Low-Temperature Preparation of Tungsten Oxide Anode Buffer Layer via Ultrasonic Spray Pyrolysis Method for Large-Area Organic Solar Cells

PubMed Central

Ji, Ran; Zheng, Ding; Zhou, Chang; Cheng, Jiang; Yu, Junsheng; Li, Lu

2017-01-01

Tungsten oxide (WO3) is prepared by a low-temperature ultrasonic spray pyrolysis method in air atmosphere, and it is used as an anode buffer layer (ABL) for organic solar cells (OSCs). The properties of the WO3 transition metal oxide material as well as the mechanism of ultrasonic spray pyrolysis processes are investigated. The results show that the ultrasonic spray pyrolysized WO3 ABL exhibits low roughness, matched energy level, and high conductivity, which results in high charge transport efficiency and suppressive recombination in OSCs. As a result, compared to the OSCs based on vacuum thermal evaporated WO3, a higher power conversion efficiency of 3.63% is reached with low-temperature ultrasonic spray pyrolysized WO3 ABL. Furthermore, the mostly spray-coated OSCs with large area was fabricated, which has a power conversion efficiency of ~1%. This work significantly enhances our understanding of the preparation and application of low temperature-processed WO3, and highlights the potential of large area, all spray coated OSCs for sustainable commercial fabrication. PMID:28773177

Optimizing the vacuum plasma spray deposition of metal, ceramic, and cermet coatings using designed experiments

NASA Astrophysics Data System (ADS)

Kingswell, R.; Scott, K. T.; Wassell, L. L.

1993-06-01

The vacuum plasma spray (VPS) deposition of metal, ceramic, and cermet coatings has been investigated using designed statistical experiments. Processing conditions that were considered likely to have a significant influence on the melting characteristics of the precursor powders and hence deposition efficiency were incorporated into full and fractional factorial experimental designs. The processing of an alumina powder was very sensitive to variations in the deposition conditions, particularly the injection velocity of the powder into the plasma flame, the plasma gas composition, and the power supplied to the gun. Using a combination of full and fractional factorial experimental designs, it was possible to rapidly identify the important spraying variables and adjust these to produce a deposition efficiency approaching 80 percent. The deposition of a nickel-base alloy metal powder was less sensitive to processing conditions. Generally, however, a high degree of particle melting was achieved for a wide range of spray conditions. Preliminary experiments performed using a tungsten carbide/cobalt cermet powder indicated that spray efficiency was not sensitive to deposition conditions. However, microstructural analysis revealed considerable variations in the degree of tungsten carbide dissolution. The structure and properties of the optimized coatings produced in the factorial experiments are also discussed.

Plasma-induced damage of tungsten coatings on graphite limiters

NASA Astrophysics Data System (ADS)

Fortuna, E.; Rubel, M. J.; Psoda, M.; Andrzejczuk, M.; Kurzydowski, K. J.; Miskiewicz, M.; Philipps, V.; Pospieszczyk, A.; Sergienko, G.; Spychalski, M.; Zielinski, W.

2007-03-01

Vaccum plasma sprayed tungsten coatings with an evaporated sandwich Re-W interlayer on graphite limiter blocks were studied after the experimental campaign in the TEXTOR tokamak. The coating morphology was modified by high-heat loads and co-deposition of species from the plasma. Co-deposits contained fuel species, carbon, boron and silicon. X-ray diffractometer phase analysis indicated the coexistence of metallic tungsten and its carbides (WC and W2C) and boride (W2B). In the Re-W layer the presence of carbon was detected in a several micrometres thick zone. In the overheated part of the limiter, the Re-W layer was transformed into a sigma phase.

Materials for Advanced Turbine Engines (MATE). Project 4: Erosion resistant compressor airfoil coating

NASA Technical Reports Server (NTRS)

Rashid, J. M.; Freling, M.; Friedrich, L. A.

1987-01-01

The ability of coatings to provide at least a 2X improvement in particulate erosion resistance for steel, nickel and titanium compressor airfoils was identified and demonstrated. Coating materials evaluated included plasma sprayed cobalt tungsten carbide, nickel carbide and diffusion applied chromium plus boron. Several processing parameters for plasma spray processing and diffusion coating were evaluated to identify coating systems having the most potential for providing airfoil erosion resistance. Based on laboratory results and analytical evaluations, selected coating systems were applied to gas turbine blades and evaluated for surface finish, burner rig erosion resistance and effect on high cycle fatigue strength. Based on these tests, the following coatings were recommended for engine testing: Gator-Gard plasma spray 88WC-12Co on titanium alloy airfoils, plasma spray 83WC-17Co on steel and nickel alloy airfoils, and Cr+B on nickel alloy airfoils.

Metal alloy coatings and methods for applying

DOEpatents

Merz, Martin D.; Knoll, Robert W.

