation. The effects of the longitudinal and transverse momentum distributions on the differential energy spectra are examined. Diffraction radiation from the finite transverse extent of the plasma is considered and shown to strongly modify the spectra and energy radiated for long-wavelength radiation. This method of transition radiation generation has the capability of producing high peak power terahertz radiation, of order 100 microJ/pulse at the plasma-vacuum interface, which is several orders of magnitude beyond current state-of-the-art terahertz sources. PMID:14995729

  20. Sterilization of dielectric containers using a fore-vacuum pressure plasma-cathode electron source

    NASA Astrophysics Data System (ADS)

    Zolotukhin, D.; Burdovitsini, V.; Oks, E.; Tyunkov, A.; Yushkov, Yu

    2015-11-01

    We describe our work on sterilization of 10 ml glass and 60 ml plastic cylindrical containers using a fore-vacuum pressure, plasma-cathode, electron beam source. Beam plasma is formed inside the vessel by injection of a low-energy electron beam at 3 - 6 keV energy and current of 50 mA, at a working gas (air) pressure of 8 Pa. The gas composition was tracked by a quadrupole gas analyzer type RGA-100. As a test biological object for sterilization we used E. coli ATCC 25922 bacteria, the inner surface of each vessel was inoculated with a bacterial suspension. We find a smooth dependence of the degree of sterilization on the total energy density injected into the vessel. The efficacy of sterilization of container inner surfaces using a fore-vacuum pressure, plasma-cathode e-beam source of relatively low energy (a few keV) electrons is thus demonstrated.

  1. Generation of high charge state platinum ions on vacuum arc plasma heated by gyrotron radiation.

    PubMed

    Yushkov, G Yu; Vodopyanov, A V; Nikolaev, A G; Izotov, I V; Savkin, K P; Golubev, S V; Oks, E M

    2014-02-01

    The hybrid high charge metal ion source based on vacuum arc plasma heated by gyrotron radiation into simple magnetic trap has been developed. Two types of magnetic traps were used: a mirror configuration and a cusp one with inherent "minimum-B" structure. Pulsed high power (>100 kW) gyrotrons with frequency 37.5 GHz and 75 GHz were used for heating the vacuum arc plasma injected into the traps. Two different ways were used for injecting the metal plasma-axial injection by a miniature arc source located on-axis near the microwave window, and simultaneous radial injection by a number of sources mounted radially at the midplane of the traps. This article represents all data gathered for platinum ions, thus making comparison of the experimental results obtained with different traps and injections convenient and accurate. PMID:24593607

  2. Phase stability and biological property evaluation of plasma sprayed hydroxyapatite coatings for orthopedic and dental applications.

    PubMed

    Vahabzadeh, Sahar; Roy, Mangal; Bandyopadhyay, Amit; Bose, Susmita

    2015-04-01

    In this work we have investigated the effects of strontium (Sr) dopant on in vitro protein release kinetics and in vivo osteogenic properties of plasma sprayed hydroxyapatite (HA) coatings, along with their dissolution behavior. Plasma sprayed HA coatings are widely used in load-bearing implants. Apart from osseointegration, the new generation of HA coating is expected to deliver biomolecules and/or drugs that can induce osteoinduction. This paper reports the preparation of crystalline and amorphous HA coatings on commercially pure titanium (Cp-Ti) using inductively coupled radio frequency (RF) plasma spray, and their stability at different solution pH. Coatings prepared at 110 mm working distance from the nozzle showed an average Ca ion release of 18 and 90 ppm in neutral and acidic environments, respectively. Decreasing the working distance to 90 mm resulted in the formation of a coating with less crystalline HA and phases with higher solubility products, and consequently higher dissolution over 32 days. A 92% release of a model protein bovine serum albumin (BSA) in phosphate buffer with pH of 7.4 was measured for Sr-doped HA (Sr-HA) coating, while only a 72% release could be measured for pure HA coating. Distortion of BSA during adsorption on coatings revealed a strong interaction between the protein and the coating, with an increase in α-helix content. Osteoid formation was found on Sr-HA implants as early as 7 weeks post implantation compared to HA coated and uncoated Ti implants. After 12 weeks post implantation, osteoid new bone was formed on HA implants; whereas, bone mineralization started on Sr-HA samples. While no osteoid was formed on bare Ti surfaces, bone was completely mineralized on HA and Sr-HA coatings after 16 weeks post implantation. Our results show that both phase stability and chemistry can have a significant influence toward in vitro and in vivo response of HA coatings on Ti implants. PMID:25638672

  3. Mathematical analysis of thermoelastic characteristics in plasma-sprayed thermal barrier coatings.

    PubMed

    Go, Jaegwi; Jungo, Yeon-Gil; Kim, Seokchan; Ali, Md Afsar; Paik, Ungyu

    2012-02-01

    The thermoelastic characteristics of plasma-sprayed thermal barrier coatings (TBCs) have been analyzed using mathematical modeling. Two types of TBC model, cylinder and circular disk which are commercial plasma-sprayed TBCs, subjecting to symmetric temperature distribution to the radial and longitudinal directions, respectively, were taken into consideration. Based on the thermoelastic theories, a second order ordinary differential equation was derived for the cylinder model and a pair of partial differential equations were set up for the circular disk model. The analytic solution was obtained from the ordinary differential equation, while a finite volume method was developed for numerical solutions to the pair of partial differential equations due to the complexity of governing equations. The thermoelastic characteristics of TBC models, such as temperature distributions, displacements, and stresses, were displayed according to the obtained solutions. The rate of heat conduction in the section of the top coat is relatively slow in comparison with the substrate, and no profound difference appears in the temperature distribution between two TBC models. The highest longitudinal tensile stress is expressed at the bond coat of both models, and the substrate is under the compressive stresses to the circumferential direction. While the cylinder expands to the positive longitudinal direction only, the expansion in the circular disk occurs to both the positive and negative longitudinal directions. Relatively large displacement and stresses exhibit in the cylinder as compared with the circular disk. In the circular disk, the stresses to the radial direction undulate at each section, and the displacement profile displays that the width of the circular disk is slightly narrowed. The results demonstrate that the mechanical and thermal properties of the top and bond coats are the crucial factors to be considered in controlling the thermoelastic characteristics of plasma-sprayed TBCs. PMID:22629912

  4. Plasma sprayed wollastonite/TiO2 composite coatings on titanium alloys.

    PubMed

    Liu, Xuanyong; Ding, Chuanxian

    2002-10-01

    Wollastonite/TiO2 composite coatings were prepared using plasma spraying technology onto Ti-6Al-4V substrate. The composite coatings exhibit obvious lamellar structure with alternating wollastonite coating and TiO2 coating. No obvious cracks exist on the interface between coatings and substrate. In the case of composite coatings, the primarily crystalline phases of the coatings are wollastonite and rutile, indicating wollastonite and TiO2 did not react during plasma spraying process. Some of rutile in the powders transforms into anatase due to plasma spraying. The mean bond strength of the composite coatings is higher than 30 MPa. The Vickers microhardness of coatings increase with the increase in the content of TiO2. Wollastonite/TiO2 composite coatings were soaked in simulated body fluid to examine their bioactivity. Carbonate-containing hydroxyapatite (CHA) layer was formed on the surface of the wollastonite and W7T3 coatings soaked in simulated body fluid, while was not formed on the surface of the TiO2 and W3T7 coatings after immersion. In addition, a rich-silica layer appeared at the interface of CHA and wollastonite and W7T3 coatings. In order to investigate the cytocompatibility of the coatings, osteoblast was seeded onto the surface of the coatings. The scanning electron microscopy observation showed that the addition of wollastonite promote the proliferation of osteoblast. It is enough to prove that the wollastonite and wollastonite/TiO2 composite coatings possess excellent cytocompatibility. PMID:12182308

  5. Influence of impact parameters of zirconia droplets on splat formation and morphology in plasma spraying

    SciTech Connect

    Shinoda, Kentaro; Koseki, Toshihiko; Yoshida, Toyonobu

    2006-10-01

    In this study, the effects of the impact parameters, namely, the diameter d{sub 0}, velocity V{sub 0}, and temperature T{sub 0}, of an impacting droplet of yttria-stabilized zirconia (YSZ) on splat morphology have been investigated systematically under plasma spraying conditions. In particular, fully molten droplets of 30-90 {mu}m in d{sub 0} that impact on a preheated quartz glass substrate at V{sub 0} of 10-70 m/s have been examined via hybrid plasma spraying. The degree of flattening of final splat morphology, {xi}, was found to be predicted by the relationship {xi}=0.43Re{sup 1/3}, where Re is the Reynolds number. The dimensionless spreading time of droplets, t{sub s}*=t{sub s}V{sub 0}/d{sub 0}, was distributed around 2.7, where t{sub s} is the spreading time of the droplet. The ideal maximum spread factor derived from the splat height was approximately proportional to Re{sup 1/4}. The latter two findings suggest that the analytical model developed by Pasandideh-Fard et al. [Phys. Fluids 8, 650 (1996)] can be applied to the droplet impact in plasma spraying especially for the case of YSZ. In addition, the thermal contact resistance of disk shaped splats decreased with the increase of V{sub 0} within the range of 10{sup -5}-10{sup -6} m{sup 2} K/W.

  6. In vitro biological response of plasma electrolytically oxidized and plasma-sprayed hydroxyapatite coatings on Ti-6Al-4V alloy.

    PubMed

    Yeung, Wing Kiu; Reilly, Gwendolen C; Matthews, Allan; Yerokhin, Aleksey

    2013-08-01

    Plasma electrolytic oxidation (PEO) is a relatively new surface modification process that may be used as an alternative to plasma spraying methods to confer bioactivity to Ti alloy implants. The aim of this study was to compare physical, chemical and biological surface characteristics of two coatings applied by PEO processes, containing different calcium phosphate (CaP) and titanium dioxide phases, with a plasma-sprayed hydroxyapatite (HA) coating. Coating characteristics were examined by X-ray diffraction, energy dispersive X-ray spectroscopy, scanning electron microscopy, surface profilometry, and wettability tests. The biological properties were determined using the human osteoblastic cell line MG-63 to assess cell viability, calcium and collagen synthesis. The tests showed that PEO coatings are significantly more hydrophilic (6%) and have 78% lower surface roughness (Ra) than the plasma-sprayed coatings. Cell behavior was demonstrated to be strongly dependent on the phase composition and surface distribution of elements in the PEO coating. MG-63 viability for the TiO2 -based PEO coating containing amorphous CaPs was significantly lower than that for the PEO coating containing crystalline HA and the plasma-sprayed coating. However, collagen synthesis on both the CaP and the TiO2 PEO coatings was significantly higher (92% and 71%, respectively) than on the plasma-sprayed coating after 14 days. PEO has been demonstrated to be a promising method for coating of orthopedic implant surfaces. PMID:23529912

  7. Damage evolution and residual stresses in plasma-sprayed zirconia thermal barrier coatings.

    SciTech Connect

    Singh, J. P.

    1999-02-03

    Air-plasma-sprayed zirconia thermal barrier coatings were subjected to thermal cycling and residual stress evolution in thermally grown oxide scale was studied by micro- and macro-ruby fluorescence spectroscopy. The macro approach reveals that compressive stress in the oxide scale increases with increasing number of thermal cycles (and thus increasing scale thickness), reaching a value of 1.8 GPa at a scale thickness of 3-4 {micro}m (80 cycles). Micro-ruby fluorescence spectroscopy indicates that protrusions of the zirconia top coat into the bond coat act as localized areas of high stress concentration, leading to damage initiation during thermal cycling.

  8. Plasma-sprayed zirconia gas path seal technology: A state-of-the-art review

    NASA Technical Reports Server (NTRS)

    Bill, R. C.

    1979-01-01

    The benefits derived from application of ceramic materials to high pressure turbine gas path seal components are described and the developmental backgrounds of various approaches are reviewed. The most fully developed approaches are those employing plasma sprayed zirconium oxide as the ceramic material. Prevention of cracking and spalling of the zirconium oxide under cyclic thermal shock conditions imposed by the engine operating cycle is the most immediate problem to be solved before implementation is undertaken. Three promising approaches to improving cyclic thermal shock resistance are described and comparative rig performance of each are reviewed. Advanced concepts showing potential for performance improvements are described.

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

    NASA Astrophysics Data System (ADS)

    Fleetwood, James D.

    Solid oxide fuel cells (SOFCs) are a promising element of comprehensive energy policies due to their direct mechanism for converting the oxidization of fuel, such as hydrogen, into electrical energy. Both very low pressure plasma spray and electrophoretic deposition allow working with high melting temperature SOFC suspension based feedstock on complex surfaces, such as in non-planar SOFC designs. Dense, thin electrolytes of ideal composition for SOFCs can be fabricated with each of these processes, while compositional control is achieved with dissolved dopant compounds that are incorporated into the coating during deposition. In the work reported, sub-micron 8 mole % Y2O3-ZrO2 (YSZ) and gadolinia-doped ceria (GDC), powders, including those in suspension with scandium-nitrate dopants, were deposited on NiO-YSZ anodes, via very low pressure suspension plasma spray (VLPSPS) at Sandia National Laboratories' Thermal Spray Research Laboratory and electrophoretic deposition (EPD) at Purdue University. Plasma spray was carried out in a chamber held at 320 - 1300 Pa, with the plasma composed of argon, hydrogen, and helium. EPD was characterized utilizing constant current deposition at 10 mm electrode separation, with deposits sintered from 1300 -- 1500 C for 2 hours. The role of suspension constituents in EPD was analyzed based on a parametric study of powder loading, powder specific surface area, polyvinyl butyral (PVB) content, polyethyleneimine (PEI) content, and acetic acid content. Increasing PVB content and reduction of particle specific surface area were found to eliminate the formation of cracks when drying. PEI and acetic acid content were used to control suspension stability and the adhesion of deposits. Additionally, EPD was used to fabricate YSZ/GDC bilayer electrolyte systems. The resultant YSZ electrolytes were 2-27 microns thick and up to 97% dense. Electrolyte performance as part of a SOFC system with screen printed LSCF cathodes was evaluated with peak power densities as high as 520 mW/cm2 at 800 C for YSZ and 350 mW/cm 2 at 800 C for YSZ/GDC bilayer electrolytes.

  10. Continuous spray forming of functionally gradient materials

    SciTech Connect

    McKechnie, T.N.; Richardson, E.H.

    1995-12-01

    Researchers at Plasma Processes Inc. have produced a Functional Gradient Material (FGM) through advanced vacuum plasma spray processing for high heat flux applications. Outlined in this paper are the manufacturing methods used to develop a four component functional gradient material of copper, tungsten, boron, and boron nitride. The FGM was formed with continuous gradients and integral cooling channels eliminating bondlines and providing direct heat transfer from the high temperature exposed surface to a cooling medium. Metallurgical and x-ray diffraction analyses of the materials formed through innovative VPS (vacuum plasma spray) processing are also presented. Applications for this functional gradient structural material range from fusion reactor plasma facing components to missile nose cones to boilers.

  11. Corrosion behavior in boiling dilute HCI solution of different ceramic coatings fabricated by plasma spraying

    NASA Astrophysics Data System (ADS)

    Yan, Dianran; He, Jining; Li, Xiangzhi; Dong, Yanchun; Zhang, Jianxin; Liu, Yangai

    2004-12-01

    An Al2O3 ceramic coating (A), a 13 wt.% TiO2-Al2O3 (13TA) composite ceramic coating, and a Ni-Al-13wt.%TiO2-Al2O3 (NA-13TA) gradient composite ceramic coating were prepared on Q235 steel by plasma spraying. The corrosion behavior of samples sprayed with these coatings in a boiling 5% HCl solution was investigated. It was shown that an A ceramic coating and a 13TA composite ceramic coating were destroyed after immersion for 17 and 23 h, respectively. The NA-13TA gradient composite ceramic coating was still sound after 14 days of immersion. The corrosion resistance of samples with the NA-13TA gradient composite ceramic coating was sharply improved due to the decreased amount of connected pores in the coating. The corrosion of the sample sprayed with the gradient ceramic coating included the partial corrosion of the surface ceramic coating and the interlayer coatings. The corrosion weight loss depended on the degree of open porosity.

  12. High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

    NASA Technical Reports Server (NTRS)

    Harder, Bryan James; Zhu, Dongming; Schmitt, Michael P.; Wolfe, Douglas E.

    2014-01-01

    Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

  13. Plasma Sprayed Ni-Al Coatings for Safe Ending Heat Exchanger Tubes

    SciTech Connect

    Allen, M.L.; Berndt, C.C.; Otterson, D.

    1998-11-01

    Brookhaven National Laboratory (BNL) has developed thermally conductive composite liners for corrosion and scale protection in heat exchanger tubes exposed to geothermal brine. The liners cannot withstand roller expansion to connect the tubes to the tubesheet. It is not possible to line the ends of the tubes with the same material after roller expansion due to the nature of the current liner application process. It was requested that BNL evaluate plasma sprayed Ni-Al coatings for safe ending heat exchanger tubes exposed to geothermal brine. The tubes of interest had an internal diameter of 0.875 inches. It is not typical to thermal spray small diameter components or use such small standoff distances. In this project a nozzle extension was developed by Zatorski Coating Company to spray the tube ends as well as flat coupons for testing. Four different Ni-Al coatings were investigated. One of these was a ductilized Ni-AlB material developed at Oak Ridge National Laboratory. The coatings were examined by optical and scanning electron microscopy. In addition, the coatings were analyzed by X-ray diffraction and subjected to corrosion, tensile adhesion, microhardness and field tests in a volcanic pool in New Zealand.

  14. Suspension Plasma Spray Fabrication of Nanocrystalline Titania Hollow Microspheres for Photocatalytic Applications

    NASA Astrophysics Data System (ADS)

    Ren, Kun; Liu, Yi; He, Xiaoyan; Li, Hua

    2015-10-01

    Hollow inorganic microspheres with controlled internal pores in close-cell configuration are usually constructed by submicron-sized particles. Fast and efficient large-scale production of the microspheres with tunable sizes yet remains challenging. Here, we report a suspension plasma spray route for making hollow microspheres from nano titania particles. The processing permits most nano particles to retain their physiochemical properties in the as-sprayed microspheres. The microspheres have controllable interior cavities and mesoporous shell of 1-3 μm in thickness. Spray parameters and organic content in the starting suspension play the key role in regulating the efficiency of accomplishing the hollow sphere structure. For the ease of collecting the spheres for recycling use, ferriferous oxide particles were used as additives to make Fe3O4-TiO2 hollow magnetic microspheres. The spheres can be easily recycled through external magnetic field collection after each time use. Photocatalytic anti-bacterial activities of the hollow spheres were assessed by examining their capability of degrading methylene blue and sterilizing Escherichia coli bacteria. Excellent photocatalytic performances were revealed for the hollow spheres, giving insight into their potential versatile applications.

  15. PLASMA SPRAYED Ni-Al COATINGS FOR SAFE ENDING HEAT EXCHANGER TUBES

    SciTech Connect

    ALLAN,M.L.; OTTERSON,D.; BERNDT,C.C.

    1998-11-01

    Brookhaven National Laboratory (BNL) has developed thermally conductive composite liners for corrosion and scale protection in heat exchanger tubes exposed to geothermal brine. The liners cannot withstand roller expansion to connect the tubes to the tubesheet. It is not possible to line the ends of the tubes with the same material after roller expansion due to the nature of the current liner application process. It was requested that BNL evaluate plasma sprayed Ni-Al coatings for safe ending heat exchanger tubes exposed to geothermal brine. The tubes of interest had an internal diameter of 0.875 inches. It is not typical to thermal spray small diameter components or use such small standoff distances. In this project a nozzle extension was developed by Zatorski Coating Company to spray the tube ends as well as flat coupons for testing. Four different Ni-Al coatings were investigated. One of these was a ductilized Ni-AIB material developed at Oak Ridge National Laboratory. The coatings were examined by optical and scanning electron microscopy. In addition, the coatings were analyzed by X-ray diffraction and subjected to corrosion, tensile adhesion, microhardness and field tests in a volcanic pool in New Zealand. It was determined that the Ni-Al coatings could be applied to a depth of two inches on the tube ends. When sprayed on flat coupons the coatings exhibited relatively high adhesion strength and microhardness. Polarization curves showed that the coating performance was variable. Measured corrosion potentials indicated that the Ni-Al coatings are active towards steel coated with thermally conductive polymers, thereby suggesting preferential corrosion. Corrosion also occurred on the coated coupons tested in the volcanic pool. This may have been exacerbated by the difficulty in applying a uniform coating to the coupon edges. The Ni-Al coatings applied to the tubes had significant porosity and did not provide adequate corrosion protection. This is associated with the short standoff distance and is not a reflection of the normal quality of plasma sprayed coatings. Even if coating porosity could be reduced, the coupling of an alloy coating to a polymer-based barrier coating in the same electrolyte is not recommended. Therefore, polymer coatings that can be field applied to the tube ends after roller expansion should be sought.

  16. The use of a macroscopic formulation describing the effects of dynamic compaction and porosity on plasma sprayed copper

    SciTech Connect

    Arrigoni, M.; Boustie, M.; Bolis, C.; Berthe, L.; Barradas, S.; Jeandin, M.

    2008-04-15

    Coatings processed by thermal deposition techniques involve porosity. The Laser adhesion test developed for testing bond strength of a coating on its substrate requires a good knowledge of shock wave propagation in such media. Experiments carried out on plasma sprayed copper samples, about 14% porous, with velocity interferometer system for any reflector measurements display the discrepancy of previously used models. Hence, a one-dimensional formulation of the compaction process, based on a simple P-{alpha} model, is proposed to improve the correlation between experimental and computed data signals obtained on a plasma sprayed copper under dynamic loading. Besides, this improvement allows the estimation of the bond strength of a plasma sprayed copper on aluminum substrate.

  17. Deposition and properties of high-velocity-oxygen-fuel and plasma-sprayed Mo-Mo2C composite coatings

    NASA Astrophysics Data System (ADS)

    Prchlik, L.; Gutleber, J.; Sampath, S.

    2001-12-01

    Molybdenum thermal-spray coatings, dispersion strengthened by molybdenum oxides and molybdenum carbides, play an important role in industrial tribological applications. Traditionally, they have been prepared by plasma and wire flame spraying. High porosity and lower cohesion strength limit their application in situations where both galling and abrasion wear is involved. In this study, high-velocity-oxygen-fuel (HVOF) deposition of molybdenum and molybdenum carbide coatings was attempted. Deposition was achieved for all powders used. Composition, microstructure, mechanical, and wear properties of the HVOF synthesized coatings were evaluated and compared with plasma-sprayed counterparts. The HVOF coatings possessed a very good abrasion resistance, whereas plasma deposits performed better in dry sliding tests. Measurements showed a close relationship between the coating surface hardness and its abrasion resistance. Results also suggested correlation between molybdenum carbide distribution in the molybdenum matrix and the sliding friction response of Mo-Mo2C coatings.

  18. Use of vacuum arc plasma guns for a metal puff Z-pinch system

    SciTech Connect

    Rousskikh, A. G.; Zhigalin, A. S.; Oreshkin, V. I.; Chaikovsky, S. A.; Labetskaya, N. A.; Baksht, R. B.

    2011-09-15

    The performance of a metal puff Z-pinch system has been studied experimentally. In this type of system, the initial cylindrical shell 4 cm in diameter was produced by ten plasma guns. Each gun initiates a vacuum arc operating between magnesium electrodes. The net current of the guns was 80 kA. The arc-produced plasma shell was compressed by using a 450-kA, 450-ns driver, and as a result, a plasma column 0.3 cm in diameter was formed. The electron temperature of the plasma reached 400 eV at an average ion concentration of 1.85 {center_dot} 10{sup 18} cm{sup -3}. The power of the Mg K-line radiation emitted by the plasma for 15-30 ns was 300 MW/cm.

  19. Anisotropic Mechanical Properties of Plasma-Sprayed Thermal Barrier Coatings at High Temperature Determined by Ultrasonic Method

    NASA Astrophysics Data System (ADS)

    Wei, Qin; Zhu, Jianguo; Chen, Wei

    2016-01-01

    The mechanical properties of plasma-sprayed thermal barrier coatings (TBC) are of great scientific and technological significance for the design and fabrication of TBC systems. The ultrasonic method combined with a sing-around method for mechanical properties measurement of TBC is deduced and the elastic modulus can be determined in the spray, or longitudinal, direction, and the transverse direction. Tested specimens of plasma-sprayed TBC are detached from the substrate and treated with thermal exposure at 1400 °C. The elastic moduli along the longitudinal and transverse directions of the TBCs are measured by different types of ultrasonic waves combined with a sing-around method, while the Poisson's ratio is also obtained simultaneously. The experimental results indicate that the magnitude of longitudinal elastic modulus is larger than that of the transverse one, and thus the plasma-sprayed TBC has an anisotropic mechanical property. Moreover, the elastic moduli along both longitudinal and transverse directions change with high-temperature exposure time, which consists of a rapid increasing stage followed by a slow decreasing stage. In addition, the magnitude of Poisson's ratio increases slightly from 0.05 to 0.2 with the high-temperature exposure time. Generally, the microstructures in the plasma-sprayed coatings and their evolution in a high-temperature environment are the main causes of the varying anisotropic mechanical properties.

  20. Anisotropic Mechanical Properties of Plasma-Sprayed Thermal Barrier Coatings at High Temperature Determined by Ultrasonic Method

    NASA Astrophysics Data System (ADS)

    Wei, Qin; Zhu, Jianguo; Chen, Wei

    2016-02-01

    The mechanical properties of plasma-sprayed thermal barrier coatings (TBC) are of great scientific and technological significance for the design and fabrication of TBC systems. The ultrasonic method combined with a sing-around method for mechanical properties measurement of TBC is deduced and the elastic modulus can be determined in the spray, or longitudinal, direction, and the transverse direction. Tested specimens of plasma-sprayed TBC are detached from the substrate and treated with thermal exposure at 1400 °C. The elastic moduli along the longitudinal and transverse directions of the TBCs are measured by different types of ultrasonic waves combined with a sing-around method, while the Poisson's ratio is also obtained simultaneously. The experimental results indicate that the magnitude of longitudinal elastic modulus is larger than that of the transverse one, and thus the plasma-sprayed TBC has an anisotropic mechanical property. Moreover, the elastic moduli along both longitudinal and transverse directions change with high-temperature exposure time, which consists of a rapid increasing stage followed by a slow decreasing stage. In addition, the magnitude of Poisson's ratio increases slightly from 0.05 to 0.2 with the high-temperature exposure time. Generally, the microstructures in the plasma-sprayed coatings and their evolution in a high-temperature environment are the main causes of the varying anisotropic mechanical properties.

  1. Effect of the thickness on properties of Al{sub 2}O{sub 3} coatings deposited by plasma spraying

    SciTech Connect

    Yin Zhijian; Tao Shunyan; Zhou Xiaming

    2011-01-15

    Al{sub 2}O{sub 3} coatings with different thicknesses (160, 320, 480 and 640 {mu}m) were deposited on stainless steel substrate by plasma spraying. The variation in microstructural characteristics and properties of coatings with various thicknesses was investigated. Powders morphology and the microstructure of as-sprayed coatings were characterized by scanning electron microscopy and optical microscopy. The microhardness was measured using a Vickers' indentor. The corrosion behaviour of plasma-sprayed Al{sub 2}O{sub 3} coatings in 1 N H{sub 2}SO{sub 4} solution at a temperature of 25 deg. C was evaluated by electrochemistry method. Experimental results indicated that surface roughness showed no obvious dependence on the coating thickness. However, the porosity of Al{sub 2}O{sub 3} coating was increased with increased thickness. The enhanced coating thickness also resulted in decreasing microhardness and reduced corrosion resistance. In this study, the Al{sub 2}O{sub 3} coating with thickness of 160 {mu}m possesses the lowest porosity, the highest hardness and superior corrosion resistance. Research Highlights: {yields} Increase of coating thickness shows no obvious effect on phase composition and surface roughness of plasma sprayed Al{sub 2}O{sub 3} coatings. {yields} Variation of porosity and microhardness presents dependence on coating thickness parameter. {yields} Increasing coating thickness leads to reduced corrosion resistance of plasma sprayed Al{sub 2}O{sub 3} coating.

  2. Plasma Sprayed Pour Tubes and Other Melt Handling Components for Use in Gas Atomization

    SciTech Connect

    Byrd, David; Rieken, Joel; Heidloff, Andy; Besser, Matthew; Anderson, Iver

    2011-04-01

    Ames Laboratory has successfully used plasma sprayed ceramic components made from yttria stabilized zirconia as melt pouring tubes for gas atomization for many years. These tubes have proven to be strong, thermal shock resistant and versatile. Various configurations are possible both internally and externally. Accurate dimensions are achieved internally with a machined fugitive graphite mandrel and externally by diamond grinding. The previous study of the effect of spray parameters on density was extended to determine the effect of the resulting density on the thermal shock characteristics on down-quenching and up-quenching. Encouraging results also prompted investigation of the use of plasma spraying as a method to construct a melt pour exit stopper that is mechanically robust, thermal shock resistant, and not susceptible to attack by reactive melt additions. The Ames Laboratory operates two close-coupled high pressure gas atomizers. These two atomizers are designed to produce fine and coarse spherical metal powders (5{mu} to 500{mu} diameter) of many different metals and alloys. The systems vary in size, but generally the smaller atomizer can produce up to 5 kg of powder whereas the larger can produce up to 25 kg depending on the charge form and density. In order to make powders of such varying compositions, it is necessary to have melt systems capable of heating and containing the liquid charge to the desired superheat temperature prior to pouring through the atomization nozzle. For some metals and alloys this is not a problem; however for some more reactive and/or high melting materials this can pose unique challenges. Figure 1 is a schematic that illustrates the atomization system and its components.

  3. The behavior of high-purity, low-density air plasma sprayed thermal barrier coatings

    SciTech Connect

    Helminiak, Yanar NM

    2009-12-01

    Research on the behavior of high-purity, low-density (85%) air plasma sprayed (APS) thermal barrier coatings (TBC) with NiCoCrAlY bond coats deposited by argon-shrouded plasma spraying is described. The microstructure of the APS topcoats is one variable in this study intended to maximize the coating thicknesses that can be applied without spallation and to minimize the thermal conduction through the YSZ layer. The specimens were evaluated using cyclic oxidation tests and important properties of the TBCs, such as resistance to sintering and phase transformation, were determined. The high purity resulted in top coats which are highly resistant to sintering and transformation from the metastable tetragonal phase to the equilibrium mixture of monoclinic and cubic phases. The porous topcoat microstructure also resulted in significant durability during thermal cycling. The actual failure mechanisms of the APS coatings were found to depend on topcoat thickness, CTE of the superalloy substrate and the nature of the thermal exposure.

  4. Fabrication and Wear Behavior of Nanostructured Plasma-Sprayed 6061Al-SiCp Composite Coating

    NASA Astrophysics Data System (ADS)

    Tailor, Satish; Mohanty, R. M.; Sharma, V. K.; Soni, P. R.

    2014-10-01

    6061Al powder with 15 wt.% SiC particulate (SiCp) reinforcement was mechanically alloyed (MA) in a high-energy attrition mill. The MA powder was then plasma sprayed onto weathering steel (Cor-Ten A242) substrate using an atmospheric plasma spray process. Results of particle size analysis and scanning electron microscopy show that the addition of SiC particles as the reinforcement influences on the matrix grain size and morphology. XRD studies revealed embedment of SiCp in the MA-processed composite powder, and nanocrystals in the MA powder and the coating. Microstructural studies showed a uniform distribution of reinforced SiC particles in the coating. The porosity level in the coating was as low as 2% while the coating hardness was increased to 232VHN. The adhesion strength of the coatings was high and this was attributed to higher degree of diffusion at the interface. The wear rate in the coatings was evaluated using a pin-on-disk type tribometer and found to decrease by 50% compared to the 6061Al matrix coating. The wear mechanism in the coating was delamination and oxidative type.

  5. Study of thermal and electrical parameters of workpieces during spray coating by electrolytic plasma jet

    NASA Astrophysics Data System (ADS)

    Khafizov, A. A.; Shakirov, Yu I.; Valiev, R. A.; Valiev, R. I.; Khafizova, G. M.

    2016-01-01

    In this paper the results are presented of thermal and electrical parameters of products in the system bottom layer - intermediate layer when applying protective coatings of ferromagnetic powder by plasma spray produced in an electric discharge with a liquid cathode, on steel samples. Temperature distribution and gradients in coating and intermediate coating were examined. Detailed descriptions of spray coating with ferromagnetic powder by plasma jet obtained in electrical discharge with liquid cathode and the apparatus for obtaining thereof is provided. Problem has been solved by using of Fourier analysis. Initial data for calculations is provided. Results of numerical analysis are provided as temporal functions of temperature in contiguity between coating and intermediate coating as well as temporal function of the value Q=q-φ where q is density of heat current directed to the free surface of intermediate coating, φ is density of heat current in contiguity between coating and intermediate coating. The analysis of data given shows that in the systems of contact heat exchange bottom layer-intermediate layer with close values of the thermophysical characteristics of constituting materials is observed a slow increase of the temperature of the contact as a function of time.

  6. Characterization of Yttria-Stabilized Zirconia Coatings Deposited by Low-Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    He, Peng-jiang; Yin, Shuo; Song, Chen; Lapostolle, Frédéric; Liao, Han-lin

    2016-02-01

    The research presented here aimed to apply plasma spraying at a low pressure of 100 Pa for fabricating the columnar structure or dense coatings. These coatings with different structures were elaborated from the vapor condensation and molten droplets, respectively, using the agglomerated YSZ powders and a relatively low power commercial F4-VB torch. It was shown that the crystallite size of coating deposited from the vapor condensation at a spraying distance of 200 mm was reduced to 17.1 nm from 43.7 nm of the feedstock. Observations indicated that a thin columnar structured coating was produced out of the line of sight of projection. In the line of sight of projection, the hybrid structured coating was obtained. The relatively dense coating was fabricated using a specifically designed extended nozzle. Investigations by means of optical emission spectroscopy were performed to analyze the nature of the plasma jet with YSZ powders. The Vickers microhardness was also conducted. It was found that the relatively dense coating showed a higher value in comparison to the hybrid structure coating, up to 1273 ± 56 Hv100g.

  7. Piezospectroscopic measurements capturing the evolution of plasma spray-coating stresses with substrate loads.

    PubMed

    Freihofer, Gregory; Fugon-Dessources, Daniela; Ergin, Emrecan; Van Newkirk, Amy; Gupta, Ankur; Seal, Sudipta; Schülzgen, Axel; Raghavan, Seetha

    2014-02-12

    Plasma-spray coatings have a unique microstructure composed of various types of microcracks and weakly bonded interfaces which dictate their nonlinear mechanical properties. The intrinsic photo-luminescence (PL) characteristics of alpha-alumina (α-Al2O3) within these coatings offer a diagnostic functionality, enabling these properties to be probed experimentally at the microscale, under substrate loading. The piezospectroscopic (PS) measurements from the coatings are capable of revealing microstructural stress at high spatial resolution. Here, for the first time, the evolution of stresses within air plasma spray (APS) coatings under increasing substrate loads were captured using piezospectroscopy. With mechanical cycling of the substrate, the PS properties revealed anelastic and inelastic behavior and a relaxation of residual tensile stress within the APS coatings. With decreasing substrate thickness, the coating was observed to sustain more stress, as the substrate's influence on the mechanical behavior decreased. The findings provide an insight into the microstructural response that can serve as the basis for model validation and subsequently drive the design process for these coatings. PMID:24422438

  8. Thermal shock behavior of alumina/MoSi2 plasma sprayed laminated composites

    SciTech Connect

    Castro, R. G.; Petrovic, J. J.; Vaidya, R. U.; Mendoza, D.

    2001-01-01

    Alumina (Al{sub 2}O{sub 3}) is very susceptible to thermal shock, which leads to strength degradation. By reinforcing Al{sub 2}O{sub 3} with molybdenum disilicide (MoSi{sub 2}) layers, the tolerance to damage caused by thermal shock can be improved. The thermal shock resistance of plasma sprayed Al{sub 2}O{sub 3}/MoSi{sub 2} laminated composites were investigated. Three laminate microstructures having different layer thickness were fabricated by atmospheric plasma spraying while maintaining a 50/50-volume fraction. Quenching experiments done on 4-point bend bars showed a gradual decrease in the strength as the change in temperature ({Delta}T) increased. Thermal shock resistant parameters (R{prime} and R-quadruple prime) provided a representative numerical value of the thermal shock resistance for the laminated composites. The corresponding material properties for the different microstructures were determined experimentally in order to calculate the R{prime} and R quadruple prime values. The intermediate layered composite showed the highest R-quadruple prime va1ue at 1061 {micro}m, while the thin layered composite had the highest R{prime} value at 474 W/m.

  9. Effect of aluminum phosphate additions on composition of three-component plasma-sprayed solid lubricant

    NASA Technical Reports Server (NTRS)

    Jacobson, T. P.; Young, S. G.

    1982-01-01

    Image analysis (IA) and electron microprobe X-ray analysis (EMXA) were used to characterize a plasma-sprayed, self-lubricating coating, NASA LUBE PS106, specified by weight percent as 35NiCr-35Ag-30CaF2. To minimize segregation of the powder mixture during the plasma-spraying procedure, monoaluminum phosphate was added to form agglomerate particles. Three concentrations of AlPO4 were added to the mixtures: 1.25, 2.5, and 6.25 percent by weight. Analysis showed that 1.25 wt% AlPO4 yielded a CaF2 deficiency, 2.5 wt% kept the coating closest to specification, and 6.25 wt% yielded excess CaF2 as well as more impurities and voids and a deficiency in silver. Photomicrographs and X-ray maps are presented. The methods of IA and EMXA complement each other, and the reasonable agreement in the results increases the confidence in determining the coating composition.

  10. A prospective randomized study comparing electrochemically deposited hydroxyapatite and plasma-sprayed hydroxyapatite on titanium stems

    PubMed Central

    2011-01-01

    Background and purpose Plasma-sprayed hydroxyapatite (HA) is a successful coating for fixation of uncemented femoral stems. There may be alternative coatings with advantages in bone remodeling and transport of bone-active substances. We investigated whether an electrochemically deposited hydroxyapatite, Bonemaster (BM), might be a safe alternative in total hip arthroplasty. Our hypothesis was that the new coating would not be inferior to the conventional one. Patients and methods 50 patients (55 hips) were included. The stem was tapered and porous-coated proximally. On top of the porous coating was either HA or BM. Patients were evaluated postoperatively and after 3, 6, 12, and 24 months to measure fixation by radiostereometric analysis (RSA), bone mineral density by dual-energy X-ray absorptiometry (DXA), and conventional radiography. Clinical evaluation was performed with Harris hip score and Oxford hip score, both preoperatively and after 2 years. Results After 2 years, the stems had subsided 0.25 (HA) and 0.28 (BM) mm and there were no statistically significant differences between the groups in any direction, regarding both migration and rotation. The BM group retained significantly more bone than the HA group in Gruen zone 1 during the first 2 years. The Harris and Oxford hip scores were similar in both groups. Interpretation Electrochemically deposited hydroxyapatite on an uncemented stem does not appear to be inferior to plasma-sprayed HA regarding clinical and radiological results, bone remodeling, and micromotion after 2 years follow-up. PMID:21189109

  11. Method of forming a plasma sprayed interconnection layer on an electrode of an electrochemical cell

    DOEpatents

    Spengler, Charles J.; Folser, George R.; Vora, Shailesh D.; Kuo, Lewis; Richards, Von L.

    1995-01-01

    A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO.sub.3 particles doped with an element selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by plasma spraying doped LaCrO.sub.3 powder, preferably compensated with chromium as Cr.sub.2 O.sub.3 and/or dopant element, preferably by plasma arc spraying; and, (C) heating the doped and compensated LaCrO.sub.3 layer to about 1100.degree. C. to 1300.degree. C. to provide a dense, substantially gas-tight, substantially hydration-free, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the unselected portion of the air electrode, and a fuel electrode can be applied to the solid electrolyte, to provide an electrochemical cell.