1991-01-01

A method of coating a substrate comprises plasma spraying a prealloyed feed powder onto a substrate, where the prealloyed feed powder comprises a significant amount of an alloy of stainless steel and at least one refractory element selected from the group consisting of titanium, zirconium, hafnium, niobium, tantalum, molybdenum, and tungsten. The plasma spraying of such a feed powder is conducted in an oxygen containing atmosphere and forms an adherent, corrosion resistant, and substantially homogenous metallic refractory alloy coating on the substrate.

Effect of 2D WS2 Addition on Cold-Sprayed Aluminum Coating

NASA Astrophysics Data System (ADS)

Loganathan, Archana; Rengifo, Sara; Hernandez, Alexander Franco; Emirov, Yusuf; Zhang, Cheng; Boesl, Benjamin; Karthikeyan, Jeganathan; Agarwal, Arvind

2017-10-01

Tungsten disulfide (WS2) has excellent solid lubrication properties due to its 2D layered structure. This study focuses on depositing Al-2 wt.% WS2 composite coating by cold spray technique. The effect of WS2 addition on the microstructure, mechanical and tribological properties of the composite coatings is examined in the as-deposited and heat-treated conditions. After heat treatment, the coating density increased to 99% with improved intersplat bonding. The microhardness of the heat-treated Al-2 wt.% WS2 coating increased by 56% as compared to the as-sprayed coating. The wear resistance of heat-treated Al-2 wt.% WS2 coating improved by 75% with a synergistic reduction in the coefficient of friction (COF) by 51%. Transmission electron microscopy investigation reveals the presence of layered WS2 within aluminum splats with a strong interface. This study shows that cold spraying can be effectively used to integrate 2D layered WS2 as a solid lubricant in the metallic coatings.

A plasma-sprayed valve coating

NASA Technical Reports Server (NTRS)

Brennan, A.; Olmore, A. B.

1980-01-01

Need to reduce wear on nickel alloy seats and poppets for Space Shuttle main engine led to fused cobalt/tungsten carbide coating. Coating, which is dense, wear-resistant, and nonporous, can be applied in controlled amounts to various substrate configurations. Ease of application to parts with intricate shapes and contours should make coating useful in automotive and aircraft manufacturing.

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.

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

NASA Technical Reports Server (NTRS)

Tawfik, Hazem

1994-01-01

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Development of Improved Rhenium Coatings for Fluorine Engine Thrust Chambers. [hydrazine-fluorine rocket engines

NASA Technical Reports Server (NTRS)

Barton, K. J.; Yurkewycz, R.; Harada, Y.; Daniels, I.

1981-01-01

Coating trials were undertaken to evaluate the application of rhenium to carbon-carbon composite sheet by plasma spraying. Optimum spray parameters and coating thickness were identified for production of coatings free from continuous defects and with adequate adherence to the substrate. A tungsten underlayer was not beneficial and possibly detracted from coating integrity. Stress calculations indicated that the proposed operating cycle of the rocket engine would not cause spalling of the rhenium coating. Calculations indicated that permeation of gases through the coating would not be significant during the expected life of the thrust chamber. The feasibility of applying rhenium coatings by laser melting was also studied. Poor wetting of the composite surface by the liquid rhenium precluded production of uniform coatings. Borate/carborate fluxes did not improve wetting characteristics.

The erosion performance of cold spray deposited metal matrix composite coatings with subsequent friction stir processing

NASA Astrophysics Data System (ADS)

Peat, Tom; Galloway, Alexander; Toumpis, Athanasios; McNutt, Philip; Iqbal, Naveed

2017-02-01

This study forms an initial investigation into the development of SprayStir, an innovative processing technique for generating erosion resistant surface layers on a chosen substrate material. Tungsten carbide - cobalt chromium, chromium carbide - nickel chromium and aluminium oxide coatings were successfully cold spray deposited on AA5083 grade aluminium. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083 using a twin powder feed system that resulted in thick (>300 μm) composite coatings. The deposited coatings were subsequently friction stir processed to embed the particles in the substrate in order to generate a metal matrix composite (MMC) surface layer. The primary aim of this investigation was to examine the erosion performance of the SprayStirred surfaces and demonstrate the benefits of this novel process as a surface engineering technique. Volumetric analysis of the SprayStirred surfaces highlighted a drop of approx. 40% in the level of material loss when compared with the cold spray deposited coating prior to friction stir processing. Micro-hardness testing revealed that in the case of WC-CoCr reinforced coating, the hardness of the SprayStirred material exhibits an increase of approx. 540% over the unaltered substrate and 120% over the as-deposited composite coating. Microstructural examination demonstrated that the increase in the hardness of the MMC aligns with the improved dispersion of reinforcing particles throughout the aluminium matrix.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sathwara, Nishit, E-mail: nishit-25@live.in; Metallurgical & Materials Engineering Department, Indus University, Ahmedabad-382115; Jariwala, C., E-mail: chetanjari@yahoo.com

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

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

NASA Astrophysics Data System (ADS)

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

2015-08-01

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

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.

The Design and Use of Tungsten Coated TZM Molybdenum Tile Inserts in the DIII-D Tokamak Divertor

DOE Office of Scientific and Technical Information (OSTI.GOV)

Murphy, Christopher; Nygren, R. E.; Chrobak, C P.