  12. Method of forming a plasma sprayed interconnection layer on an electrode of an electrochemical cell

    DOEpatents

    Spengler, C.J.; Folser, G.R.; Vora, S.D.; Kuo, L.; Richards, V.L.

    1995-06-20

    A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO{sub 3} particles doped with an element selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by plasma spraying doped LaCrO{sub 3} powder, preferably compensated with chromium as Cr{sub 2}O{sub 3} and/or dopant element, preferably by plasma arc spraying; and, (C) heating the doped and compensated LaCrO{sub 3} layer to about 1100 C to 1300 C to provide a dense, substantially gas-tight, substantially hydration-free, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the unselected portion of the air electrode, and a fuel electrode can be applied to the solid electrolyte, to provide an electrochemical cell. 6 figs.

  13. Osseointegration of atmospheric plasma-sprayed titanium implants: Influence of the native oxide layer.

    PubMed

    Cunha, Alexandre; Renz, Renata Pedrolli; Blando, Eduardo; de Oliveira, Rogério Belle; Hübler, Roberto

    2014-01-01

    The aim of this study was to evaluate in vivo the influence of the native oxide layer on osseointegration and new bone formation on the surface of atmospheric plasma-sprayed porous titanium coatings. Porous titanium coatings were deposited on all implant surfaces, and half of the samples were subsequently submitted to oxide layer removal treatment. Samples were implanted onto the cortical bone of sheep (tibia) and evaluated at 30 and 60 days. Implants were removed en bloc and the attachment of bone to implants was examined by tensile pull-out test (osseointegration assessment), light microscopy, scanning electron microscopy (histological analysis), and instrumented hardness tests (mechanical properties of mature and newly formed bone tissue). Coatings submitted to oxide layer treatment presented higher osseointegration values at both healing periods and showed more mature and mineralized bone tissue when compared with nontreated coatings. Our findings showed that the use of acid-etching in association with atmospheric plasma spraying techniques improves osseointegration of titanium implants. PMID:23568748

  14. Isothermal Oxidation Behavior of Supersonic Atmospheric Plasma-Sprayed Thermal Barrier Coating System

    NASA Astrophysics Data System (ADS)

    Bai, Yu; Ding, Chunhua; Li, Hongqiang; Han, Zhihai; Ding, Bingjun; Wang, Tiejun; Yu, Lie

    2013-10-01

    In this work, Y2O3 stabilized zirconia-based thermal barrier coatings (TBCs) were deposited by conventional atmospheric plasma spraying (APS) and high efficiency supersonic atmospheric plasma spraying (SAPS), respectively. The effect of Al2O3 layer stability on the isothermal growth behavior of thermally grown oxides (TGOs) was studied. The results revealed that the Al2O3 layer experienced a three-stage change process, i.e., (1) instantaneous growth stage, (2) steady-state growth stage, and (3) depletion stage. The thickness of Al2O3 scale was proved to be an important factor for the growth rate of TGOs. The SAPS-TBCs exhibited a higher Al2O3 stability and better oxidation resistance as compared with the APS-TBCs. Additionally, it was found that inner oxides, especially nucleated on the top of the crest, continually grew and swallowed the previously formed Al2O3 layer, leading to the granulation and disappearance of continuous Al2O3 scale, which was finally replaced by the mixed oxides and spinel.

  15. Electrochemical Impedance Studies on Tribocorrosion Behavior of Plasma-Sprayed Al2O3 Coatings

    NASA Astrophysics Data System (ADS)

    Liu, Zhe; Chu, Zhenhua; Chen, Xueguang; Dong, Yanchun; Yang, Yong; Li, Yingzhen; Yan, Dianran

    2015-06-01

    In this paper, the tribocorrosion of plasma-sprayed Al2O3 coatings in simulated seawater was investigated by electrochemical impedance spectroscopy (EIS) technique, complemented by scanning electron microscopy to observe the morphology of the tribocorrosion attack. Base on EIS of plasma-sprayed Al2O3 coatings undergoing long-time immersion in simulated seawater, the corrosion process of Al2O3 coatings can be divided into the earlier stage of immersion (up to 20 h) and the later stage (beyond 20 h). Then, the wear tests were carried out on the surface of Al2O3 coating undergoing different times of immersion to investigate the influence of wear on corrosion at different stages. The coexistence of wear and corrosion condition had been created by a boron nitride grinding head rotating on the surface of coatings corroded in simulated seawater. The measured EIS and the values of the fitting circuit elements showed that wear accelerated corrosion at the later stage, meanwhile, corrosion accelerated wear with the immersion time increasing.

  16. Reactive Plasma Spraying of Fine Al2O3/AlN Feedstock Powder

    NASA Astrophysics Data System (ADS)

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

    2013-12-01

    Reactive plasma spraying (RPS) is a promising technology for in situ formation of aluminum nitride (AlN) coatings. Recently, AlN-based coatings were fabricated by RPS of alumina (Al2O3) powder in N2/H2 thermal plasma. This study investigated the feasibility of RPS of a fine Al2O3/AlN mixture and the influence of the plasma gases (N2, H2) on the nitriding conversion, and coating microstructure and properties. Thick AlN/Al2O3 coatings with high nitride content were successfully fabricated. The coatings consist of h-AlN, c-AlN, Al5O6N, γ-Al2O3, and a small amount of α-Al2O3. Use of fine particles enhanced the nitriding conversion and the melting tendency by increasing the surface area. Furthermore, the AlN additive improved the AlN content in the coatings. Increasing the N2 gas flow rate improved the nitride content and complete crystal growth to the h-AlN phase, and enhanced the coating thickness. On the other hand, though the H2 gas is required for plasma nitriding of the Al2O3 particles, increasing its flow rate decreased the nitride content and the coating thickness. Remarkable influence of the plasma gases on the coating composition, microstructure, and properties was observed during RPS of the fine particles.

  17. Investigations on the Initial Stress Evolution During Atmospheric Plasma Spraying of YSZ by In Situ Curvature Measurement

    NASA Astrophysics Data System (ADS)

    Mutter, Markus; Mauer, Georg; Mücke, Robert; Vaßen, Robert; Back, Hyoung Chul; Gibmeier, Jens

    2016-03-01

    The residual stresses within plasma-sprayed coatings are an important factor that can influence the lifetime as well as the performance in operation. The investigation of stresses evolving during deposition and post-deposition cooling for atmospheric plasma spraying of yttria-stabilized zirconia coatings using in situ measurement of the samples curvature is a powerful tool for identifying the factors that contribute to stress generation. Under various spray conditions, the first deposition pass leads to a significantly larger increase in samples curvature than the subsequent passes. It is shown in this work that the amount of curvature change at the onset of spraying is significantly influenced by the spray conditions, as well as by the substrate material. More information on the origin of this steep curvature increase at the onset of spraying was obtained by single splat experiments, which yielded information on the splat bonding behavior under various conditions. A comparison of the compressive yield strength for different substrate materials indicated the influence of substrate residual stress relaxation. Residual stress measurements using the incremental hole-drilling method and x-ray diffraction confirmed that the coating deposition affects the substrate residual stress level. The yield strength data were combined with the substrate near-surface temperature during deposition, obtained by finite element simulations, and with the measured residual stress-profile. This revealed that residual stress relaxation is the key factor for the initial curvature increase.

  18. Investigations on the Initial Stress Evolution During Atmospheric Plasma Spraying of YSZ by In Situ Curvature Measurement

    NASA Astrophysics Data System (ADS)

    Mutter, Markus; Mauer, Georg; Mücke, Robert; Vaßen, Robert; Back, Hyoung Chul; Gibmeier, Jens

    2016-04-01

    The residual stresses within plasma-sprayed coatings are an important factor that can influence the lifetime as well as the performance in operation. The investigation of stresses evolving during deposition and post-deposition cooling for atmospheric plasma spraying of yttria-stabilized zirconia coatings using in situ measurement of the samples curvature is a powerful tool for identifying the factors that contribute to stress generation. Under various spray conditions, the first deposition pass leads to a significantly larger increase in samples curvature than the subsequent passes. It is shown in this work that the amount of curvature change at the onset of spraying is significantly influenced by the spray conditions, as well as by the substrate material. More information on the origin of this steep curvature increase at the onset of spraying was obtained by single splat experiments, which yielded information on the splat bonding behavior under various conditions. A comparison of the compressive yield strength for different substrate materials indicated the influence of substrate residual stress relaxation. Residual stress measurements using the incremental hole-drilling method and x-ray diffraction confirmed that the coating deposition affects the substrate residual stress level. The yield strength data were combined with the substrate near-surface temperature during deposition, obtained by finite element simulations, and with the measured residual stress-profile. This revealed that residual stress relaxation is the key factor for the initial curvature increase.

  19. Contact Resistance Reduction Using Vacuum Loadlock System and Plasma Dry Cleaning

    NASA Astrophysics Data System (ADS)

    Miya, Hironobu; Shingubara, Shoso; Sakaue, Hiroyuki; Takahagi, Takayuki

    2005-06-01

    The contact resistance between Si substrates and P-doped poly-Si films was investigated using a vacuum loadlock system with various wafer transfer environments. When compared to that in air atmosphere, the contact resistance was reduced by 40% and 50% in nitrogen atmosphere and under vacuum, respectively. Furthermore, the use of a plasma dry cleaning method to remove the native oxide before P-doped poly-Si deposition decreased the contact resistance by 60% compared with that in air. The surface treated with plasma dry cleaning was analyzed by secondary-ion mass spectroscopy (SIMS) and X-ray photoelectron spectroscopy (XPS) and was found to be terminated by SiOxFy or SiFx, which suppressed the formation of an interface oxide and the adsorption of organic compounds.

  20. Generation of high charge state platinum ions on vacuum arc plasma heated by gyrotron radiation

    NASA Astrophysics Data System (ADS)

    Yushkov, G. Yu.; Vodopyanov, A. V.; Nikolaev, A. G.; Izotov, I. V.; Savkin, K. P.; Golubev, S. V.; Oks, E. M.

    2014-02-01

    The hybrid high charge metal ion source based on vacuum arc plasma heated by gyrotron radiation into simple magnetic trap has been developed. Two types of magnetic traps were used: a mirror configuration and a cusp one with inherent "minimum-B" structure. Pulsed high power (>100 kW) gyrotrons with frequency 37.5 GHz and 75 GHz were used for heating the vacuum arc plasma injected into the traps. Two different ways were used for injecting the metal plasma—axial injection by a miniature arc source located on-axis near the microwave window, and simultaneous radial injection by a number of sources mounted radially at the midplane of the traps. This article represents all data gathered for platinum ions, thus making comparison of the experimental results obtained with different traps and injections convenient and accurate.

  1. Comparing 193 nm photoresist roughening in an inductively coupled plasma system and vacuum beam system

    NASA Astrophysics Data System (ADS)

    Titus, M. J.; Nest, D. G.; Chung, T.-Y.; Graves, D. B.

    2009-12-01

    We present a comparison of blanket 193 nm photoresist (PR) roughening and chemical modifications of samples processed in a well-characterized argon (Ar) inductively coupled plasma (ICP) system and an ultra-high vacuum beam system. In the ICP system, PR samples are irradiated with Ar vacuum ultraviolet (VUV) and Ar ions, while in the vacuum beam system, samples are irradiated with either a Xe-line VUV source or Ar-lamp VUV source with Ar ions. Sample temperature, photon flux, ion flux and ion energy are controlled and measured. The resulting chemical modifications to bulk 193 nm PR and surface roughness are analysed with Fourier transform infrared (FTIR) spectroscopy and atomic force microscopy. We demonstrate that under VUV-only conditions in the vacuum beam and ICP (with no substrate bias applied) systems 193 nm PR does not roughen. However, roughness increases with simultaneous high energy (>70 eV) ion bombardment and VUV irradiation and is a function of VUV fluence, substrate temperature and photon-to-ion flux ratio. PR processed in the ICP system experiences increased etching, probably due to release of H- and O-containing gaseous products and subsequent chemical etching, in contrast to samples in the vacuum beam system where etch-products are rapidly pumped away. The surface roughness structure and behaviour, however, remain similar and this is attributed to the synergy between VUV-photon and positive ions.

  2. Superior Performance of High-Velocity Oxyfuel-Sprayed Nanostructured TiO2 in Comparison to Air Plasma-Sprayed Conventional Al2O3-13TiO2

    NASA Astrophysics Data System (ADS)

    Lima, R. S.; Marple, B. R.

    2005-09-01

    Air plasma-sprayed conventional alumina-titania (Al2O3-13wt.%TiO2) coatings have been used for many years in the thermal spray industry for antiwear applications, mainly in the paper, printing, and textile industries. This work proposes an alternative to the traditional air plasma spraying of conventional aluminatitania by high-velocity oxyfuel (HVOF) spraying of nanostructured titania (TiO2). The microstructure, porosity, hardness (HV 300 g), crack propagation resistance, abrasion behavior (ASTM G65), and wear scar characteristics of these two types of coatings were analyzed and compared. The HVOF-sprayed nanostructured titania coating is nearly pore-free and exhibits higher wear resistance when compared with the air plasma-sprayed conventional alumina-titania coating. The nanozones in the nanostructured coating act as crack arresters, enhancing its toughness. By comparing the wear scar of both coatings (via SEM, stereoscope microscopy, and roughness measurements), it is observed that the wear scar of the HVOF-sprayed nanostructured titania is very smooth, indicating plastic deformation characteristics, whereas the wear scar of the air plasma-sprayed alumina-titania coating is very rough and fractured. This is considered to be an indication of a superior machinability of the nanostructured coating.

  3. Expansion of a slab of a three-component plasma with negative ions into vacuum

    SciTech Connect

    Medvedev, Yu. V.

    2010-06-15

    The expansion of a slab of a three-component collisionless plasma with negative ions into vacuum is studied by particle-in-cell numerical simulations. It is found that, when the ion temperatures are low in comparison with the electron temperature, the expansion process goes through several characteristic stages. The breaking phenomenon, the onset of multistream motion, and the development of instability are described.

  4. Plasma spraying of functionally graded yttria stabilized zirconia/NiCoCrAlY coating system using composite powders

    NASA Astrophysics Data System (ADS)

    Khor, K. A.; Gu, Y. W.; Dong, Z. L.

    2000-06-01

    Pre-alloyed and plasma spheroidized composite powders were used as the feedstock in the plasma spraying of functionally graded yttria stabilized zirconia (YSZ)/NiCoCrAlY coatings. The ball milling parameters of the composite powders and the plasma spraying parameters for preparing functionally graded materials (FMGs) coatings were optimized to obtain the best performance for the thermal barrier coatings (TBCs). Microstructure, physical, mechanical, and thermal properties of YSZ/NiCoCrAlY FGMs coatings were investigated and compared with those of traditional duplex coatings. Results showed that the advantages of using pre-alloyed composite powders in plasma spraying were to ensure chemical homogeneity and promote uniform density along the graded layers. Microstructure observation showed the gradient distribution of YSZ and NiCoCrAlY phases in the coating, and no clear interface was found between two adjacent different layers. Oxidation occurred during plasma spray and the resultant aluminum oxide combines with YSZ in a wide range of proportions. The bond strength of functionally graded coatings was about twice as high as that of the duplex coatings because of the significant reduction of the residual stresses in the coatings. The thermal cycling resistance of functionally graded coating was much better than that of duplex coating.

  5. Atmospheric plasma sprayed (APS) coatings of Al2O3-TiO2 system for photocatalytic application.

    PubMed

    Stengl, V; Ageorges, H; Ctibor, P; Murafa, N

    2009-05-01

    The goal of this study is to examine the photocatalytic ability of coatings produced by atmospheric plasma spraying (APS). The plasma gun used is a common gas-stabilized plasma gun (GSP) working with a d.c. current and a mixture of argon and hydrogen as plasma-forming gas. The TiO(2) powders are particles of about 100 nm which were agglomerated to a mean size of about 55 mum, suitable for spraying. Composition of the commercial powder is 13 wt% of TiO(2) in Al(2)O(3), whereas also in-house prepared powder with the same nominal composition but with agglomerated TiO(2) and conventional fused and crushed Al(2)O(3) was sprayed. The feedstock materials used for this purpose are alpha-alumina and anatase titanium dioxide. The coatings are analyzed by scanning electron microscopy (SEM), energy dispersion probe (EDS) and X-ray diffraction. Photocatalytic degradation of acetone is quantified for various coatings. All plasma sprayed coatings show a lamellar structure on cross section, as typical for this process. Anatase titania from feedstock powder is converted into rutile titania and alpha-alumina partly to gamma-alumina. Coatings are proven to catalyse the acetone decomposition when irradiated by UV rays. PMID:19424550

  6. On the ion front of a plasma expanding into a vacuum

    SciTech Connect

    Allen, J. E.; University College, Oxford, Oxford OX1 4BH ; Perego, M.

    2014-03-15

    Calculations are reported on the expansion of a plasma into a vacuum, using a model of cold ions and Boltzmann electrons. The initial distribution of the ions at the edge of the plasma greatly affects the subsequent expansion. An initial abrupt drop of ion density leads to an expansion in which the abrupt drop is maintained. A finite slope, however, leads to the formation of a peak of ion density at the ion front. The subsequent behaviour may lead to wave breaking and the formation of multi-valued ion velocity distributions.

  7. Atomic hydrogen density measurements in an ion source plasma using a vacuum ultraviolet absorption spectrometer

    SciTech Connect

    Stutzin, G.C.; Young, A.T.; Schlachter, A.S.; Stearns, J.W.; Leung, K.N.; Kunkel, W.B.; Worth, G.T.; Stevens, R.R.

    1989-01-01

    A system to determine the density and temperature of ground state hydrogen atoms in a plasma by vacuum ultraviolet laser absorption spectroscopy is described. The continuous tunability of the spectrometer allows for analysis at any of the Lyman transitions. The narrow bandwidth of the laser system allows for the accurate determination of the absorption lineshape and hence the translational temperature. The utility of the system is exemplified by data obtained on an ion-source plasma. The measurements demonstrate the quality of the data as well as illustrating the behavior of this ion source under varying discharge conditions. 9 refs., 5 figs., 1 tab.

  8. Measurements and simulations of shock wave generated plasma-vacuum interface

    SciTech Connect

    Kaganovich, D.; Helle, M. H.; Gordon, D. F.; Ting, A.

    2011-12-15

    A controlled gradient gas jet was designed, constructed, and tested at the Naval Research Laboratory for the generation of high density and sharp gradient plasma regions. The gas jet uses a laser-generated shock wave to control the density gradient at the vacuum and neutral gas interface. The length scale of the laser produced plasma density gradient is fully controlled by the strength of the shock wave and can be varied continuously from100 {mu}m for a weak shock to under 20 {mu}m in case of strong shock wave as verified by the experimental results and simulations.

  9. Multilayer vacuum window for wide-band microwave plasma diagnostic systems

    SciTech Connect

    Cavazzana, Roberto; Moresco, Maurizio

    2006-10-15

    Microwave diagnostics, e.g., reflectometry and electron cyclotron emission in plasma machines, often require large windows displaying low attenuation and reflection on a wide band, in addition to some basic features such as vacuum tightness and mechanical robustness. Wide-band matching is usually achieved by coating the window with dielectric layers of suitable permittivity and thickness. On the vacuum side the coating must also be vacuum compatible and resistant to the thermal radiation coming from plasma. On the RFX machine, to satisfy these requirements, a boron nitride disk properly machined on the surface facing the plasma has been clamped to the existing fused silica window. The addition of a Teflon layer on the air side allowed to attain power reflection coefficients as low as 0.025 in the frequency ranges of 26.5-40, 40-56, and 56-75 GHz and as low as 0.01 in the frequency ranges of 75-92 and 92-110 GHz.

  10. Oxidation and ablation of polymers by vacuum-UV radiation from low pressure plasmas

    NASA Astrophysics Data System (ADS)

    Fozza, A. C.; Roch, J.; Klemberg-Sapieha, J. E.; Kruse, A.; Holländer, A.; Wertheimer, M. R.

    1997-08-01

    Low-pressure glow discharge plasmas are increasingly used as an effective method for the surface modification of polymers; they can also serve in the laboratory to simulate low Earth orbital environment (LEO). Although Vacuum-Ultraviolet (VUV, λ < 200 nm) is an important component of plasma environment, only few studies have focused on its effects so far. The emission from low-pressure microwave plasma in the VUV-UV regions was investigated in order to use this plasma as light sources for the study of the VUV/UV effects on various polymers (polyethylene, polymethylmethacrylate, etc.) or high molecular weight oligomers (hexatriacontane). We have employed a quartz crystal microbalance (QCM) in order to measure in situ the net mass change of the polymeric films exposed to VUV/UV radiation originating from hydrogen plasmas. Measurements were made with the specimens in vacuum, or immersed in low-pressure oxygen, directly exposed to the VUV/UV (perpendicular to the radiation flux), or only to the VUV-generated atomic oxygen, AO (parallel to the radiation flux). Following irradiation, samples were analysed by X-ray Photoelectron Spectroscopy (XPS), in order to study the evolution of the oxygen content and of the various functional groups.

  11. Collisionless plasma expansion into vacuum: Two new twists on an old problem

    SciTech Connect

    Arefiev, Alexey V.; Breizman, Boris N.

    2009-05-15

    The paper deals with a generic problem of collisionless plasma expansion into vacuum in the regimes where the expanding plasma consists of hot electrons and cold ions. The expansion is caused by electron pressure and serves as an energy transfer mechanism from electrons to ions. This process is often described under the assumption of Maxwellian electrons, which easily fails in the absence of collisions. The paper discusses two systems with a naturally occurring non-Maxwellian distribution: an expanding laser-irradiated nanoplasma and a supersonic jet coming out of a magnetic nozzle. The presented rigorous kinetic description demonstrates how the deviation from the Maxwellian distribution fundamentally alters the process of ion acceleration during plasma expansion. This result points to the critical importance of a fully kinetic treatment in problems with collisionless plasma expansion.

  12. Arc-Cathode Coupling in the Modeling of a Conventional DC Plasma Spray Torch

    NASA Astrophysics Data System (ADS)

    Alaya, M.; Chazelas, C.; Mariaux, G.; Vardelle, A.

    2015-01-01

    The plasma torch is the basis of the plasma spray process and understanding of the electric arc dynamics within the plasma torch is necessary for better control of torch and process instabilities. Numerical simulation is a useful tool for investigating the effect of the torch geometry and operating parameters on the electric arc characteristics provided that the model of arc dynamics is reliable and the boundary conditions of the computational domain are well founded. However, such a model should also address the intricate transient and 3D interactions between the electrically conducting fluid and electromagnetic, thermal, and acoustics phenomena. Especially, the description of the electrode regions where the electric arc connects with solid material is an important part of a realistic model of the plasma torch operation as the properties of electric arcs at atmospheric pressure depend not only on the arc plasma medium, but also on the electrodes. This paper describes the 3D and time-dependent numerical simulation of a plasma arc and is focused on the cathode boundary conditions. This model was used to investigate the differences in arc characteristics when the cathode is included into the numerical domain and coupled with the arc. The magnetic and thermal coupling between the cathode and arc made it possible to get rid of the current density boundary condition at the cathode tip that is delicate to predetermine. It also allowed a better prediction of the cathode flow jet generated by the pumping action induced by the interaction of the self-magnetic field with the electric current and so it allowed a better description of the dynamics of arc. It should be a necessary step in the development of a fully predictive model of DC plasma torch operation.

  13. Effect of Substrate and Its Shape on in-Flight Particle Characteristics in Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Pourang, K.; Moreau, C.; Dolatabadi, A.

    2016-01-01

    Obtaining a uniform coating on curved mechanical parts such as gas turbine blades is one of the industrial challenges in suspension plasma spraying. Through a three dimensional numerical analysis, this study is aimed at providing a better understanding of the effect of substrate curvature on in-flight particle temperature, velocity, and trajectory. The high temperature and high velocity plasma flow is simulated inside the plasma torch using a uniform volumetric heat source in the energy equation. The suspension of yttria-stabilized zirconia particles is molded as a multicomponent droplet while catastrophic breakup regime is considered for simulating the secondary break up when the suspension interacts with the plasma flow. A two-way coupled Eulerian-Lagrangian approach along with a stochastic discrete model was used to track the particle trajectory. Particle size distribution in the vicinity of the substrate at different stand-off distances has been investigated. The results show that sub-micron particles obtain higher velocity and temperature compared to the larger particles. However, due to the small Stokes number associated with sub-micron particles, they are more sensitive to the change of the gas flow streamlines in the vicinity of a curved substrate.

  14. Bulge Testing and Interface Fracture Characterization of Plasma-Sprayed and HIP Bonded Zr Coatings on U-Mo

    NASA Astrophysics Data System (ADS)

    Hollis, K.; Liu, C.; Leckie, R.; Lovato, M.

    2015-01-01

    Bulge testing using a pressurized fluid to fracture the interface between bonded material layers along with three-dimensional digital image correlation to measure the sample distortion caused by pressurized fluid was applied to plasma-sprayed coatings. The initiation fracture toughness associated with the bonded materials was measured during the testing. The bulge testing of the uranium-molybdenum alloy plasma sprayed with zirconium and clad in aluminum is presented. The initiation fracture toughness was observed to increase with the increasing cathodic arc-cleaning current and the use of alternating polarity transferred arc current. This dependence was linked to the interface composition of oxide and mixed metal phases along with the interface temperature during spray deposition.

  15. Plasma sprayed hydroxyapatite coatings on titanium substrates. Part 1: Mechanical properties and residual stress levels.

    PubMed

    Tsui, Y C; Doyle, C; Clyne, T W

    1998-11-01

    Hydroxyapatite (HA) coatings have been sprayed on to substrates of Ti-6Al-4V, using a range of input power levels and plasma gas mixtures. Coatings have also been produced on substrates of mild steel and tungsten, in order to explore certain aspects of the mechanical behaviour of HA without the complication of yielding or creep in the substrate. Studies have been made of the phase constitution, porosity, degree of crystallinity, OH ion content, microstructure and surface roughness of the HA coatings. The Young's moduli in tension and in compression were evaluated by the cantilever beam bend test using a tungsten/HA composite beam. The flexural Young's modulus was determined using a free-standing deposit under the same test. Adhesion was characterised using the single-edge notch-bend test; this is considered superior to the tensile bond strength test in common use. Measured interfacial fracture energies were of the order 1-10 J m(-2). Stress levels were investigated using specimen curvature measurements in conjunction with a numerical process model. The quenching stress for HA was measured to be about 10-25 MPa and the residual stress level in HA coatings at room temperature are predicted to lie in the approximate range of 20-40 MPa (tensile). These residual stresses could be reduced in magnitude by maintaining the substrate at a low temperature (possibly below room temperature) during spraying and it may be worthwhile to explore this. Ideally, the HA coating should have low porosity, high cohesive strength, good adhesion to the substrate, a high degree of crystallinity and high chemical purity and phase stability. In practice, such combinations are rather difficult to achieve by just varying the spraying parameters. PMID:9870753

  16. Deposition of Functional Coatings Based on Intermetallic Systems TiAl on the Steel Surface by Vacuum Arc Plasma

    NASA Astrophysics Data System (ADS)

    Budilov, V.; Vardanyan, E.; Ramazanov, K.

    2015-11-01

    Laws governing the formation of intermetallic phase by sequential deposition of nano-sized layers coatings from vacuum arc plasma were studied. Mathematical modeling process of deposition by vacuum arc plasma was performed. In order to identify the structural and phase composition of coatings and to explain their physical and chemical behaviour XRD studies were carried out. Production tests of the hardened punching tools were performed.

  17. Influence of NH4Cl Powder Addition for Fabrication of Aluminum Nitride Coating in Reactive Atmospheric Plasma Spray Process

    NASA Astrophysics Data System (ADS)

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

    2011-01-01

    Reactive plasma spray is the key to fabricating aluminum nitride (AlN) thermally sprayed coatings. It was possible to fabricate AlN/Al composite coatings using atmospheric plasma spray process through plasma nitriding of Al powders (Al 30 μm). The nitriding reaction and the AlN content could be improved by controlling the spray distance and the feedstock powder particle size. Increasing the spray distance and/or using smaller particle size of Al powders improved the in-flight nitriding reaction. However, it was difficult to fabricate thick and dense AlN coatings with an increase in the spray distance and/or when using fine particles. Thus, the coatings thickness was suppressed because of the complete nitriding of some particles (formation of AlN particles) during flight, which prevents the particle deposition. Furthermore, the excessive vaporization of Al fine particles (due to increased particle temperature) decreased the deposition efficiency. To fabricate thick AlN coatings in the reactive plasma spray process, improving the nitriding reaction of the large Al particles at short spray distance is required to decrease the vaporization of Al particles during flight. This study investigated the influence of adding ammonium chloride (NH4Cl) powders on the nitriding process of large Al powders and on the microstructure of the fabricated coatings. It was possible to fabricate thick AlN coatings at 100 mm spray distance with small addition of NH4Cl powders to the Al feedstock powders (30 μm). Addition of NH4Cl to the starting Al powders promoted the formation of AlN through changing the reaction path to vapor-phase nitridation chlorination-nitridation sequences as confirmed by the thermodynamic analysis of possible intermediate reactions. This changes the nitriding reaction to a mild way, so it is more controlled with no explosive mode and with relatively low heating rates. Thus, NH4Cl acts as a catalyst, nitrogen source, and diluent agent. Furthermore, the evolved gases from the sublimation or decomposition of NH4Cl can prevent the Al particles coalescing after melting.

  18. Effect of electron energy distribution functions on plasma generated vacuum ultraviolet in a diffusion plasma excited by a microwave surface wave

    SciTech Connect

    Zhao, J. P.; Chen, L.; Funk, M.; Sundararajan, R.; Nozawa, T.; Samukawa, S.

    2013-07-15

    Plasma generated vacuum ultraviolet (VUV) in diffusion plasma excited by a microwave surface wave has been studied by using dielectric-based VUV sensors. Evolution of plasma VUV in the diffusion plasma as a function of the distance from the power coupling surface is investigated. Experimental results have indicated that the energy and spatial distributions of plasma VUV are mainly controlled by the energy distribution functions of the plasma electrons, i.e., electron energy distribution functions (EEDFs). The study implies that by designing EEDF of plasma, one could be able to tailor plasma VUV in different applications such as in dielectric etching or photo resist smoothing.

  19. Formation of Expanded Austenite on a Cold-Sprayed AISI 316L Coating by Low-Temperature Plasma Nitriding

    NASA Astrophysics Data System (ADS)

    Adachi, Shinichiro; Ueda, Nobuhiro

    2015-12-01

    Low-temperature plasma nitriding at temperatures below 450 °C is commonly applied to austenitic stainless steels to enhance wear resistance, while maintaining corrosion resistance, by forming expanded austenite (known as the S-phase). In this work, low-temperature plasma nitriding of cold-sprayed AISI 316L coatings was examined. A cold-spray technique was developed to produce metal coatings with less oxidation. However, the cold-sprayed AISI 316L coating obtained by use of nitrogen gas as propellant contained many interconnected pores and cracks, and was, consequently, unsuitable as an anticorrosive coating. Therefore, laser post-treatment was used to modify the coating and increase its density to similar to that of bulk steel. The anticorrosive performance of this coating on a carbon steel substrate in NaCl solution was substantially improved. Subsequent low-temperature plasma nitriding enhanced the wear resistance by two orders of magnitude. It is concluded that cold-sprayed AISI 316L coatings treated by laser post-treatment and subsequent low-temperature plasma nitriding could be used as protective coatings under severe wear and corrosion conditions.

  20. Manufacturing of composite titanium-titanium nitride coatings by reactive very low pressure plasma spraying (R-VLPPS)

    NASA Astrophysics Data System (ADS)

    Vautherin, B.; Planche, M.-P.; Quet, A.; Bianchi, L.; Montavon, G.

    2014-11-01

    Very Low Pressure Plasma Spraying (VLPPS) is an emerging spray process nowadays intensively studied by many research centers in the World. To date, studies are mostly focused on the manufacturing of ceramic or metallic coatings. None refers to composite coatings manufacturing by reactive plasma spraying under very low pressure (i.e., ~150 Pa). This paper aims at presenting the carried-out developments and some results concerning the manufacturing of composite coatings by reactive spraying. Titanium was selected as metallic material in order to deposit titanium-nitride titanium coatings (Ti-TiN). Nitrogen was used as plasma gas and was injected along an Ar-H2-N2 plasma jet via a secondary injector in order to reach the nitrogen content on the substrate surface. Thus, different kind of reactive mechanisms were highlighted. Resulting coatings were characterized by Scanning Electron Microscopy (SEM) observations. Porous microstructures are clearly identified and the deposits exhibit condensed vapours and molten particles. Glow Discharge Optical Emission Spectroscopy (GDOES) analysis evidenced nitrogen inside the deposits and X-Ray Diffraction (XRD) analysis confirmed the formation of titanium nitride phases, such as TiN and Ti2N, depending upon the location of the nitrogen injection. Microhardness values as high as 800 VHN were measured on manufactured samples (to be compared to 220 VHN for pure titanium VLPPS-manufactured coatings).

  1. Improvement in the properties of plasma-sprayed metallic, alloy and ceramic coatings using dry-ice blasting

    NASA Astrophysics Data System (ADS)

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

    2011-10-01

    Dry-ice blasting, as an environmental-friendly method, was introduced into atmospheric plasma spraying for improving properties of metallic, alloy and ceramic coatings. The deposited coatings were then compared with coatings plasma-sprayed using conventional air cooling in terms of microstructure, temperature, oxidation, porosity, residual stress and adhesion. It was found that a denser steel or CoNiCrAlY alloy coating with a lower content of oxide can be achieved with the application of dry-ice blasting during the plasma spraying. In addition, the adhesive strength of Al 2O 3 coating deposited with dry-ice blasting exceeded 60 MPa, which was nearly increased by 30% compared with that of the coating deposited with conventional air cooling. The improvement in properties of plasma-sprayed metallic, alloy and ceramic coatings caused by dry-ice blasting was attributed to the decrease of annulus-ringed disk like splats, the better cooling efficiency of dry-ice pellets and even the mechanical effect of dry-ice impact.

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

  3. Characterization of gas tunnel type plasma sprayed hydroxyapatite-nanostructure titania composite coatings

    NASA Astrophysics Data System (ADS)

    Yugeswaran, S.; Kobayashi, A.; Ucisik, A. Hikmet; Subramanian, B.

    2015-08-01

    Hydroxyapatite (HA) can be coated onto metal implants as a ceramic biocompatible coating to bridge the growth between implants and human tissue. Meanwhile many efforts have been made to improve the mechanical properties of the HA coatings without affecting its bioactivity. In the present study, nanostructure titania (TiO2) was mixed with HA powder and HA-nanostructure TiO2 composite coatings were produced by gas tunnel type plasma spraying torch under optimized spraying conditions. For this purpose, composition of 10 wt% TiO2 + 90 wt% HA, 20 wt% TiO2 + 80 wt% HA and 30 wt% TiO2 + 70 wt% HA were selected as the feedstock materials. The phase, microstructure and mechanical properties of the coatings were characterized. The obtained results validated that the increase in weight percentage of nanostructure TiO2 in HA coating significantly increased the microhardness, adhesive strength and wear resistance of the coatings. Analysis of the in vitro bioactivity and cytocompatibility of the coatings were done using conventional simulated body fluid (c-SBF) solution and cultured green fluorescent protein (GFP) labeled marrow stromal cells (MSCs) respectively. The bioactivity results revealed that the composite coating has bio-active surface with good cytocompatibility.

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

    DOE PAGESBeta

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

    2014-06-09

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

  5. Sliding Wear Response of Nanostructured YSZ Suspension Plasma-Sprayed Coating

    NASA Astrophysics Data System (ADS)

    Kossman, S.; Chicot, D.; Decoopman, X.; Iost, A.; van Gorp, A.; Meillot, E.; Puchi-Cabrera, E. S.; Santana, Y. Y.; Staia, M. H.

    2014-12-01

    Nanostructured yttria-stabilized zirconia coatings for applications in high-temperature environments can be deposited by suspension plasma spraying (SPS) techniques. The present research has been conducted in order to study the sliding wear response of a SPS ZrO2-8% mol. Y2O3 coating (75 μm in thickness) deposited onto a Haynes 230 substrate, using pin-on-disc tests. Some of the coated samples were subsequently heat-treated for 1 h at 300 and 600 °C. Samples characterization prior and after the wear tests was carried out by SEM, EDS, XRD and optical profilometry techniques. Instrumented indentation was employed to determine elastic modulus and hardness. The results have shown that the as-sprayed and heat-treated samples experienced severe wear (10-13 m3/Nm) and the worst wear performance corresponded to the sample heat treated at 600 °C. Such a behavior could be related to both the structural changes that took place during heat treatment and the nature and level of the residual stresses in the coatings. In general, the morphologies of the wear tracks observed by SEM have shown a smoothing of the surface, brittle fracture, smearing and grain pull-out.

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

    SciTech Connect

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

    2014-06-09

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

  7. Effect of Sintering on Mechanical and Physical Properties of Plasma-Sprayed Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dong-Ming; Miller, Robert A.

    2004-01-01

    The effect of sintering on mechanical and physical properties of free-standing plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings (TBCs) was determined by annealing them at 1316 C in air. Mechanical and physical properties of the TBCs, including strength, modes I and II fracture toughness, elastic modulus, Poisson s response, density, microhardness, fractography, and phase stability, were determined at ambient temperature as a function of annealing time ranging from 0 to 500 h. All mechanical and physical properties, except for the amount of monoclinic phase, increased significantly in 5 to 100 h and then reached a plateau above 100 h. Annealing resulted in healing of microcracks and pores and in grain growth, accompanying densification of the TBC s body due to the sintering effect. However, an inevitable adverse effect also occurred such that the desired lower thermal conductivity and good expansivity, which makes the TBCs unique in thermal barrier applications, were degraded upon annealing. A model was proposed to assess and quantify all the property variables in response to annealing in a normalized scheme. Directionality of as-sprayed TBCs appeared to have an insignificant effect on their properties, as determined via fracture toughness, microhardness, and elastic modulus measurements.

  8. Development and the Implementation of High-Temperature Reliable Heaters in Plasma Spray Technology

    NASA Astrophysics Data System (ADS)

    Prudenziati, Maria

    2008-06-01

    Many problems have been encountered during development of reliable high-temperature heaters by means of atmospheric plasma spray and procedures commonly adopted in thermal spray technology, especially due to poor steel substrate corrosion resistance, notably affected by grit-blasting operations, but also deriving from contamination of insulating layers, dielectric arcs, and failures due to hot spots in the heating elements. While seeking the origin of these problems, a close scrutiny of every single step of the preparation process and analyses of the coatings were carried out using laser confocal scanning microscopy, optical and electronic microscopy, fluorescence analysis, X-ray diffraction, and ancillary techniques. The electrical properties of both alumina layers and metal strips prepared with Ni, NiCr, NiAl commercial powders for the heating elements were studied and cross-related to the failures in the heaters. The article reports the main results of these investigations, delineates the innovations introduced to overcome or circumvent the problems, and underlines the distinct characteristics of new heaters, whose reliability has been proven up to now with temperatures of up to 600 °C in air.