Future tokamak devices are envisioned to utilize a high-Z metal divertor with tungsten as theleading candidate. However, tokamak experiments with tungsten divertors have seen significantdetrimental effects on plasma performance. The DIII-D tokamak presently has carbon as theplasma facing surface but to study the effect of tungsten on the plasma and its migration aroundthe vessel, two toroidal rows of carbon tiles in the divertor region were modified with high-Zmetal inserts, composed of a molybdenum alloy (TZM) coated with tungsten. A dedicated twoweek experimental campaign was run with the high-Z metal inserts. One row was coated withtungsten containing naturally occurring levels ofmore » isotopes. The second row was coated withtungsten where the isotope 182W was enhanced from the natural level of 26% up to greater than90%. The different isotopic concentrations enabled the experiment to differentiate between thetwo different sources of metal migration from the divertor. Various coating methods wereexplored for the deposition of the tungsten coating, including chemical vapor deposition,electroplating, vacuum plasma spray, and electron beam physical vapor deposition. The coatingswere tested to see if they were robust enough to act as a divertor target for the experiment. Testsincluded cyclic thermal heating using a high power laser and high-fluence deuterium plasmabombardment. The issues associate with the design of the inserts (tile installation, thermal stress,arcing, leading edges, surface preparation, etc.), are reviewed. The results of the tests used toselect the coating method and preliminary experimental observations are presented.« less

Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

McGrann, Roy T. R.; Rybicki, Edmund F.; Shadley, John R.; Brindley, William J.

1997-01-01

To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.

Tungsten coating by ATC plasma spraying on CFC for WEST tokamak

NASA Astrophysics Data System (ADS)

Firdaouss, M.; Desgranges, C.; Hernandez, C.; Mateus, C.; Maier, H.; Böswirth, B.; Greuner, H.; Samaille, F.; Bucalossi, J.; Missirlian, M.

2017-12-01

In the field of fusion experiments using a tokamak, the plasma facing components (PFC) are the closest object to the hot plasma. Due to the plasma-wall interaction, the material composing the PFC may enter the plasma and disturb the experiments. In the past, the main material for PFC was carbon (CFC, graphite), while the future reactors like ITER will be fully metallic, in particular tungsten. The Tore Supra tokamak has been transformed in an x-point divertor fusion device within the frame of the WEST (W (tungsten) Environment in Steady-state Tokamak) project in order to have plasma conditions close to those expected in ITER. The PFC other than the divertor has been coated with W to transform Tore Supra into a fully metallic environment. Different coating techniques have been selected for different kind of PFC. This paper gives an overview on the coating process used for the antennae protection limiter, the associated validation programme and concludes on the adequacy of the W coating with the WEST experimental programme requirements and gives perspectives on the development to be pursued.

Compositions of corrosion-resistant Fe-based amorphous metals suitable for producing thermal spray coatings

DOEpatents

Farmer, Joseph C; Wong, Frank M.G.; Haslam, Jeffery J; Ji, Xiaoyan; Day, Sumner D; Blue, Craig A; Rivard, John D.K.; Aprigliano, Louis F; Kohler, Leslie K; Bayles, Robert; Lemieux, Edward J; Yang, Nancy; Perepezko, John H; Kaufman, Larry; Heuer, Arthur; Lavernia, Enrique J

2013-09-03

A method of coating a surface comprising providing a source of amorphous metal that contains manganese (1 to 3 atomic %), yttrium (0.1 to 10 atomic %), and silicon (0.3 to 3.1 atomic %) in the range of composition given in parentheses; and that contains the following elements in the specified range of composition given in parentheses: chromium (15 to 20 atomic %), molybdenum (2 to 15 atomic %), tungsten (1 to 3 atomic %), boron (5 to 16 atomic %), carbon (3 to 16 atomic %), and the balance iron; and applying said amorphous metal to the surface by a spray.

Compositions of corrosion-resistant Fe-based amorphous metals suitable for producing thermal spray coatings

DOEpatents

Farmer, Joseph C.; Wong, Frank M. G.; Haslam, Jeffery J.; Ji, Xiaoyan; Day, Sumner D.; Blue, Craig A.; Rivard, John D. K.; Aprigliano, Louis F.; Kohler, Leslie K.; Bayles, Robert; Lemieux, Edward J.; Yang, Nancy; Perepezko, John H.; Kaufman, Larry; Heuer, Arthur; Lavernia, Enrique J.

2013-07-09

A method of coating a surface comprising providing a source of amorphous metal that contains manganese (1 to 3 atomic %), yttrium (0.1 to 10 atomic %), and silicon (0.3 to 3.1 atomic %) in the range of composition given in parentheses; and that contains the following elements in the specified range of composition given in parentheses: chromium (15 to 20 atomic %), molybdenum (2 to 15 atomic %), tungsten (1 to 3 atomic %), boron (5 to 16 atomic %), carbon (3 to 16 atomic %), and the balance iron; and applying said amorphous metal to the surface by a spray.