  9. Behavior of Calcia-Stabilized Zirconia Coating at High Temperature, Deposited by Air Plasma Spraying System

    NASA Astrophysics Data System (ADS)

    Bhatty, M. Billah; Khalid, F. Ahmad; Khan, A. Nusair

    2012-01-01

    Thermal barrier coatings (TBCs) are employed to protect metallic components from heat, oxidation, and corrosion in hostile environments. In this paper Ni-20Cr bond coat followed by CaZrO3 top coat was deposited on 316 stainless steel substrates by air plasma spray coating technique. Isothermal treatment of coated samples was carried out to investigate the effect of heat exposure on the microstructure and metallurgical phase changes of TBCs system. The fractured surface of as-sprayed and delaminated CaZrO3 coatings was also studied to observe the splats morphology, structural defects, and lamellas internal microstructure. CaZrO3 coating was found to be stable for 100 h at 700 °C but accelerated degradation was observed at 900 °C even at 20 h and lead to delamination after 60 h of exposure time. Chromium rich oxide formation was found to be responsible for the complete delamination of the top coat. Further, the formation of meta-stable monoclinic phase was also observed on the top surface of the top coat.

  10. Advanced Microscopic Study of Suspension Plasma-Sprayed Zirconia Coatings with Different Microstructures

    NASA Astrophysics Data System (ADS)

    Sokołowski, Paweł; Pawłowski, Lech; Dietrich, Dagmar; Lampke, Thomas; Jech, David

    2016-01-01

    The present paper is focused on the characterization of the differences between two microstructures that can be obtained using SPS technology, namely (i) columnar and (ii) two-zone microstructure including lamellas and fine unmelted particulates. The optimization of spray parameters was made, and the advanced microstructural studies of obtained coatings were performed. The work was focused on zirconia stabilized by yttria (YSZ, ZrO2 + 14 wt.% Y2O3) and both by yttria and ceria (YCSZ, ZrO2 + 24 wt.% CeO2 + 2.5 wt.% Y2O3) which are frequently used as thermal barrier coatings. Two types of microstructure were achieved using two different plasma torches, namely SG-100 of Praxair and Triplex of Oerlikon Metco. The microstructure of prepared coatings was analyzed using scanning electron microscopy with secondary electrons detector and backscattered electrons. Energy dispersive spectroscopy was performed to analyze the chemical composition of sprayed coatings. By electron backscatter diffraction grain shape, size, and crystal orientation were determined. The analysis enabled the discussion of the coatings growth mechanism. Finally, the Shape From Shading technique was applied to recreate and to analyze 3D views of coatings' topographies, and using laser confocal microscopy, the surface roughness was examined.

  11. Deposition of titanium nitride layers by electric arc - Reactive plasma spraying method

    NASA Astrophysics Data System (ADS)

    Şerban, Viorel-Aurel; Roşu, Radu Alexandru; Bucur, Alexandra Ioana; Pascu, Doru Romulus

    2013-01-01

    Titanium nitride (TiN) is a ceramic material which possesses high mechanical properties, being often used in order to cover cutting tools, thus increasing their lifetime, and also for covering components which are working in corrosive environments. The paper presents the experimental results on deposition of titanium nitride coatings by a new combined method (reactive plasma spraying and electric arc thermal spraying). In this way the advantages of each method in part are combined, obtaining improved quality coatings in the same time achieving high productivity. Commercially pure titanium wire and C45 steel as substrate were used for experiments. X-ray diffraction analysis shows that the deposited coatings are composed of titanium nitride (TiN, Ti2N) and small amounts of Ti3O. The microstructure of the deposited layers, investigated both by optical and scanning electron microscopy, shows that the coatings are dense, compact, without cracks and with low porosity. Vickers microhardness of the coatings presents maximum values of 912 HV0.1. The corrosion tests in 3%NaCl solution show that the deposited layers have a high corrosion resistance compared to unalloyed steel substrate.

  12. Development of metallic substrate supported planar solid oxide fuel cells fabricated by atmospheric plasma spraying

    NASA Astrophysics Data System (ADS)

    Takenoiri, Shunji; Kadokawa, Naruaki; Koseki, Kazuo

    2000-09-01

    A planar solid oxide fuel cell (SOFC) consisting of a cell supported with a porous metallic substrate and a metallic separator has been developed. In the fabrication of the cell, anodes and electrolytes were formed on sintered Ni-felt substrates using flame spraying (FS) and atmospheric plasma spraying (APS), respectively. The APS is also applied to form (LaSr)MnO3 protective coatings on the metallic separators. With these metallic cells and separators, a 3 kW-class stack, which consisted of 30 cells (15-cell block×2) was constructed and operated. The active electrode area of the cell was 600 cm2. The stack generated 3.3 kW at 970 °C when the current density was 0.3 Acm-2 and the fuel utilization 50%. It did not show any degradation for the initial 2100 h, but a few cells in the lower 15-cell block became unstable after 2100 h. On the other hand, the upper 15-cell block was stably operated for 3200 h.

  13. Surface oxidation of GaN(0001): Nitrogen plasma-assisted cleaning for ultrahigh vacuum applications

    SciTech Connect

    Gangopadhyay, Subhashis; Schmidt, Thomas Kruse, Carsten; Figge, Stephan; Hommel, Detlef; Falta, Jens

    2014-09-01

    The cleaning of metal-organic vapor-phase epitaxial GaN(0001) template layers grown on sapphire has been investigated. Different procedures, performed under ultrahigh vacuum conditions, including degassing and exposure to active nitrogen from a radio frequency nitrogen plasma source have been compared. For this purpose, x-ray photoelectron spectroscopy, reflection high-energy electron diffraction, and scanning tunneling microscopy have been employed in order to assess chemical as well as structural and morphological surface properties. Initial degassing at 600 °C under ultrahigh vacuum conditions only partially eliminates the surface contaminants. In contrast to plasma assisted nitrogen cleaning at temperatures as low as 300 °C, active-nitrogen exposure at temperatures as high as 700 °C removes the majority of oxide species from the surface. However, extended high-temperature active-nitrogen cleaning leads to severe surface roughening. Optimum results regarding both the removal of surface oxides as well as the surface structural and morphological quality have been achieved for a combination of initial low-temperature plasma-assisted cleaning, followed by a rapid nitrogen plasma-assisted cleaning at high temperature.

  14. Observations of the plasma dynamics of a vacuum spark from its soft x-ray emission

    SciTech Connect

    Chuaqui, H.; Favre, M.; Saavedra, R.; Wyndham, E.S.; Choi, P.; Dumitrescu-Zoita, C.; Soto, L.; Aliaga Rossel, R.; Mitchell, I.H.

    1997-10-01

    Experimental observations of the plasma dynamics in a vacuum spark are presented which permit measurements of the electron density and temperature during a large part of the compression phase of the pinch. The vacuum spark is generated by a low-impedance pulse forming line with a maximum current in excess of 100 kA. The discharge is operated in the hybrid mode in a titanium plasma. A laser focused onto the cathode provides the preionizing source. Soft x-ray emission from the current sheath is observed with an x-ray framing camera well before maximum compression. These observations are compared with holographic interferograms, both showing the formation of an axisymmetric rhombic boundary to the plasma sheath. The temperature and density of both the sheath and the internal plasma are observed until the formation of hot spots at the time of maximum compression. The temperature evolution of the hot spots is presented, showing a repeatable behavior that depends on the axial position. {copyright} {ital 1997 American Institute of Physics.}

  15. Observation of THz emission from a laser-plasma accelerated electron bunch crossing a plasma-vacuum boundary

    SciTech Connect

    Leemans, W.P.; Geddes, C.G.R.; Faure, J.; Toth, Cs.; van Tilborg, J.; Schroeder, C.B.; Esarey, E.; Fubiani, G.; Auerbach, D.; Marcelis, B.; Carnahan, M.A.; Kaindl, R.A.; Byrd, J.; Martin, M.C.

    2003-04-15

    Coherent radiation in the 0.3 - 3 THz range has been generated from femto second electron bunches at a plasma-vacuum boundary via transition radiation. The bunches produced by a laser-plasma accelerator contained 1.5 nC of charge. The THz energy per pulse within a limited 30 mrad collection angle was 3.5 nJ and scaled quadratically with bunch charge, consistent with coherent emission. Modeling indicates that this broadband source produces about 0.3 muJ per pulse within a 100 mrad angle, and that increasing the transverse plasma size and electron beam energy could provide more than 100 muj/pulse.

  16. Photo-Catalytic Activity and Photo-Absorption of Plasma-Sprayed Nano-Structured TiO2 Coatings

    NASA Astrophysics Data System (ADS)

    Bozorgtabar, Maryamossadat; Salehi, Mehdi; Rahimipour, Mohammadreza; Jafarpour, Mohammadreza

    Titanium dioxide coatings were deposited by utilizing atmospheric plasma-spraying system. The agglomerated P25/20 nano-powder and different spraying parameters (e.g., Argon flow rate and spray distance) were used to determine their influences on the microstructure, crystalline structure, photo-absorption, and photo-catalytic performance of the coatings. The microstructure and phases of as-sprayed TiO2 coatings were characterized by scanning electron microscope SEM and X-ray diffraction, respectively. Surface characteristics were investigated by Fourier Transform Infrared. Photo-catalytic efficiency of the elaborated samples was also determined in an environmental test chamber set-up and evaluated from the conversion rate of ethanol. The photo-absorption was determined by UV-Vis spectrophotometer. The as-sprayed TiO2 coating was photo-catalytically reactive for the degradation of ethanol. The photo-catalytic activity was influenced by spray conditions. It is found that the photo-catalytic activity is significantly influenced by anatase content, surface area, and surface state. The results showed that the argon flow rate has an influence on the microstructure, anatase content, and photo-catalytic activity of the TiO2 coatings.

  17. High energy density capacitors for vacuum operation with a pulsed plasma load

    NASA Technical Reports Server (NTRS)

    Guman, W. J.

    1976-01-01

    Results of the effort of designing, fabricating, and testing of a 40 joules/lb (88.2 joules/Kg) high voltage energy storage capacitor suitable for operating a pulsed plasma thruster in a vacuum environment for millions of pulses are presented. Using vacuum brazing and heli-arc welding techniques followed by vacuum and high pressure helium leak tests it was possible to produce a hermetically sealed relatively light weight enclosure for the dielectric system. An energy density of 40 joules/lb was realized with a KF-polyvinylidene fluoride dielectric system. One capacitor was D.C. life tested at 4 KV (107.8 joules/lb) for 2,000 hours before it failed. Another exceeded 2,670 hours without failure at 38.3 joules/lb. Pulse life testing in a vacuum exceeded 300,000 discharges with testing still in progress. The D.C. life test data shows a small decrease in capacitance and an increase in dissipation factor with time. Heat transfer from the load to the capacitor must also be considered besides the self-heat generated by the capacitor.

  18. Microstructural Analysis and Photocatalytic Activity of Plasma-Sprayed Titania-Hydroxyapatite Coatings

    NASA Astrophysics Data System (ADS)

    Ye, F.-X.; Ohmori, A.; Tsumura, T.; Nakata, K.; Li, C.-J.

    2007-12-01

    Hydroxyapatite (HAp Ca10(PO4)6(OH)2) is known to be a biomaterial and an adsorbent for chromatography. In this study, HAp was agglomerated with anatase TiO2 to manufacture thermal-spray powders to improve the adsorption activity of TiO2, and then to improve its photocatalytic activity. The microstructures, compositions and photocatalytic activity of plasma-sprayed TiO2, TiO2-10%HAp, TiO2-30%HAp, and HAp coatings were investigated. Due to the low thermal conductivity of HAp compound, not all HAp particles fully melted even under the arc current of 800 A. The addition of HAp inhibited the phase transformation of anatase TiO2 to rutile. Under the arc current of 600 A, the anatase content in the TiO2, TiO2-10%HAp and TiO2-30%HAp coatings was 11, 20 and 42%, respectively. With the increasing of the spraying distance from 70 to 110 mm, the anatase content in the TiO2-30%HAp coatings decreased from 34 to 17% under arc current of 700 A. Furthermore, a slight decomposition of HAp to α-Ca3(PO4)2 was found in the TiO2-30%HAp coatings, it did not decompose to CaO and P2O5 according to the XRD and EDAX analysis. The addition of the secondary gas of helium had no significant influence on the melting state of the TiO2-HAp feedstock powders. Moreover, the HAp in the TiO2-10%HAp and TiO2-30%HAp coatings had adsorption characteristic to acetaldehyde. The photocatalytic activity of TiO2-10%HAp coating was highest among TiO2, TiO2-10%HAp, and TiO2-30%HAp coatings sprayed under the arc current of 600 A for the optimum adsorption property and anatase content.

  19. Synthesis, characterization and physical properties of Al-Cu-Fe quasicrystalline plasma sprayed coatings

    SciTech Connect

    Daniel, S.

    1995-11-09

    Our lab has been working with plasma spraying of both high pressure gas atomized (HPGA) and cast and crushed quasicrystal powders. A major component of this research includes comparative studies of PAS coatings formed with starting powders prepared by both techniques. In addition, a thorough investigation of the effects of starting powder particle size on coating microstructure is included. During the course of the overall research, an interest developed in forming Al-Cu-Fe materials with finer grain sizes. Therefore, a brief study was performed to characterize the effect of adding boron to Al-Cu-Fe materials prepared by different techniques. In addition to characterizing the microstructural features of the above materials, oxidation and wear behavior was also examined.

  20. Determination of the Mechanical Properties of Plasma-Sprayed Hydroxyapatite Coatings Using the Knoop Indentation Technique

    NASA Astrophysics Data System (ADS)

    Hasan, Md. Fahad; Wang, James; Berndt, Christopher

    2015-06-01

    The microhardness and elastic modulus of plasma-sprayed hydroxyapatite coatings were evaluated using Knoop indentation on the cross section and on the top surface. The effects of indentation angle, testing direction, measurement location and applied load on the microhardness and elastic modulus were investigated. The variability and distribution of the microhardness and elastic modulus data were statistically analysed using the Weibull modulus distribution. The results indicate that the dependence of microhardness and elastic modulus on the indentation angle exhibits a parabolic shape. Dependence of the microhardness values on the indentation angle follows Pythagoras's theorem. The microhardness, Weibull modulus of microhardness and Weibull modulus of elastic modulus reach their maximum at the central position (175 µm) on the cross section of the coatings. The Weibull modulus of microhardness revealed similar values throughout the thickness, and the Weibull modulus of elastic modulus shows higher values on the top surface compared to the cross section.

  1. Microstructure and Pitting Corrosion Behavior of Plasma-Sprayed Fe-Si Nanocomposite Coating

    NASA Astrophysics Data System (ADS)

    Shi, Xi; Meng, Xinjing; Zhong, Qingdong; Yang, Jian; Shu, Mingyong; Han, Hongbo; Bui, QuocBinh

    2016-04-01

    In this study, Fe-Si nanoparticle composite coating (FSN) and Fe-Si microparticle composite coating (FSM) were prepared via atmospheric plasma spraying, and FSN was thermally treated under hydrogen atmosphere at 1120 °C for holding time of 2.5 h (TFSN). Under transmission electron microscopy, many unmelted nanoscale particles were observed in FSN, while no substantial particles were found in TFSN. On scanning electron microscopy analysis, pores and cracks were observed in FSM and FSN, while no defects were found in TFSN. Scanning electrochemical microscopy testing in 3.5 wt.% NaCl for 5 h revealed that FSM underwent severe pitting corrosion, FSN showed relatively minor pitting corrosion, and TFSN had no pitting corrosion.

  2. Mechanical Properties of Air Plasma Sprayed Environmental Barrier Coating (EBC) Materials

    NASA Technical Reports Server (NTRS)

    Richards, Bradley; Zhu, Dongming; Ghosn, Louis; Wadley, Haydn

    2015-01-01

    Development work in Environmental Barrier Coatings (EBCs) for Ceramic Matrix Composites (CMCs) has focused considerably on the identification of materials systems and coating architectures to meet application needs. The evolution of these systems has occurred so quickly that modeling efforts and requisite data for modeling lag considerably behind development. Materials property data exists for many systems in the bulk form, but the effects of deposition on the critical properties of strength and fracture behavior are not well studied. We have plasma sprayed bulk samples of baseline EBC materials (silicon, ytterbium disilicate) and tested the mechanical properties of these materials to elicit differences in strength and toughness. We have also endeavored to assess the mixed-mode fracture resistance, Gc, of silicon in a baseline EBC applied to SiCSiC CMC via four point bend test. These results are compared to previously determined properties of the comparable bulk material.

  3. Influence of plasma spraying deposition process on optical properties of hydroxyapatite

    NASA Astrophysics Data System (ADS)

    Belka, Radosław; Kowalski, Szymon; Żórawski, Wojciech; Suchańska, Małgorzata

    2015-09-01

    Hydroxyapatite (HAp) is a well-known bioceramic, nonorganic material of the bones of the vertebrate responsible for their mechanical durability. In human bones it occupies 60-80 % of the volume depending on a number of factors. Synthetic HAp is valued in bone endoprosthetic to its high biocompatibility. It is widely used to fill cavities of bone and as the coating of bone implants to increase their biocompatibility and adhesion to bone surface. In this paper a diffuse reflectance spectra of plasma-spraying deposited hydroxyapatite were presented and compared with pure powder samples. Optical band gap were estimated basing on Kubelka-Munk functions and Tauc plot extrapolation. We found that deposition process affects the value of band gap.

  4. Hot Corrosion Resistance and Mechanical Behavior of Atmospheric Plasma Sprayed Conventional and Nanostructured Zirconia Coatings

    NASA Astrophysics Data System (ADS)

    Saremi, Mohsen; Keyvani, Ahmad; Heydarzadeh Sohi, Mahmoud

    Conventional and nanostructured zirconia coatings were deposited on In-738 Ni super alloy by atmospheric plasma spray technique. The hot corrosion resistance of the coatings was measured at 1050°C using an atmospheric electrical furnace and a fused mixture of vanadium pent oxide and sodium sulfate respectively. According to the experimental results nanostructured coatings showed a better hot corrosion resistance than conventional ones. The improved hot corrosion resistance could be explained by the change of structure to a dense and more packed structure in the nanocoating. The evaluation of mechanical properties by nano indentation method showed the hardness (H) and elastic modulus (E) of the YSZ coating increased substantially after hot corrosion.

  5. Electrochemical polarisation studies on plasma-sprayed nickel-based superalloy

    NASA Astrophysics Data System (ADS)

    Khan, M. Adam

    2015-08-01

    The plasma-sprayed NiCr-Cr2O3 and Al2O3-40 % TiO2 powders are deposited as coating on nickel-based superalloy. The electrochemical polarisation studies were carried out with 1.0 M H2SO4 solution as a corrosive medium. The corrosion current density of the coated sample was found to be decreased and exhibits better corrosion resistance than bare metal. The characterisation studies on the exposed sample result reveal that the bare metal has undergone severe intergranular attack and segregation on austenitic phase. The corrosion products formed are in the form of sulphides, and contribution of sulphur was noticed through EDS analysis.

  6. Study of X-ray emission from plasma focus device using vacuum photodiode

    NASA Astrophysics Data System (ADS)

    Talukdar, N.; Borthakur, T. K.; Neog, N. K.

    2013-10-01

    A newly fabricated vacuum photodiode (VPD) is used to measure time resolved X-ray emission and electron temperature from plasma focus device operated in hydrogen medium. The VPD signals are compared with the PIN diode signal and observed to be of similar in nature. The acquired signals from VPD are deduced to measure electron temperature and X-ray radiated power for four different anode tips (cylindrical, diverging, oval and converging). The electron temperatures are found to be 0.64, 1.5, 0.60 and 0.55 keV for cylindrical, diverging, oval and converging anode tips respectively in hydrogen plasma. The X-ray radiated powers are observed to be varying with respect to the shape of the anode tips and it is found highest in case of converging tip and lowest for the diverging one. Results indicate that VPD could efficiently be employed as an X-ray diagnostics in plasma focus device.

  7. Deposition of nanostructured photocatalytic zinc ferrite films using solution precursor plasma spraying

    SciTech Connect

    Dom, Rekha; Sivakumar, G.; Hebalkar, Neha Y.; Joshi, Shrikant V.; Borse, Pramod H.

    2012-03-15

    Highlights: Black-Right-Pointing-Pointer Highly economic solution precursor route capable of producing films/coating even for mass scale production. Black-Right-Pointing-Pointer Pure spinel phase ZnFe{sub 2}O{sub 4} porous, immobilized films deposited in single step. Black-Right-Pointing-Pointer Parameter optimization yields access to nanostructuring in SPPS method. Black-Right-Pointing-Pointer The ecofriendly immobilized ferrite films were active under solar radiation. Black-Right-Pointing-Pointer Such magnetic system display advantage w.r.t. recyclability after photocatalyst extraction. -- Abstract: Deposition of pure spinel phase, photocatalytic zinc ferrite films on SS-304 substrates by solution precursor plasma spraying (SPPS) has been demonstrated for the first time. Deposition parameters such as precursor solution pH, concentration, film thickness, plasma power and gun-substrate distance were found to control physico-chemical properties of the film, with respect to their crystallinity, phase purity, and morphology. Alkaline precursor conditions (7 < pH {<=} 10) were found to favor oxide film formation. The nanostructured films produced under optimized conditions, with 500 mM solution at pH {approx} 8.0, yielded pure cubic phase ZnFe{sub 2}O{sub 4} film. Very high/low precursor concentrations yielded mixed phase, less adherent, and highly inhomogeneous thin films. Desired spinel phase was achieved in as-deposited condition under appropriately controlled spray conditions and exhibited a band gap of {approx}1.9 eV. The highly porous nature of the films favored its photocatalytic performance as indicated by methylene blue de-coloration under solar radiation. These immobilized films display good potential for visible light photocatalytic applications.

  8. Antibacterial and biological characteristics of plasma sprayed silver and strontium doped hydroxyapatite coatings

    PubMed Central

    Fielding, Gary A.; Roy, Mangal; Bandyopadhyay, Amit

    2012-01-01

    Infection in primary total joint prostheses is estimated to occur in up to 3% of all surgeries. As a measure to improve the antimicrobial properties of implant materials, silver (Ag) was incorporated into plasma sprayed hydroxyapatite (HA) coatings. To offset potential cytotoxic effects of Ag in the coatings, strontium (Sr) was also added as a binary dopant. HA powder were doped with 2.0 wt% Ag2O, 1.0 wt% SrO and the powder was then heat treated at 800° C. Titanium substrates were coated using a 30 kW plasma spray system equipped with a supersonic nozzle. X-ray diffraction (XRD) confirmed the phase purity and high crystallinity of the coatings. Samples were evaluated for mechanical stability by adhesive bond strength testing. Results show that the addition of dopants did not affect the overall bond strength of the coatings. The antibacterial efficacies of the coatings were tested against Pseudomonas aeruginosa. Samples that contained the Ag2O dopant were found to be highly effective against the bacterial colonization. In vitro cell-material interactions using human fetal osteoblast (hFOB) cells were characterized by 3-(4,5-Dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) assay for cell viability, field emission scanning electron microscopy (FESEM) for cell morphology and confocal imaging for the important differentiation marker alkaline phosphatase (ALP). Our results showed evidence of cytotoxic effects in the Ag-HA coatings, characterized by poor cellular morphology and cell death and nearly complete impediment of functional ALP activity. The addition of SrO to Ag-HA coatings was able to effectively offset these negative effects and improve the performance when compared to pure HA coated samples. PMID:22487928

  9. New developments in metal ion implantation by vacuum arc ion sources and metal plasma immersion

    SciTech Connect

    Brown, I.G.; Anders, A.; Anders, S.

    1996-12-31

    Ion implantation by intense beams of metal ions can be accomplished using the dense metal plasma formed in a vacuum arc discharge embodied either in a vacuum arc ion source or in a metal plasma immersion configuration. In the former case high energy metal ion beams are formed and implantation is done in a more-or-less conventional way, and in the latter case the substrate is immersed in the plasma and repetitively pulse-biased so as to accelerate the ions at the high voltage plasma sheath formed at the substrate. A number of advances have been made in the last few years, both in plasma technology and in the surface modification procedures, that enhance the effectiveness and versatility of the methods, including for example: controlled increase of the in charge states produced; operation in a dual metal-gaseous ion species mode; very large area beam formation; macroparticle filtering; and the development of processing regimes for optimizing adhesion, morphology and structure. These complementary ion processing techniques provide the plasma tools for doing ion surface modification over a very wide parameter regime, from pure ion implantation at energies approaching the MeV level, through ion mixing at energies in the {approximately}1 to {approximately}100 keV range, to IBAD-like processing at energies from a few tens of eV to a few keV. Here the authors review the methods, describe a number of recent developments, and outline some of the surface modification applications to which the methods have been put. 54 refs., 9 figs.

  10. Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants

    NASA Astrophysics Data System (ADS)

    Hussain, T.; Dudziak, T.; Simms, N. J.; Nicholls, J. R.

    2013-06-01

    This article presents a systematic evaluation of coatings for advanced fossil fuel plants and addresses fireside corrosion in coal/biomass-derived flue gases. A selection of four candidate coatings: alloy 625, NiCr, FeCrAl and NiCrAlY were deposited onto superheaters/reheaters alloy (T91) using high-velocity oxy-fuel (HVOF) and plasma spraying. A series of laboratory-based fireside corrosion exposures were carried out on these coated samples in furnaces under controlled atmosphere for 1000 h at 650 °C. The tests were carried out using the "deposit-recoat" test method to simulate the environment that was anticipated from air-firing 20 wt.% cereal co-product mixed with a UK coal. The exposures were carried out using a deposit containing Na2SO4, K2SO4, and Fe2O3 to produce alkali-iron tri-sulfates, which had been identified as the principal cause of fireside corrosion on superheaters/reheaters in pulverized coal-fired power plants. The exposed samples were examined in an ESEM with EDX analysis to characterize the damage. Pre- and post-exposure dimensional metrologies were used to quantify the metal damage in terms of metal loss distributions. The thermally sprayed coatings suffered significant corrosion attack from a combination of aggressive combustion gases and deposit mixtures. In this study, all the four plasma-sprayed coatings studied performed better than the HVOF-sprayed coatings because of a lower level of porosity. NiCr was found to be the best performing coating material with a median metal loss of ~87 μm (HVOF sprayed) and ~13 μm (plasma sprayed). In general, the median metal damage for coatings had the following ranking (in the descending order: most to the least damage): NiCrAlY > alloy 625 > FeCrAl > NiCr.

  11. Metal vapor plasma behavior during vacuum arc remelting of alloy 718

    SciTech Connect

    Zanner, F.J.; Maguire, M.C.; Williamson, R.L. ); Adasczik, C.B. ); Roberts, R.R. ); Strohecker, R. )

    1992-01-01

    A production vacuum arc remelt (VAR) furnace was modified to enable direct viewing of the metal vapor arc and molten electrode tip during melting of 432 mm dia. alloy 718 electrodes into 508 mm dia. ingots. Diffuse and constricted arcing conditions were characterized using high speed cinematography, standard video format, and monochromatic imaging. Constricted arcing was observed while melting electrodes contaminated with oxide slag of the type used for refractory linings in vacuum induction furnaces. Monochromatic imaging was used in visualize the ion distribution in the arc plasma; these images clearly showed whether the arc operated in a diffuse or constricted model. Diffuse arc melting conditions were very similar to those previously reported in the literature for smaller laboratory sized melts.

  12. Metal vapor plasma behavior during vacuum arc remelting of alloy 718

    SciTech Connect

    Zanner, F.J.; Maguire, M.C.; Williamson, R.L.; Adasczik, C.B.; Roberts, R.R.; Strohecker, R.

    1992-05-01

    A production vacuum arc remelt (VAR) furnace was modified to enable direct viewing of the metal vapor arc and molten electrode tip during melting of 432 mm dia. alloy 718 electrodes into 508 mm dia. ingots. Diffuse and constricted arcing conditions were characterized using high speed cinematography, standard video format, and monochromatic imaging. Constricted arcing was observed while melting electrodes contaminated with oxide slag of the type used for refractory linings in vacuum induction furnaces. Monochromatic imaging was used in visualize the ion distribution in the arc plasma; these images clearly showed whether the arc operated in a diffuse or constricted model. Diffuse arc melting conditions were very similar to those previously reported in the literature for smaller laboratory sized melts.

  13. Gap length dependence of two-dimensional electron and copper vapour density distribution over vacuum plasma

    NASA Astrophysics Data System (ADS)

    Inada, Y.; Kamiya, T.; Matsuoka, S.; Kumada, A.; Ikeda, H.; Hidaka, K.

    2015-12-01

    Shack-Hartmann type laser wavefront sensors were used for simultaneous visualisation of two-dimensional electron and copper vapour density distributions over vacuum plasmas in a breakdown phase and sustainable arc phase. Our experimental results for a 3-mm gap between Cu electrodes showed that the electrons in the vacuum breakdown stage were mainly supplied from the ionisation process of the copper vapour evaporating from the anode. In addition, the electron and copper vapour densities in an intense arc mode for the 3-mm gap were comparable to those for the 1.2-mm gap in our previous experiments. The validity of the observation results was verified by simultaneously recorded voltage and current waveforms demonstrating an inversely proportional decrease in arc column conductance with increasing gap length.

  14. Direct-current cathodic vacuum arc system with magnetic-field mechanism for plasma stabilization

    SciTech Connect

    Zhang, H.-S.; Komvopoulos, K.

    2008-07-15

    Filtered cathodic vacuum arc (FCVA) deposition is characterized by plasma beam directionality, plasma energy adjustment via substrate biasing, macroparticle filtering, and independent substrate temperature control. Between the two modes of FCVA deposition, namely, direct current (dc) and pulsed arc, the dc mode yields higher deposition rates than the pulsed mode. However, maintaining the dc arc discharge is challenging because of its inherent plasma instabilities. A system generating a special configuration of magnetic field that stabilizes the dc arc discharge during film deposition is presented. This magnetic field is also part of the out-of-plane magnetic filter used to focus the plasma beam and prevent macroparticle film contamination. The efficiency of the plasma-stabilizing magnetic-field mechanism is demonstrated by the deposition of amorphous carbon (a-C) films exhibiting significantly high hardness and tetrahedral carbon hybridization (sp{sup 3}) contents higher than 70%. Such high-quality films cannot be produced by dc arc deposition without the plasma-stabilizing mechanism presented in this study.

  15. Studies on the Sliding Wear Performance of Plasma Spray Ni-20Cr and Ni3Al Coatings

    NASA Astrophysics Data System (ADS)

    Kaur, Maninder; Singh, Harpreet; Singh, Balraj; Singh, Bhupinder

    2010-01-01

    Two metallic powders namely Ni-20Cr and Ni3Al were coated on AISI 309 SS steel by shrouded plasma spray process. The wear behavior of the bare, Ni-20Cr and Ni3Al-coated AISI 309 SS steel was investigated according to ASTM Standard G99-03 on a Pin-on-Disc Wear Test Rig. The wear tests were carried out at normal loads of 30 and 50 N with a sliding velocity of 1 m/s. Cumulative wear rate and coefficient of friction (μ) were calculated for all the cases. The worn-out surfaces were then examined by scanning electron microscopy analysis. Both the as-sprayed coatings exhibited typical splat morphology. The XRD analysis indicated the formation of Ni phase for the Ni-20Cr coating and Ni3Al phase for the Ni3Al coating. It has been concluded that the plasma-sprayed Ni-20Cr and Ni3Al coatings can be useful to reduce the wear rate of AISI 309 SS steel. The coatings were found to be adherent to the substrate steel during the wear tests. The plasma-sprayed Ni3Al coating has been recommended as a better choice to reduce the wear of AISI 309 SS steel, in comparison with the Ni-20Cr coating.

  16. Preparation of Aluminum Coatings by Atmospheric Plasma Spraying and Dry-Ice Blasting and Their Corrosion Behavior

    NASA Astrophysics Data System (ADS)

    Dong, Shu-Juan; Song, Bo; Zhou, Gen-Shu; Li, Chang-Jiu; Hansz, Bernard; Liao, Han-Lin; Coddet, Christian

    2013-10-01

    Aluminum coating, as an example of spray coating material with low hardness, was deposited by atmospheric plasma spraying while dry-ice blasting was applied during the deposition process. The deposited coatings were characterized in terms of microstructure, porosity, phase composition, and the valence states. The results show that the APS aluminum coatings with dry-ice blasting present a porosity of 0.35 ± 0.02%, which is comparable to the bulk material formed by the mechanical compaction. In addition, no evident oxide has been detected, except for the very thin and impervious oxide layer at the outermost layer. Compared to plasma-sprayed Al coatings without dry-ice blasting, the adhesion increased by 52% for Al substrate using dry-ice blasting, while 25% for steel substrate. Corrosion behavior of coated samples was evaluated in 3.5 wt.% NaCl aqueous using electrochemistry measurements. The electrochemical results indicated that APS Al coating with dry-ice blasting was more resistant to pitting corrosion than the conventional plasma-sprayed Al coating.

  17. Vacuum arc plasma generation and thin film deposition from a TiB2 cathode

    NASA Astrophysics Data System (ADS)

    Zhirkov, Igor; Petruhins, Andrejs; Naslund, Lars-Ake; Kolozsvári, Szilard; Polcik, Peter; Rosen, Johanna

    2015-11-01

    We have studied the utilization of TiB2 cathodes for thin film deposition in a DC vacuum arc system. We present a route for attaining a stable, reproducible, and fully ionized plasma flux of Ti and B by removal of the external magnetic field, which leads to dissipation of the vacuum arc discharge and an increased active surface area of the cathode. Applying a magnetic field resulted in instability and cracking, consistent with the previous reports. Plasma analysis shows average energies of 115 and 26 eV, average ion charge states of 2.1 and 1.1 for Ti and B, respectively, and a plasma ion composition of approximately 50% Ti and 50% B. This is consistent with measured resulting film composition from X-ray photoelectron spectroscopy, suggesting a negligible contribution of neutrals and macroparticles to the film growth. Also, despite the observations of macroparticle generation, the film surface is very smooth. These results are of importance for the utilization of cathodic arc as a method for synthesis of metal borides.

  18. Vacuum arc plasma generation and thin film deposition from a TiB{sub 2} cathode

    SciTech Connect

    Zhirkov, Igor Petruhins, Andrejs; Naslund, Lars-Ake; Rosen, Johanna; Kolozsvári, Szilard; Polcik, Peter

    2015-11-02

    We have studied the utilization of TiB{sub 2} cathodes for thin film deposition in a DC vacuum arc system. We present a route for attaining a stable, reproducible, and fully ionized plasma flux of Ti and B by removal of the external magnetic field, which leads to dissipation of the vacuum arc discharge and an increased active surface area of the cathode. Applying a magnetic field resulted in instability and cracking, consistent with the previous reports. Plasma analysis shows average energies of 115 and 26 eV, average ion charge states of 2.1 and 1.1 for Ti and B, respectively, and a plasma ion composition of approximately 50% Ti and 50% B. This is consistent with measured resulting film composition from X-ray photoelectron spectroscopy, suggesting a negligible contribution of neutrals and macroparticles to the film growth. Also, despite the observations of macroparticle generation, the film surface is very smooth. These results are of importance for the utilization of cathodic arc as a method for synthesis of metal borides.

  19. Development of a Ni/Al2O3 Cermet-Supported Tubular Solid Oxide Fuel Cell Assembled with Different Functional Layers by Atmospheric Plasma-Spraying

    NASA Astrophysics Data System (ADS)

    Li, Cheng-Xin; Li, Chang-Jiu; Yang, Guan-Jun

    2009-03-01

    A cermet-supported tubular configuration amenable to preparation by a relatively low-cost thermal spraying process is proposed. An Al2O3-Ni cermet thick deposit prepared by flame spraying is employed as both support tube and anode current collector. Atmospheric plasma spraying (APS) has been employed to prepare the anode, cathode, and stabilized ZrO2-based electrolyte with the aim of reducing manufacturing costs. Gas-tightness of the APS electrolyte has been achieved by a postdensification process. The effects of the densification process on the gas-tightness of the plasma-sprayed YSZ electrolyte and the open-circuit voltage of the SOFC have been investigated. The effects of the microstructures of the plasma-sprayed anode, electrolyte, and cathode on the performance of the SOFC test cell have been investigated.

  20. Influence of laser treatment on the corrosion properties of plasma-sprayed Ni-coated WC coatings

    NASA Astrophysics Data System (ADS)

    Xie, Guozhi; Zhang, Jinxian; Lu, Yijun; He, Ziyi; Hu, Bing; Zhang, Dongjie; Wang, Keyu; Lin, Pinghua

    2007-09-01

    The electrochemical corrosion of plasma spray Ni-coated WC cermet coatings, after laser treatment, has been studied in 3.5% NaCl solution through immersion test. The main corrosion mechanism for as-sprayed coating is the galvanic corrosion between coating and substrate, resulting in the detachment of coating from substrate, while the homogeneous corrosion occurs for the laser treatment coating. However, the corrosion trace for the as-sprayed pure coating could not be found. It is found that the electrochemical corrosion has been found heavily depending on the galvanic corrosion between the coating and the substrate. The defects, such as pores and laminar structures in the coating, could act as the infiltration paths of the electrolyte.

  1. Challenges Upon Reactive Plasma Spray Nitriding: Al Powders and Fabrication of AlN Coatings as a Case Study

    NASA Astrophysics Data System (ADS)

    Shahien, Mohammed; Yamada, Motohiro; Fukumoto, Masahiro

    2016-05-01

    Reactive plasma spraying (RPS) is a promising technology for the in situ formation of several ceramic coatings. The focus of this paper is to summarize the state of our current knowledge about the RPS process and using the nitriding of Al particles and the fabrication of aluminum nitride coatings, as a case study. The aspects and challenges in this process such as the influence of the plasma power, in-flight time, particle size, nitriding mechanism, splat morphology, in-flight particle diagnostics, N2 plasma gas, and the feeding rate on the RPS process are analyzed and discussed.

  2. Preparation of Nanocomposite GDC/LSCF Cathode Material for IT-SOFC by Induction Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Shen, Yan; Almeida, Veronica Alexandra B.; Gitzhofer, François

    2011-01-01

    Homogeneous mixtures of Ce0.8Gd0.2O1.9 (GDC) and La0.6Sr0.4Co0.2Fe0.8O3 (LSCF) nanopowders were successfully synthesized using induction plasma by axial injection of a solution. The resulting nanocomposite powders consisted of two kinds of nanopowders with different mass ratio of GDC/LSCF, such as 3/7 and 6/4. The morphological features, crystallinity, and the phases of the synthesized powders were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), local energy-dispersive x-ray spectroscopy (EDS) analysis, and x-ray diffraction (XRD). The nanopowders are almost globular in shape with a diameter smaller than 100 nm and their BET specific areas are around 20 m2 g-1. The GDC and LSCF phases are well distributed in the nanopowders. In addition, suspensions, made with the as-synthesized composite nanopowders and ethanol, were used to deposit cathode coatings using suspension plasma spray (SPS). Micro-nanostructures of the coatings are discussed. The coatings are homogeneous and porous (51% porosity) with cauliflower structures.

  3. Probe characterization of high-current driven metal plasma in a vacuum-arc rail gun

    NASA Astrophysics Data System (ADS)

    Vijayan, T.; Roychowdhury, P.; Venkatramani, N.

    2004-10-01

    The characteristics of metal plasma launched by high-current electric arc in a vacuum-arc rail gun are determined by employing electrical and magnetic probes. These measurements are validated by results from theoretical simulations. The arc coupled nonlinear circuit equations are solved simultaneously with the Newtonian arc motion and revealed the undercritically damped behavior of the arc current identical to the arc-current signal recorded by the Rogowski magnetic probe. Similarly the arc velocity and displacement derived from the signatures of B-dot probes are shown to concur closely with the results of J ×B propulsion from simulation. The heating of plasma is formulated in a three-electron population regime with direct arc energy coupling through magnetohydrodynamic, ion-acoustic, Coulomb, and neutral interactions. This results in high temperature (Te) of hundreds of eV in the arc as revealed by the simulation. Hence Te of the rapidly cooling and equilibrating plasma that emerged from the muzzle is high around 80-90eV, which is confirmed by Langmuir electric probe measurements. Density ne of this metal plasma is shown to be in the range 4×1021-6×1021m-3 and includes multiple ion charge states. The exit velocity of the plasma measured by a pair of Langmuir probes is close to 2.2×106cm/s and matched well with the arc velocity determined by the B-dot probes and the results from simulation.