Microstructure and corrosive wear resistance of plasma sprayed Ni-based coatings after TIG remelting

NASA Astrophysics Data System (ADS)

Tianshun, Dong; Xiukai, Zhou; Guolu, Li; Li, Liu; Ran, Wang

2018-02-01

Ni based coatings were prepared on steel substrate by means of plasma spraying, and were remelted by TIG (tungsten inert gas arc) method subsequently. The microstructure, microhardness, electrochemical corrosion and corrosive wear resistance under PH = 4, PH = 7 and PH = 10 conditions of the coatings before and after remelting were investigated. The results showed that the TIG remelting obviously reduced the defects and dramatically decreased the coating’s porosity from 7.2% to 0.4%. Metallurgical bonding between the remelted coating and substrate was achieved. Meanwhile, the phase compositions of as-sprayed coating were γ-Ni, Mn5Si2 and Cr2B, while the phase compositions of the remelting coating were Fe3Ni, Cr23C6, Cr2B and Mn5Si2. The microhardness of the coating decreased from 724 HV to 608 HV, but the fracture toughness enhanced from 2.80 MPa m1/2 to 197.3 MPa m1/2 after remelting. After corrosive wear test, the average wear weight loss and 3D morphology of wear scar of two coatings indicated that the wear resistance of the remelted coating was remarkably higher than that of as-sprayed coating. Therefore, TIG remelting treatment was a feasible method to improve the coating’s microstructure and enhance its corrosive wear resistance.

Effect of Powder-Feeding Modes During Plasma Spray on the Properties of Tungsten Carbide Composite Coatings

NASA Astrophysics Data System (ADS)

Zhong, Yi-ming; Du, Xiao-dong; Wu, Gang

2017-05-01

A WC-reinforced composite coating was fabricated on the surface of 45 steel samples by plasma, cladding process with WC powder added to the molten pool synchronously or in the tail of the molten pool. The microstructure, phase composition, and element distribution in the coating were analyzed. The results show that the undissolved WC particles and crystallized carbide (WC, W2C) were distributed uniformly in the sub-eutectic matrix in both cases. Fewer of the WC particles are dissolved in the matrix when they are injected into the tail of the molten pool. There are fewer needle-like tungsten carbide formations seen in the composite coating fabricated by back-feeding process than in that formed by synchronous feeding. The former results in a finer microstructure and a higher concentration gradient of elements near the interface between the WC particles and the coating matrix.

In-Service Evaluation of HVOF Coated Main Landing Gear on Navy P-3 Aircraft

NASA Technical Reports Server (NTRS)

Devereaux, jon L.; Forrest, Clint

2008-01-01

Due to the environmental and health concerns with Electroplated Hard Chrome (EHC), the Hard Chrome Alternatives Team (HCAT) has been working to provide an alternative wear coating for EHC. The US Navy selected Tungsten-Carbide Cobalt (WC- 17Co) High Velocity Oxy-Fuel (HVOF) thermal spray coating for this purpose and completed service evaluations on select aircraft components to support the HCAT charter in identifying an alternative wear coating for chrome plating. Other benefits of WC-Co thermal spray coatings over EHC are enhanced corrosion resistance, improved durability, and exceptional wear properties. As part of the HCAT charter and to evaluate HVOF coatings on operational Navy components, the P-3 aircraft was selected for a service evaluation to determine the coating durability as compared to chrome plating. In April 1999, a VP-30 P-3 aircraft was outfitted with a right-hand Main Landing Gear (MLG) shock strut coated with WCCo HYOF thermal spray applied to the piston barrel and four axle journals. The HVOF coating on the piston barrel and axle journals was applied by Southwest United Industries, Inc. This HVOF coated strut assembly has since completed 6,378 landings. Teardown analysis .for this WC-Co HVOF coated MLG asset is significant in assessing the durability of this wear coating in service relative to EHC and to substantiate Life Cycle Cost (LCC) data to support a retrograde transition from EHC to HVOF thermal spray coatings. Findings from this teardown analysis may also benefit future transitions to HVOF thermal spray coatings by identifying enhancements to finishing techniques, mating bearing and liner material improvements, improved seal materials, and improvements in HVOF coating selection.

Changes of composition and microstructure of joint interface of tungsten coated carbon by high heat flux

NASA Astrophysics Data System (ADS)

Tokunaga, K.; Matsubara, T.; Miyamoto, Y.; Takao, Y.; Yoshida, N.; Noda, N.; Kubota, Y.; Sogabe, T.; Kato, T.; Plöchl, L.

2000-12-01

Tungsten coatings of 0.5 and 1 mm thickness were successfully deposited by the vacuum plasma spraying (VPS) technique on carbon/carbon fiber composite (CFC), CX-2002U and isotropic fine grained graphite, IG-430U. High heat flux experiments by irradiation of electron beam with uniform profile were performed on the coated samples in order to prove the suitability and load limit of such coating materials. The cross-sectional composition and structure of the interface of VPS-W and carbon material samples were investigated. Compositional analyses showed that the Re/W multi-layer acts as diffusion barrier for carbon and suppresses tungsten carbide formation in the VPS-W layer at high temperature about 1300°C. Microstructure of the joint interface of the sample changed in the case of a peak temperature of about 2800°C. The multi-layer structure completely disappeared and compositional distribution was almost uniform in the interface of the sample after melting and resolidification. The diffusion barrier for carbon is not expected to act in this stage.

Hydrogen plasma tests of some insulating coating systems for the nuclear rocket thrust chamber

NASA Technical Reports Server (NTRS)

Current, A. N.; Grisaffe, S. J.; Wycoff, K. C.

1972-01-01

Several plasma-sprayed and slurry-coated insulating coating systems were evaluated for structural stability in a low-pressure hot hydrogen environment at a maximum heat flux of 19.6 million watts/sq meter. The heat was provided by an electric-arc plasma generator. The coating systems consisted of a number of thin layers of metal oxides and/or metals. The materials included molybdenum, nichrome, tungsten, alumina, zirconia, and chromia. The study indicates potential usefulness in this environment for some coatings, and points up the need for improved coating application techniques.

Spray Characteristics and Tribo-Mechanical Properties of High-Velocity Arc-Sprayed WC-W2C Iron-Based Coatings

NASA Astrophysics Data System (ADS)

Tillmann, W.; Hagen, L.; Kokalj, D.

2017-10-01

In terms of arc-sprayed coatings, the lamellar coating microstructure is mainly affected by the atomization behavior of the molten electrode tips. When using compressed air, oxide formations occur during atomization, across the particle-laden spray plume and when the molten droplets splash onto the substrate. Within the scope of this study, the potential of a high-velocity arc-spraying process due to elevated atomization gas pressures and its effect on the spray and coating characteristics was analyzed using a cast tungsten carbide (CTC)-reinforced FeCMnSi cored wire. Since the atomization behavior corresponds with the electrode phenomena, the power spectrum and the droplet formation were observed during spraying. The tribo-mechanical properties of CTC-FeCMnSi coatings were examined in dry sliding experiments and indentation tests. In addition, adhesion tests and metallographic investigations were carried out to analyze the bonding strength, cohesive behavior, and lamellar microstructure. The occurrence of oxide phases was evaluated by x-ray diffraction and electron microscopy. Moreover, the oxygen content was determined by using glow discharge optical emission spectroscopy as well as energy-dispersive x-ray spectroscopy. With respect to elevated atomization gas pressures, a dense microstructure with improved adhesion to the substrate and reduced surface roughness was observed. Dry sliding experiments revealed an advanced wear behavior of specimens, when using above average increased atomization gas pressures. Analytic methods verified the existence of oxide phases, which were generated during spraying. A significant change of the extent and type of oxides, when applying an increased flow rate of the atomization gas, cannot be observed. Besides an enhanced coating quality, the use of increased atomization gas pressure exhibited good process stability.

Thermionic converter performance with oxide collectors

NASA Technical Reports Server (NTRS)

Lieb, D.; Goodale, D.; Briere, T.; Balestra, C.

1977-01-01

Thermionic converters using a variety of metal oxide collector surfaces have been fabricated and tested. Both work function and power output data are presented and evaluated. Oxides of barium, strontium, zinc, tungsten and titanium have been incorporated into a variable spacing converter. Tungsten oxide was found to give the highest converter performance and to furnish oxygen for the emitter at the same time. Oxygenated emitters operate at reduced cesium pressure with an increase in electrode spacing. Electron spectroscopy for chemical analysis (ESCA) performed on several tungsten oxide collectors showed cesium penetration of the oxide layer, possibly forming a cesium tungstate bronze. Titanium oxide showed high performance but did not furnish oxygen for the emitter; strontium oxide, in the form of a sprayed layer, appeared to dissociate in the presence of cesium. Sprayed coatings of barium and zinc oxides produced collector work functions of about 1.3 eV, but had excessive series resistance. Lanthanum hexaboride, in combination with oxygen introduced through a silver tube, and cesium produced a low work function collector and better than average performance.

Alloyed coatings for dispersion strengthened alloys

NASA Technical Reports Server (NTRS)

Wermuth, F. R.; Stetson, A. R.

1971-01-01

Processing techniques were developed for applying several diffusion barriers to TD-Ni and TD-NiCr. Barrier coated specimens of both substrates were clad with Ni-Cr-Al and Fe-Cr-Al alloys and diffusion annealed in argon. Measurement of the aluminum distribution after annealing showed that, of the readily applicable diffusion barriers, a slurry applied tungsten barrier most effectively inhibited the diffusion of aluminum from the Ni-Cr-Al clad into the TD-alloy substrates. No barrier effectively limited interdiffusion of the Fe-Cr-Al clad with the substrates. A duplex process was then developed for applying Ni-Cr-Al coating compositions to the tungsten barrier coated substrates. A Ni-(16 to 32)Cr-3Si modifier was applied by slurry spraying and firing in vacuum, and was then aluminized by a fusion slurry process. Cyclic oxidation tests at 2300 F resulted in early coating failure due to inadequate edge coverage and areas of coating porosity. EMP analysis showed that oxidation had consumed 70 to 80 percent of the aluminum in the coating in less than 50 hours.