  4. Improved Oxidation Life of Segmented Plasma Sprayed 8YSZ Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    Smialek, James L.

    2004-03-01

    Unconventional plasma sprayed thermal barrier coating (TBC) systems were produced and evaluated by interrupted or cyclic furnace oxidation life testing. First, approximately 250 µm thick 8YSZ coatings were directly sprayed onto grit blasted surfaces of PWA 1484, without a bond coat, to take advantage of the excellent oxidation resistance of this superalloy. For nominal sulfur (S) contents of 1 ppmw, total coating separation took place at relatively short times (200 h at 1100°C). Reductions in the S content, by melt desulfurization commercially (0.3 ppmw) or by hydrogen (H2) annealing in the laboratory (0.01 ppmw), improved scale adhesion and extended life appreciably, by factors of 5-10. However, edge-initiated failure persisted, producing massive delamination as one sheet of coating. Secondly, surfaces of melt desulfurized PWA 1484 were machined with a grid of grooves or ribs (˜250 µm wide and high), resulting in a segmented TBC surface macrostructure, for the purpose of subverting this failure mechanism. In this case, failure occurred only as independent, single-segment events. For grooved samples, 1100 °C segment life was extended to ˜1000h for 5 mm wide segments, with no failure observed out to 2000 h for segments ≤2.5 mm wide. Ribbed samples were even more durable, and segments ≤6 mm remained intact for 2000 h. Larger segments failed by buckling at times inversely related to the segment width and decreased by oxidation effects at higher temperatures. This critical buckling size was consistent with that predicted for elastic buckling of a TBC plate subject to thermal expansion mismatch stresses. Thus, low S substrates demonstrate appreciable coating lives without a bond coat, while rib segmenting extends life considerably.

  5. Enhanced ion charge states in vacuum arc plasmas using a ''current spike'' method

    SciTech Connect

    Bugaev, A. S.; Oks, E. M.; Yushkov, G. Yu.; Anders, A.; Brown, I. G.

    2000-02-01

    Ion charge state distributions of vacuum arc ion sources are correlated to the arc operating voltage. An enhancement of ion charge state via an increase of the arc voltage can be achieved utilizing the transient processes that accompany an arc current spike. A current spike of 100-1000 A and several microseconds width was produced on top of the main arc current pulse (100 A, 250 {mu}s). The ion charge state distribution was measured by charge-to-mass spectrometry. The measured charge state distributions were used as input data to the plasma model of partial local Saha equilibrium, giving the time-dependent electron temperature of the plasma at the freezing zone near the cathode spot. (c) 2000 American Institute of Physics.

  6. Deposition of Composite LSCF-SDC and SSC-SDC Cathodes by Axial-Injection Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Harris, Jeffrey; Qureshi, Musab; Kesler, Olivera

    2012-06-01

    The performance of solid oxide fuel cell cathodes can be improved by increasing the number of electrochemical reaction sites, by controlling microstructures, or by using composite materials that consist of an ionic conductor and a mixed ionic and electronic conductor. LSCF (La0.6Sr0.4Co0.2Fe0.8O3-δ) and SSC (Sm0.5Sr0.5CoO3) cathodes were manufactured by axial-injection atmospheric plasma spraying, and composite cathodes were fabricated by mixing SDC (Ce0.8Sm0.2O1.9) into the feedstock powders. The plasma power was varied by changing the proportion of nitrogen in the plasma gas. The microstructures of cathodes produced with different plasma powers were characterized by scanning electron microscopy and gas permeation measurements. The deposition efficiencies of these cathodes were calculated based on the mass of the sprayed cathode. Particle surface temperatures were measured in-flight to enhance understanding of the relationship between spray parameters, microstructure, and deposition efficiency.

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

    NASA Astrophysics Data System (ADS)

    Wang, Youliang

    Porous La1-xSrxMnO3 (LSM) perovskite cathodes and Yttria Stabilized Zirconia (YSZ)-Nickel (Ni) anodes were successfully deposited by direct current arc solution precursor plasma spray (DC-SPPS), in which a solution precursor of the product material was injected into DC plasma jet. The deposition mechanisms, such as the changes in the solution precursor with the increase of temperature and the evolution of the droplet as it moved along the plasma jet, as well as the impact of the synthesized particles onto the substrate, were investigated. The effects of processing parameters on the microstructure and phase composition of the fabricated LSM cathode and Ni-YSZ anode were examined systematically using TGA/TDA, XRD and SEM. Coating deposition efficiencies and porosities as a function of processing parameters were analyzed by statistical experimental design techniques, based on which the deposition processes were optimized. In addition, the hardness and electrical resistance of the fabricated coatings were measured. From the theoretical and experimental analyses conducted, a comprehensive description of the DC-SPPS process was developed. The precursor solution droplets undergo breakup; solvent evaporation and precursor salt precipitation and crystallization; precursor salt melting and decomposition; nucleation and growth of particles of the product phase; agglomeration, sintering, and perhaps melting of these particles; and impact onto the substrate. The breakup of droplets can only occur in the short period of time after the droplets are injected into the plasma jet. Agglomeration of droplets or particles may occur at any point along the plasma plume. This work has clearly established: (a) the critical importance of droplet breakup and the agglomeration of precursors or synthesized particles in-flight in the plasma jet in determining the structure of the deposited coating, and (b) the basis of the low deposition efficiencies obtained in DC-SPPS. The microstructure and phase composition of the deposited coatings were dependent on several processing parameters. By changing process parameters, phase pure LSM perovskite cathode coatings with 20%--40% porosity were produced. The LSM coatings were mainly built up by porous agglomerates of small spherical particles. Anode coatings predominately consist of porous agglomerates of small spherical YSZ particles (0.5 mum) homogenously distributed in a continuous Ni matrix. The anode coatings have 29--51% porosity.

  8. Structure and electronic properties features of amorphous chalhogenide semiconductor films prepared by ion-plasma spraying

    SciTech Connect

    Korobova, N. Timoshenkov, S.; Almasov, N.; Prikhodko, O.; Tsendin, K.

    2014-10-21

    Structure of amorphous chalcogenide semiconductor glassy As-S-Se films, obtained by high-frequency (HF) ion-plasma sputtering has been investigated. It was shown that the length of the atomic structure medium order and local structure were different from the films obtained by thermal vacuum evaporation. Temperature dependence of dark conductivity, as well as the dependence of the spectral transmittance has been studied. Conductivity value was determined at room temperature. Energy activation conductivity and films optical band gap have been calculated. Temperature and field dependence of the drift mobility of charge carriers in the HF As-S-Se films have been shown. Bipolarity of charge carriers drift mobility has been confirmed. Absence of deep traps for electrons in the As{sub 40}Se{sub 30}S{sub 30} spectrum of localized states for films obtained by HF plasma ion sputtering was determined. Bipolar drift of charge carriers was found in amorphous As{sub 40}Se{sub 30}S{sub 30} films obtained by ion-plasma sputtering of high-frequency, unlike the films of these materials obtained by thermal evaporation.

  9. Formation of single pinched plasma point in the cathode plasma jet of a multipicosecond laser-triggered vacuum discharge

    SciTech Connect

    Moorti, A.; Naik, P. A.; Gupta, P. D.; Bhat, R. K.

    2008-09-15

    Characteristics of cathode plasma jet pinching and x-ray emission from a multipicosecond laser-triggered vacuum discharge are presented. Discharge was created in between a planar Al cathode and a conical point-tip Ti anode (separation: 2-15 mm, circuit inductance of {approx}0.53 {mu}H, peak discharge current of {approx}3 kA, and rise time of {approx}400 ns). For anode-cathode separation of {approx}13.5 mm, only a single pinched plasma point was formed in the cathode plasma jet at a distance of {approx}9.5 mm from the cathode. Quantitative analysis of the x-ray signals recorded using a pin diode with different filters and viewing different regions of the discharge, shows soft ({approx}keV photon energy) x-ray emission from the plasma point with a flux of {approx}(3-5)x10{sup 10} photons/sr, and multi-keV x-ray emission from the Ti anode with K{alpha} ({approx}4.51 keV) photon flux of {approx}10{sup 10} photons/sr.

  10. Formation of single pinched plasma point in the cathode plasma jet of a multipicosecond laser-triggered vacuum discharge.

    PubMed

    Moorti, A; Naik, P A; Gupta, P D; Bhat, R K

    2008-09-01

    Characteristics of cathode plasma jet pinching and x-ray emission from a multipicosecond laser-triggered vacuum discharge are presented. Discharge was created in between a planar Al cathode and a conical point-tip Ti anode (separation: 2-15 mm, circuit inductance of approximately 0.53 microH, peak discharge current of approximately 3 kA, and rise time of approximately 400 ns). For anode-cathode separation of approximately 13.5 mm, only a single pinched plasma point was formed in the cathode plasma jet at a distance of approximately 9.5 mm from the cathode. Quantitative analysis of the x-ray signals recorded using a pin diode with different filters and viewing different regions of the discharge, shows soft ( approximately keV photon energy) x-ray emission from the plasma point with a flux of approximately (3-5)x10(10) photons/sr, and multi-keV x-ray emission from the Ti anode with Kalpha ( approximately 4.51 keV) photon flux of approximately 10(10) photons/sr. PMID:19044407

  11. Synthesis of Nanosized Titanium Oxide and Nitride Through Vacuum Arc Plasma Expansion Technique

    NASA Astrophysics Data System (ADS)

    Lepeshev, A. A.; Karpov, I. V.; Ushakov, A. V.; Fedorov, L. Yu.; Shaihadinov, A. A.

    2016-12-01

    Physical vapor deposition techniques such vacuum arc plasma deposition — which are very commonly used in thin film technology — appear to hold much promise for the synthesis of nanocrystalline thin films as well as nanoparticles. Monodisperse and spherical titanium oxide (TiO2) and nitride nanoparticles were produced at room temperature as a cluster beam in the gas phase using a cluster-deposition source. Using the basic principles of the gas condensation method, this study has developed vacuum arc nanoparticle synthesis system. We demonstrate that major process deposition parameter is the pressure in the plasma chamber. This is the major advantage of these techniques over thermal evaporation. Our method affords TiN powders with high specific surface areas exceeding 200m2g-1. TEM micrograph of TiO2 nanoparticles prepared at an oxygen pressure of 60Pa show an average particle size of 6nm. TiO2 nanoparticles prepared at an oxygen pressure of 70Pa were observed to not have a reduced average particle size.

  12. Modification of a metallic surface in a vacuum arc discharge plasma using thermally stimulated ion diffusion

    NASA Astrophysics Data System (ADS)

    Muboyadzhyan, S. A.

    2008-12-01

    A new process for modifying a metallic surface in a vacuum arc discharge plasma using thermally stimulated ion diffusion is considered. The effect of the bias voltage (negative substrate potential) on the processes that occur on the surface of a treated part is studied when the substrate material interacts with an accelerated metallic-ion flow. The phase and elemental compositions of the modified layer are studied for substrates made of nickel-based superalloys, austenitic and martensitic steels, and titanium-based alloys. The heat resistance, the salt corrosion resistance, and the corrosion cracking resistance of steels and titanium-based alloys are investigated after their modification in vacuum arc plasmas of pure metals (Ti, Zr, Al, Cr, Y) and related alloys. The surface modification caused by the thermally stimulated ion saturation of the surfaces of parts made from structural materials is shown to change the structural-phase states of their surfaces and, correspondingly, the properties of these materials in relation to the state of the surface.

  13. Integrity of plasma vacuum boundary in loss-of-coolant accident

    SciTech Connect

    Kobayashi, S.; Shimizu, T.; Seki, Y.

    1989-03-01

    If a loss-of-coolant accident occurs in a fusion reactor, the temperature in the vacuum vessel will rise. If the decay heat is not removed, then the plasma vacuum boundary may melt. In this paper, the effects of the decay heat in a LOCA are analyzed numerically based on the Fusion Experimental Reactor (FER). In the case of a loss-of-coolant accident with the plasma shut down, it is assumed that the decay heat is removed by the radiation of the divertor only. If the radiant effect is a quarter of the black radiation, the divertor plate will not melt, because the temperature rise is less than 150 K. Secondly, it is assumed that the decay heat is removed by the radiation between the outer shield and the heat shield. When the initial shield temperature is now and the amount of the shield is large, the temperature rise is negligible, because the heat capacity is large enough to absorb the heat. The effect of the natural convection outside of the cryostat is negligible to remove the heat.

  14. Plasma transport in stochastic magnetic field caused by vacuum resonant magnetic perturbations at diverted tokamak edge

    SciTech Connect

    Park, G.; Chang, C. S.; Joseph, I.; Moyer, R. A.

    2010-10-15

    A kinetic transport simulation for the first 4 ms of the vacuum resonant magnetic perturbations (RMPs) application has been performed for the first time in realistic diverted DIII-D tokamak geometry [J. Luxon, Nucl. Fusion 42, 614 (2002)], with the self-consistent evaluation of the radial electric field and the plasma rotation. It is found that, due to the kinetic effects, the stochastic parallel thermal transport is significantly reduced when compared to the standard analytic model [A. B. Rechester and M. N. Rosenbluth, Phys. Rev. Lett. 40, 38 (1978)] and the nonaxisymmetric perpendicular radial particle transport is significantly enhanced from the axisymmetric level. These trends agree with recent experimental result trends [T. E. Evans, R. A. Moyer, K. H. Burrell et al., Nat. Phys. 2, 419 (2006)]. It is also found, as a side product, that an artificial local reduction of the vacuum RMP fields in the vicinity of the magnetic separatrix can bring the kinetic simulation results to a more detailed agreement with experimental plasma profiles.

  15. A Plasma Window for Transmission of Radiation and Particle Beams from Vacuum to Atmosphere for Various Applications

    NASA Astrophysics Data System (ADS)

    Hershcovitch, Ady

    1997-11-01

    Many industrial and scientific processes like electron beam melting and welding, material modification by ion implantation, dry etching, and micro-fabrication, as well as generation of synchrotron radiation are performed almost exclusively in vacuum nowadays, since the electron and ion guns and their extractors must be kept at a reasonably high vacuum. Consequently, there are numerous drawbacks, among which are low production rates due to required pumping time, limits the vacuum volume sets on the size of target objects. In a small number of applications like non-vacuum electron beam welding, and various processes involving UV and x-ray radiation, thin vacuum walls or long stages of differential pumping are used. But, the resultant degradations of particle and radiation beams severely limit those applications. A novel apparatus, which utilized a short plasma arc, was successfully used to maintain a pressure of 7.6 x exp(-6) Torr in a vacuum chamber with a 2.36mm aperture to atmosphere, i.e., a plasma was successfully used to "plug" a hole to atmosphere while maintaining a reasonably high vacuum in the chamber. Successful transmission of charged particle beams from a vacuum through the plasma to atmosphere was accomplished. More details can be found in A. Hershcovitch, J. Appl. Physics 78, p. 5283 (1995). In addition to sustaining a vacuum atmosphere interface, the plasma has very strong lensing effect on charged particles. The plasma current generates an azimuthal magnetic field which exerts a radial Lorentz on charged particles moving parallel to the current channel. With proper orientation of the current direction, the Lorentz force is radially inward. This feature can be used to focus in beams to a very small spot size, and to overcome beam dispersion due to scattering by atmospheric atoms and molecules. Relatively hot plasma at the atmosphere boundary rarefies the atmospheric gases to further enhance particle beam propagation to the materials to target. Recent experimental results, with a plasma window coupled to a venturi, show a factor of three further enhancement in vacuum-atmosphere separation.

  16. Mechanisms for the formation and transport of ion fluxes in the plasma of a high-current vacuum spark

    SciTech Connect

    Dolgov, A. N.; Zemchenkova, N. V.; Klyachin, N. A.; Prokhorovich, D. E.

    2010-09-15

    The processes of ion flux formation in the plasma of a high-current vacuum spark were investigated experimentally. It is shown that multicharged ions are generated in the neck formed in the erosion products of the inner electrode. The plasma escaping from the neck region plays a role of a piston dragging particles of the cold peripheral plasma into ambient space. As the discharge current increases, the flux of the evaporated electrode material grows, the degree of ionization of the plasma produced decreases, and the efficiency of plasma heating caused by the pinching effect is reduced.

  17. Investigation of reactions between vanadium oxide and plasma-sprayed yttria-stabilized zirconia coatings

    SciTech Connect

    Chen, Zun; Speakman, Scott A; Howe, Jane Y; Wang, Hsin; Porter, Wallace D; Trice, Rodney

    2009-01-01

    The phase evolution occurring during the reaction between corrosive V{sub 2}O{sub 5} (T{sub m} = 690 C) and a plasma-sprayed 7 wt.% Y{sub 2}O{sub 3}ZrO{sub 2} (YSZ) coating from 700 to 900 C has been investigated in situ by X-ray diffraction. The temperature and time of interaction between the V{sub 2}O{sub 5} and YSZ coating determines the phases observed. Between 700 and 750 C, reaction products of ZrV{sub 2}O{sub 7} and YVO{sub 4} were observed within minutes of reaching the test temperature. m-ZrO{sub 2} was observed after 220 and 60 min at 700 and 750 C, respectively. The simultaneous formation of both ZrV{sub 2}O{sub 7} and YVO{sub 4} at the beginning of the reaction along with the delay of the m-ZrO{sub 2} formation suggests similar reactivity between both Zr and Y with V{sub 2}O{sub 5}. The weight percent of the ZrV{sub 2}O{sub 7} phase began to diminish after 150 and 60 min at 700 and 750 C, respectively. For reaction temperatures of 800 and 900 C, there is a rapid decrease in the amount of t{prime}-ZrO{sub 2} and a rapid increase in the amount of m-ZrO{sub 2} with reaction time. YVO{sub 4} was also observed at these reaction temperatures. SEM and TEM microstructural observations confirmed the phases detected from the in situ XRD experiments. Reactions between YSZ and V{sub 2}O{sub 5} suggest that the formation of a liquid phase due to the high solubility of both zirconia and yttria in vanadia is the dominate mechanism that damages the coating. The thermal conductivity of a plasma-sprayed YSZ coating reacted with up to 1 wt.% V{sub 2}O{sub 5} did not significantly change due to the small volume affected.

  18. Failure of thick, low density air plasma sprayed thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Helminiak, Michael Aaron

    This research was directed at developing fundamental understandings of the variables that influence the performance of air plasma sprayed (APS) yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC). Focus was placed on understanding how and why each variable influenced the performance of the TBC system along with how the individual variables interacted with one another. It includes research on the effect of surface roughness of NiCoCrAlY bond coats deposited by argon-shrouded plasma spraying, the interdiffusion behavior of bond coats coupled to commercial superalloys, and the microstructural and compositional control of APS topcoats to maximize the coating thicknesses that can be applied without spallation. The specimens used for this research were prepared by Praxair Surface Technologies and have been evaluated using cyclic oxidation and thermal shock tests. TBC performance was sensitive to bond coat roughness with the rougher bond coats having improved cyclic performance than the smoother bond coats. The explanation being the rough bond coat surface hindered the propagation of the delamination cracks. The failure mechanisms of the APS coatings were found to depend on a combination of the topcoat thickness, topcoat microstructure and the coefficient of thermal expansion (CTE) mismatch between the superalloy and topcoat. Thinner topcoats tended to fail at the topcoat/TGO interface due to bond coat oxidation whereas thicker topcoats failed within the topcoat due to the strain energy release rate of the thicker coating exceeding the fracture strength of the topcoat. Properties of free-standing high and conventional purity YSZ topcoats of both a lowdensity (LD) and dense-vertically fissure (DVF) microstructures were evaluated. The densification rate and phase evolution were sensitive to the YSZ purity and the starting microstructure. Increasing the impurity content resulted in enhanced sintering and phase decomposition rates, with the exception of the conventional-purity DVF which exhibited a density decrease during sintering. A combination of the DVF and LD topcoat microstructures (dual TBC) resulted in significant increase in cyclic durability. A 1275 mum thick dual TBC coating was found to have a comparable furnace cyclic life to that of a 100 im LD TBC.