Wear behavior of carbide tool coated with Yttria-stabilized zirconia nano particles.

NASA Astrophysics Data System (ADS)

Jadhav, Pavandatta M.; Reddy, Narala Suresh Kumar

2018-04-01

Wear mechanism takes predominant role in reducing the tool life during machining of Titanium alloy. Challenges of wear mechanisms such as variation in chip, high pressure loads and spring back are responsible for tool wear. In addition, many tool materials are inapt for machining due to low thermal conductivity and volume specific heat of these materials results in high cutting temperature during machining. To confront this issue Electrostatic Spray Coating (ESC) coating technique is utilized to enhance the tool life to an acceptable level. The Yttria Stabilized Zirconia (YSZ) acts as a thermal barrier coating having high thermal expansion coefficient and thermal shock resistance. This investigation focuses on the influence of YSZ nanocoating on the tungsten carbide tool material and improve the machinability of Ti-6Al-4V alloy. YSZ nano powder was coated on the tungsten carbide pin by using ESC technique. The coatings have been tested for wear and friction behavior by using a pin-on-disc tribological tester. The dry sliding wear test was performed on Titanium alloy (Ti-6Al-4V) disc and YSZ coated tungsten carbide (pin) at ambient atmosphere. The performance parameters like wear rate and temperature rise were considered upon performing the dry sliding test on Ti-6Al-4V alloy disc. The performance parameters were calculated by using coefficient of friction and frictional force values which were obtained from the pin on disc test. Substantial resistance to wear was achieved by the coating.

Corrosion resistant amorphous metals and methods of forming corrosion resistant amorphous metals

DOEpatents

Farmer, Joseph C.; Wong, Frank M.G.; Haslam, Jeffery J.; Yang, Nancy; Lavernia, Enrique J.; Blue, Craig A.; Graeve, Olivia A.; Bayles, Robert; Perepezko, John H.; Kaufman, Larry; Schoenung, Julie; Ajdelsztajn, Leo

2014-07-15

A system for coating a surface comprises providing a source of amorphous metal, providing ceramic particles, and applying the amorphous metal and the ceramic particles to the surface by a spray. The coating comprises a composite material made of amorphous metal that contains one or more of the following elements in the specified range of composition: yttrium (.gtoreq.1 atomic %), chromium (14 to 18 atomic %), molybdenum (.gtoreq.7 atomic %), tungsten (.gtoreq.1 atomic %), boron (.ltoreq.5 atomic %), or carbon (.gtoreq.4 atomic %).

Corrosion resistant amorphous metals and methods of forming corrosion resistant amorphous metals

DOEpatents

Farmer, Joseph C [Tracy, CA; Wong, Frank M. G. [Livermore, CA; Haslam, Jeffery J [Livermore, CA; Yang, Nancy [Lafayette, CA; Lavernia, Enrique J [Davis, CA; Blue, Craig A [Knoxville, TN; Graeve, Olivia A [Reno, NV; Bayles, Robert [Annandale, VA; Perepezko, John H [Madison, WI; Kaufman, Larry [Brookline, MA; Schoenung, Julie [Davis, CA; Ajdelsztajn, Leo [Walnut Creek, CA

2009-11-17

A system for coating a surface comprises providing a source of amorphous metal, providing ceramic particles, and applying the amorphous metal and the ceramic particles to the surface by a spray. The coating comprises a composite material made of amorphous metal that contains one or more of the following elements in the specified range of composition: yttrium (.gtoreq.1 atomic %), chromium (14 to 18 atomic %), molybdenum (.gtoreq.7 atomic %), tungsten (.gtoreq.1 atomic %), boron (.ltoreq.5 atomic %), or carbon (.gtoreq.4 atomic %).

Development of tungsten armor and bonding to copper for plasma-interactive components

NASA Astrophysics Data System (ADS)

Smid, I.; Akiba, M.; Vieider, G.; Plöchl, L.

1998-10-01

For the highest sputtering threshold of all possible candidates, tungsten will be the most likely armor material in highly loaded plasma-interactive components of commercially relevant fusion reactors. The development of new materials, as well as joining and coating techniques are needed to find the best balance in plasma compatibility, lifetime, reliability, neutron irradiation resistance, and safety. Further important issues for selection are availability, costs of machining and production, etc. Tungsten doped with lanthanum oxide is a commercially available W grade for electrodes, designed for low electron work function, higher recrystallization temperature, reduced secondary grain growth, and machinability at relatively low costs. W-Re and related tungsten base alloys are preferred for application at high temperatures, when high strength, high thermal shock and recrystallization resistance are required. Due to the high costs and limited global availability of Re, however, the amount of such alloys in a commercial reactor should be kept low. Newly measured material properties up to high temperatures are presented for lanthanated and W-Re alloys, and the impact on fusion application is discussed. Recently developed coatings of chemical vapor deposited tungsten (CVD-W) on copper substrates have proven to be resistant to repeated thermal and shock loading. Layers of more than 5 mm, as required for the International Thermonuclear Experimental Reactor (ITER), became available. Vacuum plasma sprayed tungsten (VPS-W) in particular is attractive for its lower costs, and the potential of in situ repair. However, the advantage of sacrificial plasma-interactive tungsten coatings in long-term fusion devices has yet to be demonstrated. A durable and reliable joining of bulk tungsten to copper is needed to achieve an acceptable component lifetime in a fusion environment. The material properties of the copper alloys proposed for ITER, and their impact on the quality of bonding to tungsten is discussed. Future materials R&D should concern issues such as plasma compatibility, and above all neutron irradiation damage of promising tungsten-copper joints.

Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps

NASA Astrophysics Data System (ADS)

Varis, T.; Suhonen, T.; Ghabchi, A.; Valarezo, A.; Sampath, S.; Liu, X.; Hannula, S.-P.

2014-08-01

Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.

Interaction between the compact tori and coated stainless-steel samples

NASA Astrophysics Data System (ADS)

Rohollahi, A.; Khatir, S.; Xiao, C.; Hirose, A.

2017-02-01

The surface damages due to the transient heat load and particle fluxes on the surface of the coated stainless-steel (SS) samples have been investigated. University of Saskatchewan compact torus injector has been used to inject the high heat load and the particle flux on the surface of stainless samples with three different types of coatings. The type 1 samples were made from a SS plate coated by tungsten. The other two samples had additional films of either nickel (type 2) or chromium (type 3) on the type 1 samples. The vacuum plasma spray technique has been applied for the coating of the samples. Surface cracking and melting have been observed on the surface after the samples were impacted by many high-speed and dense plasmoids.

Recent progress of tungsten R&D for fusion application in Japan

NASA Astrophysics Data System (ADS)

Ueda, Y.; Lee, H. T.; Ohno, N.; Kajita, S.; Kimura, A.; Kasada, R.; Nagasaka, T.; Hatano, Y.; Hasegawa, A.; Kurishita, H.; Oya, Y.

2011-12-01

The status of ongoing research projects of tungsten R&D in Japan is summarized in this paper. For tungsten material development, a new improved fabrication technique, the so-called superplasticity-based microstructural modification, is described. This technique successfully improved fracture strength and ductility at room temperature. Recent results on vacuum plasma spray W coating and W brazing on ferritic steels and vanadium alloys are explained. Feasibility of these techniques for the manufacture of the blanket is successfully demonstrated. The latest findings on the effect of neutron damage in tungsten on T retention and on the change in mechanical and electrical properties are described. Retention characteristics for neutron-damaged W were different compared to those for ion-damaged W. Upon neutron irradiation, tungsten alloys containing transmutation elements of W (Re and Os) show changes in properties that are different compared with those shown by pure W. The effects of mixed plasma exposure (D/He/C) are described. Both D/He and D/C mixed ion irradiations significantly affect ion-driven permeation in W. He bubble dynamics play a key role in nano-structure formation on the W surface.

Surface cracking and melting of different tungsten grades under transient heat and particle loads in a magnetized coaxial plasma gun

NASA Astrophysics Data System (ADS)

Kikuchi, Y.; Sakuma, I.; Iwamoto, D.; Kitagawa, Y.; Fukumoto, N.; Nagata, M.; Ueda, Y.

2013-07-01

Surface damage of pure tungsten (W), W alloys with 2 wt.% tantalum (W-Ta) and vacuum plasma spray (VPS) W coating on a reduced activation material of ferritic steel (F82H) due to repetitive ELM-like pulsed (˜0.3 ms) deuterium plasma irradiation has been investigated by using a magnetized coaxial plasma gun. Surface cracks appeared on a pure W sample exposed to 10 plasma pulses of ˜0.3 MJ m-2, while a W-Ta sample did not show surface cracks with similar pulsed plasma irradiation. The energy density threshold for surface cracking was significantly increased by the existence of the alloying element of tantalum. No surface morphology change of a VPS W coated F82H sample was observed under 10 plasma pulses of ˜0.3 MJ m-2, although surface melting and cracks in the resolidification layer occurred at higher energy density of ˜0.9 MJ m-2. There was no indication of exfoliation of the W coating from the substrate of F82H after the pulsed plasma exposures.

Applications in the Nuclear Industry for Thermal Spray Amorphous Metal and Ceramic Coatings

NASA Astrophysics Data System (ADS)

Blink, J.; Farmer, J.; Choi, J.; Saw, C.