  19. Continuous spray forming of functionally gradient materials

    SciTech Connect

    McKechnie, T.N.; Richardson, E.H.; Watson, R.D.

    1995-12-31

    Researchers at Plasma Processes Inc. have produced a Functional Gradient Material (FGM) through advanced vacuum plasma spray processing for high heat flux applications. Outlined in this paper are the manufacturing methods used to develop a four component functional gradient material of copper, tungsten, boron, and boron nitride. The FGM was formed with continuous gradients and integral cooling channels eliminating bondlines and providing direct heat transfer from the high temperature exposed surface to a cooling medium. Metallurgical and X-ray diffraction analyses of the materials formed through innovative VPS processing are also presented. Applications for this functional gradient structural material range from fusion reactor plasma facing components to missile nose cones to boilers.

  20. An Assessment of the Residual Stresses in Low Pressure Plasma Sprayed Coatings on an Advanced Copper Alloy

    NASA Technical Reports Server (NTRS)

    Raj, S. V.; Ghosn, L. J.; Agarwal, A.; Lachtrupp, T. P.

    2002-01-01

    Modeling studies were conducted on low pressure plasma sprayed (LPPS) NiAl top coat applied to an advanced Cu-8(at.%)Cr-4%Nb alloy (GRCop-84) substrate using Ni as a bond coat. A thermal analysis suggested that the NiAl and Ni top and bond coats, respectively, would provide adequate thermal protection to the GRCop-84 substrate in a rocket engine operating under high heat flux conditions. Residual stress measurements were conducted at different depths from the free surface on coated and uncoated GRCop-84 specimens by x-ray diffraction. These data are compared with theoretically estimated values assessed by a finite element analysis simulating the development of these stresses as the coated substrate cools down from the plasma spraying temperature to room temperature.

  1. Al2O3/Al Cermets by Plasma Spraying: Optical Response of Experimental and Numerically Represented Materials

    NASA Astrophysics Data System (ADS)

    Toru, D.; Echegut, R.; Quet, A.; De Sousa Meneses, D.; del Campo, L.; Piombini, H.; Echegut, P.; Bianchi, L.

    2016-01-01

    Optical properties of plasma-sprayed coatings and numerically represented samples were studied at wavelengths ranging from visible to mid-infrared. The paper focuses on Al2O3 and Al2O3/Al cermet coatings with different metal concentrations. Microstructure and composition of the samples were characterized in order to explain their optical response that is highly dependent on volume and/or surface scattering as a function of the wavelength range. 2D scanning electron microscopy and 3D x-ray microtomography images were exploited to get statistical data in order to numerically represent simplified samples from the complex microstructure of plasma-sprayed coatings. A Monte Carlo ray-tracing model, based on geometrical optical laws, was then applied to reproduce experimental trends of the acquired optical spectra. Good agreement with the experimental data was obtained.

  2. Production of flexible metal matrix composites reinforced with continuous Si-Ti-C-O fibers by atmospheric plasma spraying

    SciTech Connect

    Waku, Y.; Nakagawa, N.; Ohsora, Y.; Takahashi, T.; Shimizu, K.; Yamamura, T.; Ohmori, A. Osaka University, )

    1992-06-01

    An experiment is conducted to fabricate a flexible prepreg sheet with a continuous Si-Ti-C-O fiber by means of an air-plasma spraying method for use as an MMC plate. Plasma spraying is conducted under atmospheric conditions, and the prepreg and MMC sheets are investigated by means of a three-point flexural test and Auger electron spectroscopy to study strength and oxidation qualities. The oxidation layer is found to be about 200 A in depth, and the longitudinal and transverse flexural strengths of a unidirectionally reinforced MMC plate fabricated by hot pressing at 660 C are given as 1.0 and 0.25 GPa, respectively. The technique outlined is shown to be useful for developing squeeze-cast MMCs reinforced with Si-Ti-C-O that have high specific strength, specific modulus, and heat resistance. 18 refs.

  3. Preliminary study of cyclic thermal shock resistance of plasma-sprayed zirconium oxide turbine outer air seal shrouds

    NASA Technical Reports Server (NTRS)

    Bill, R. C.; Wisander, D. W.

    1977-01-01

    Several experimental concepts representing potential high pressure turbine seal material systems were subjected to cyclic thermal shock exposures similar to those that might be encountered under severe engine start-up and shut-down sequences. All of the experimental concepts consisted of plasma-sprayed yttria stabilized ZrO2 on the high temperature side of the blade tip seal shroud. Between the ZrO2 and a cooled, dense metal backing, various intermediate layer concepts intended to mitigate thermal stresses were incorporated. Performance was judged on the basis of the number of thermal shock cycles required to cause loss of seal material through spallation. The most effective approach was to include a low modulus, sintered metal pad between the ZrO2 and the metallic backing. It was also found that reducing the density of the ZrO2 layer significantly improved the performance of specimens with plasma-sprayed metal/ceramic composite intermediate layers.

  4. Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 C

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1973-01-01

    Plasma-sprayed composites, which have good oxidation-resistance and self-lubricating characteritics to 900 C, were developed. The composites are a nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication; they are applied to bearing surfaces by plasma spraying layers about 0.050 centimeters thick which are then machined to 0.025 centimeters. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 3.5 x 10 to the 7th power N/sq M (5000 psi) and a thrust load of 1960N (440 lbs). Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated, bearing temperatures cycles between 25 and 900 C.

  5. Fabrication of ceramic substrate-reinforced and free forms by mandrel plasma spraying metal-ceramic composites

    NASA Technical Reports Server (NTRS)

    Quentmeyer, R. J.; Mcdonald, G.; Hendricks, R. C.

    1985-01-01

    Components fabricated of, or coated with, ceramics have lower parasitic cooling requirements. Techniques are discussed for fabricating thin-shell ceramic components and ceramic coatings for applications in rocket or jet engine environments. Thin ceramic shells with complex geometric forms involving convolutions and reentrant surfaces were fabricated by mandrel removal. Mandrel removal was combined with electroplating or plasma spraying and isostatic pressing to form a metal support for the ceramic. Rocket engine thrust chambers coated with 0.08 mm (3 mil) of ZrO2-8Y2O3 had no failures and a tenfold increase in engine life. Some measured mechanical properties of the plasma-sprayed ceramic are presented.

  6. Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 C

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1974-01-01

    Plasma-sprayed composites, which have good oxidation resistance and self-lubricating characteristics to 900 C, were developed. The composites are a nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication; they are applied to bearing surfaces by plasma spraying layers about 0.050 cm thick which are then machined to 0.025 cm. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 5000 psi and a thrust load of 440 lb. Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated bearing temperature cycles between 25 and 900 C.

  7. X-Ray Spectroscopic Measurements from Copper and Tin Vacuum Spark Plasmas

    SciTech Connect

    Chew, S. H.; Yap, S. L.; Wong, C. S.

    2008-05-20

    X-ray emissions of copper and tin plasmas produced by a low energy and low inductance vacuum spark were studied. Both the time resolved and the time integrated measurements of the x-ray emissions were carried out using an x-ray spectrometer (XR-100 CR), a PIN diode and an x-ray diode (XRD). The x-ray spectra of the copper plasma obtained shows strong K{sub {alpha}} and K{sub {beta}} line radiations embedded in the continuum radiation. It is found that the hot spot formed has an electron temperature in the range from 2 keV to 3 keV. At this electron temperature, the dominant ionic specie is Cu{sup 27+} indicating that the plasma is not hot enough for the emission of the K line radiations. The emission of copper K lines is therefore believed to be produced by the energetic electron beam associated with sausage instability. For the case of tin plasma, strong L{sub {alpha}} superimposed on the continuum background was observed. These tin spectra are predominantly the result of the interaction of electron beam generated from the transient hollow cathode effect with the anode tip.

  8. IMPACT OF THERMAL ENVIRONMENT AND SPRAY-DRIED PLASMA ON THE ACUTE PHASE RESPONSE OF PIGS CHALLENGED WITH LIPOPOLYSACCHARIDE (LPS)

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Forty barrows (TR4 x C22) were weaned at 17 d of age (6.27 +/- 0.30 kg) and housed 2 pigs/pen in a thermal neutral environment (TN: constant 26.7 C) and fed diets with or without 7% spray-dried plasma (SDP). On d 7, one pig/pen was moved into a cold environment (CE: constant 15.6 C). Pigs were fitt...

  9. Optical Coherence Tomography for Inspection of Highly Scattering Ceramic Media: Glass Powders and Plasma-Sprayed Coatings

    SciTech Connect

    Veilleux, J.; Boulos, M. I.; Moreau, C.; Levesque, D.; Dufour, M.

    2006-03-06

    Optical coherence tomography (OCT) is used to collect images of spherical glass powders with mean diameter ranging from 10 to 150 microns. Appropriate peak distance measurements on image interferograms provide a good approximation of particle size distribution. The relationship between the light penetration depth inside powders and the particle diameter is also discussed based on Mie theory. Thereafter, OCT images of plasma-sprayed ceramic coatings are presented as well as an approach for establishing light penetration depth inside zirconia coatings.

  10. RETRACTED: Chemical densification of plasma sprayed yttria stabilized zirconia (YSZ) coatings for high temperature wear and corrosion resistance

    NASA Astrophysics Data System (ADS)

    Ye, Yaping; Fehr, Karl Thomas; Faulstich, Martin; Wolf, Gerhard

    2012-12-01

    Plasma-sprayed yttria stabilized zirconia (YSZ) ceramic coatings have been widely used as wear- and corrosion-resistant coatings in high temperature applications and an aggressive environment due to their high hardness, wear resistance, heat and chemical resistance, and low thermal conductivity. The highly porous structure of plasma-sprayed ceramic coatings and their poor adhesion to the substrate usually lead to the coating degradation and failure. In this study, a two-layer system consisting of atmospheric plasma-sprayed 8 wt.% yttria-stabilized zirconia (8YSZ) and Ni-based alloy coatings was post-treated by means of a novel chemical sealing process at moderate temperatures of 600-800 °C. Microstructure characteristics of the YSZ coatings were studied using an electron probe micro-analyzer (EPMA). Results revealed that the ceramic top coat was densified by the precipitated zirconia in the open pores. Therefore, the sealed YSZ coatings exhibit reduced porosity, higher hardness and a better adhesion onto the bond coat. The mechanisms for the sealing process were also proposed.

  11. Sheath expansion and plasma dynamics in the presence of electrode evaporation: Application to a vacuum circuit breaker

    SciTech Connect

    Sarrailh, P.; Garrigues, L.; Hagelaar, G. J. M.; Boeuf, J. P.; Sandolache, G.; Rowe, S.

    2009-09-01

    During the postarc dielectric recovery phase in a vacuum circuit breaker, a cathode sheath forms and expels the plasma from the electrode gap. The success or failure of current breaking depends on how efficiently the plasma is expelled from the electrode gap. The sheath expansion in the postarc phase can be compared to sheath expansion in plasma immersion ion implantation except that collisions between charged particles and atoms generated by electrode evaporation may become important in a vacuum circuit breaker. In this paper, we show that electrode evaporation plays a significant role in the dynamics of the sheath expansion in this context not only because charged particle transport is no longer collisionless but also because the neutral flow due to evaporation and temperature gradients may push the plasma toward one of the electrodes. Using a hybrid model of the nonequilibrium postarc plasma and cathode sheath coupled with a direct simulation Monte Carlo method to describe collisions between heavy species, we present a parametric study of the sheath and plasma dynamics and of the time needed for the sheath to expel the plasma from the gap for different values of plasma density and electrode temperatures at the beginning of the postarc phase. This work constitutes a preliminary step toward understanding and quantifying the risk of current breaking failure of a vacuum arc.

  12. Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell

    DOEpatents

    Kuo, Lewis J. H.; Vora, Shailesh D.

    1995-01-01

    A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an electrode structure of an electrochemical cell by: (A) providing an electrode structure; (B) forming on a selected portion of the electrode surface, an interconnection layer having the general formula La.sub.1-x M.sub.x Cr.sub.1-y N.sub.y O.sub.3, where M is a dopant selected from the group of Ca, Sr, Ba, and mixtures thereof, and where N is a dopant selected from the group of Mg, Co, Ni, Al, and mixtures thereof, and where x and y are each independently about 0.075-0.25, by thermally spraying, preferably plasma arc spraying, a flux added interconnection spray powder, preferably agglomerated, the flux added powder comprising flux particles, preferably including dopant, preferably (CaO).sub.12. (Al.sub.2 O.sub.3).sub.7 flux particles including Ca and Al dopant, and LaCrO.sub.3 interconnection particles, preferably undoped LaCrO.sub.3, to form a dense and substantially gas-tight interconnection material bonded to the electrode structure by a single plasma spraying step; and, (C) heat treating the interconnection layer at from about 1200.degree. to 1350.degree. C. to further densify and heal the micro-cracks and macro-cracks of the thermally sprayed interconnection layer. The result is a substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode structure. The electrode structure can be an air electrode, and a solid electrolyte layer can be applied to the unselected portion of the air electrode, and further a fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell for generation of electrical power.

  13. Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell

    DOEpatents

    Kuo, L.J.H.; Vora, S.D.

    1995-02-21

    A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an electrode structure of an electrochemical cell by: (A) providing an electrode structure; (B) forming on a selected portion of the electrode surface, an interconnection layer having the general formula La{sub 1{minus}x}M{sub x}Cr{sub 1{minus}y}N{sub y}O{sub 3}, where M is a dopant selected from the group of Ca, Sr, Ba, and mixtures thereof, and where N is a dopant selected from the group of Mg, Co, Ni, Al, and mixtures thereof, and where x and y are each independently about 0.075--0.25, by thermally spraying, preferably plasma arc spraying, a flux added interconnection spray powder, preferably agglomerated, the flux added powder comprising flux particles, preferably including dopant, preferably (CaO){sub 12}(Al{sub 2}O{sub 3}){sub 7} flux particles including Ca and Al dopant, and LaCrO{sub 3} interconnection particles, preferably undoped LaCrO{sub 3}, to form a dense and substantially gas-tight interconnection material bonded to the electrode structure by a single plasma spraying step; and (C) heat treating the interconnection layer at from about 1,200 to 1,350 C to further densify and heal the micro-cracks and macro-cracks of the thermally sprayed interconnection layer. The result is a substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode structure. The electrode structure can be an air electrode, and a solid electrolyte layer can be applied to the unselected portion of the air electrode, and further a fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell for generation of electrical power. 4 figs.

  14. The low cycle fatigue behavior of a plasma-sprayed coating material

    NASA Technical Reports Server (NTRS)

    Gayda, J.; Gabb, T. P.; Miner, R. V., Jr.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C, but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  15. Low cycle fatigue behaviour of a plasma-sprayed coating material

    NASA Technical Reports Server (NTRS)

    Gayda, J.; Gabb, T. P.; Miner, R. V.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  16. Plasma-Sprayed Thermal Barrier Coatings with Enhanced Splat Bonding for CMAS and Corrosion Protection

    NASA Astrophysics Data System (ADS)

    Liu, Tao; Yao, Shu-Wei; Wang, Li-Shuang; Yang, Guan-Jun; Li, Cheng-Xin; Li, Chang-Jiu

    2016-01-01

    The infiltration of molten CMAS in thermal barrier coatings (TBCs) at high temperature is significantly affected by the microstructure of the ceramic coating. Enhancing the bonding ratio between splats can reduce the interconnected pores and suppress the infiltration of the molten CMAS into the coating. In this study, a dual-layered (DL) TBC with the dense 8YSZ on the top of the conventional porous 8YSZ was proposed to enhance CMAS corrosion of atmospheric plasma-sprayed YSZ. The dense YSZ coating with improved lamellar bonding was deposited at a higher deposition temperature. The microstructure of the coatings before and after CMAS attack test was characterized by scanning electron microscopy. It was clearly revealed that by adjusting the microstructure and applying a dense ceramic layer with the improved interface bonding on the top of porous TBC, the infiltration of CMAS into porous YSZ coating can be effectively suppressed. Moreover, by designing DL TBCs, the thermal conductivity of the TBC system exhibits a limited increase. Thus with the design of DL structure, the TBCs with high CMAS corrosion resistance and low thermal conductivity can be achieved.

  17. Low cycle fatigue behavior of a plasma-sprayed coating material

    SciTech Connect

    Gayda, J.; Gabb, T.P.; Miner, R.V. Jr.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C, but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  18. A TEM Study of the Microstructure of Plasma-Sprayed YSZ Near Inter-splat Interfaces

    NASA Astrophysics Data System (ADS)

    Yang, Er-Juan; Luo, Xiao-Tao; Yang, Guan-Jun; Li, Cheng-Xin; Li, Chang-Jiu.

    2015-08-01

    The splat interface bonding state which changes heat transfer conditions and thus the cooling rate during splat cooling may influence the interface microstructure. In this paper, YSZ coating was deposited by atmospheric plasma spraying with substrate cooling during deposition. Subsequent characterization was implemented using high resolution transmission electron microscopy to examine the local microstructures near the interfaces at the bonded and unbonded zones. Selected area diffraction analyses of the splats across both the bonded interface and unbonded interface revealed that all bulk splats present a metastable tetragonal structure. Results showed that the size of columnar grains within a splat was significantly influenced by the interface bonding. At the unbonded region in the splat, large columnar grains form which can be attributed to poor thermal contact of melt to the underlying splat surface before its solidification. At the bonded zones, the splat presents a much fine columnar grain structure, which is attributed to good thermal contact of the melt to the underlying splat before solidification. Moreover, it is evident that the bonded interface region presents a distinct microstructure feature from the fine columnar grains suggesting the crystal defect of high density of dislocations at the interface.

  19. Process-Property Relationship for Air Plasma-Sprayed Gadolinium Zirconate Coatings

    NASA Astrophysics Data System (ADS)

    Dwivedi, Gopal; Tan, Yang; Viswanathan, Vaishak; Sampath, Sanjay

    2015-02-01

    The continuous need of elevating operating temperature of gas turbine engines has introduced several challenges with the current state-of-the-art yttria-stabilized zirconia (YSZ)-based thermal barrier coatings (TBCs), requiring examination of new TBC material with high temperature phase stability, lower thermal conductivity, and resistance to environmental ash particles. Gadolinium zirconate (Gd2Zr2O7) (GDZ) has been shown to meet many of these requirements, and has, in fact, been successfully implemented in to engine components. However, several fundamental issues related to the process-ability, toughness, and microstructural differences for GDZ when compared to equivalent YSZ coating. This study seeks to critically address the process-structure-property correlations for plasma-sprayed GDZ coating subjected to controlled parametric exploration. Use of in-flight diagnostics coupled with in situ and ex situ coating property monitoring allows examination and comparison of the process-property interplay and the resultant differences between the two TBC compositions. The results indicate that it is feasible to retain material chemistry and fabricate relevant microstructures of interest with GDZ with concomitant performance advantages such as low conductivity, mechanical compliance, sintering resistance, and suppression of environmentally induced damage from ash particles. This study provides a framework for optimal design and manufacturing of emergent multi-layer and multi-material TBCs.

  20. Effect of substrate preheating temperature and coating thickness on residual stress in plasma sprayed hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Tang, Dapei

    2015-07-01

    A thermal-mechanical coupling model was developed based on thermal-elastic- plastic theory according the special process of plasma spraying Hydroxyapatite (HA) coating upon Ti-6Al-4V substrate. On the one hand, the classical Fourier transient heat conduction equation was modified by introducing the effect item of deformation on temperature, on the other hand, the Johnson-Cook model, suitable for high temperature and high strain rate conditions, was used as constitutive equation after considering temperature softening effect, strain hardening effect and strain rate reinforcement effect. Based on the above coupling model, the residual stress field within the HA coating was simulated by using finite element method (FEM). Meanwhile, the substrate preheating temperature and coating thickness on the influence of residual stress components were calculated, respectively. The failure modes of coating were also preliminary analyzed. In addition, in order to verify the reliability of calculation, the material removal measurement technique was applied to determine the residual stress of HA coating near the interface. Some important conclusions are obtained.