2009-06-01

Amorphous metal and ceramic thermal spray coatings have been developed with excellent corrosion resistance and neutron absorption. These coatings, with further development, could be cost-effective options to enhance the corrosion resistance of drip shields and waste packages, and limit nuclear criticality in canisters for the transportation, aging, and disposal of spent nuclear fuel. Iron-based amorphous metal formulations with chromium, molybdenum, and tungsten have shown the corrosion resistance believed to be necessary for such applications. Rare earth additions enable very low critical cooling rates to be achieved. The boron content of these materials and their stability at high neutron doses enable them to serve as high efficiency neutron absorbers for criticality control. Ceramic coatings may provide even greater corrosion resistance for waste package and drip shield applications, although the boron-containing amorphous metals are still favored for criticality control applications. These amorphous metal and ceramic materials have been produced as gas-atomized powders and applied as near full density, nonporous coatings with the high-velocity oxy-fuel process. This article summarizes the performance of these coatings as corrosion-resistant barriers and as neutron absorbers. This article also presents a simple cost model to quantify the economic benefits possible with these new materials.

Selected fretting-wear-resistant coatings for titanium - 6-percent-aluminum - 4-percent-vanadium alloy

NASA Technical Reports Server (NTRS)

Bill, R. C.

1976-01-01

A titanium - 6-percent-aluminum - 4-percent-vanadium alloy (Ti-6Al-4V) was subjected to fretting-wear exposures against uncoated Ti-6Al-4V as a baseline and against various coatings and surface treatments applied to Ti-6Al-4V. The coatings evaluated included plasma-sprayed tungsten carbide with 12 percent cobalt, aluminum oxide with 13 percent titanium oxide, chromium oxide, and aluminum bronze with 10 percent aromatic polyester; polymer-bonded polyimide, polyimide with graphite fluoride, polyimide with molybdenum disulfide (MoS2), and methyl phenyl silicone bonded MoS2, preoxidation surface treatment, a nitride surface treatment, and a sputtered MoS2 coating. Results of wear measurements on both the coated and uncoated surfaces after 300,000 fretting cycles indicated that the polyimide coating was the most wear resistant and caused the least wear to the uncoated mating surface.

Photoelectrochemical performance of W-doped BiVO4 thin films deposited by spray pyrolysis

NASA Astrophysics Data System (ADS)

Holland, S. Keith; Dutter, Melissa R.; Lawrence, David J.; Reisner, Barbara A.; DeVore, Thomas C.

2014-01-01

The effects of tungsten doping and hydrogen annealing on the photoelectrochemical (PEC) performance of bismuth vanadate (BiVO4) photoanodes for solar water splitting were studied. Thin films of BiVO were deposited on indium tin oxide-coated glass slides by ultrasonic spray pyrolysis of an aqueous solution containing bismuth nitrate and vanadium oxysulfate. Tungsten doping was achieved by adding either silicotungstic acid (STA) or ammonium metatungstate (AMT) to the precursor. The 1.7- to 2.2-μm-thick films exhibited a highly porous microstructure. Undoped films that were reduced at 375°C in 3% H exhibited the largest photocurrent densities under 0.1 W cm-2 AM1.5 illumination, where photocurrent densities of up to 1.3 mA cm-2 at 0.5 V with respect to Ag/AgCl were achieved. Films doped with 1% or 5% (atomic percent) tungsten from either STA or AMT exhibited reduced PEC performance and greater sample-to-sample performance variations. Powder x-ray diffraction data indicated that the films continue to crystallize in the monoclinic polymorph at low doping levels but crystallize in the tetragonal scheelite structure at higher doping. It is surmised that the phase and morphology differences promoted by the addition of W during the deposition process reduced the PEC performance as measured by photovoltammetry.

High-temperature properties of joint interface of VPS-tungsten coated CFC

NASA Astrophysics Data System (ADS)

Tamura, S.; Liu, X.; Tokunaga, K.; Tsunekawa, Y.; Okumiya, M.; Noda, N.; Yoshida, N.

2004-08-01

Tungsten coated carbon fiber composite (CFC) is a candidate material for the high heat flux components in fusion reactors. In order to investigate the high-temperature properties at the joint interface of coating, heat load experiments by using electron beam were performed on VPS-tungsten coated CX-2002U samples. After the heat load test for 3.6 ks at 1400 °C, tungsten-rhenium multilayer (diffusion barrier for carbon) at the joint interface of coating was observed clearly. But, at the temperatures above 1600 °C, the multilayer was disappeared and a tungsten carbide layer was formed in the VPS-tungsten coating. At the temperatures below 1800 °C, the thickness of this layer logarithmically increased with increasing its loading time. At 2000 °C, the growth of the tungsten carbide layer was proportional to the square root of loading time. These results indicate that the diffusion barrier for carbon is not expected to suppress the carbide formation at the joint interface of the VPS-tungsten coating above 1600 °C.

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.

Development of refractory armored silicon carbide by infrared transient liquid phase processing

NASA Astrophysics Data System (ADS)

Hinoki, Tatsuya; Snead, Lance L.; Blue, Craig A.

2005-12-01

Tungsten (W) and molybdenum (Mo) were coated on silicon carbide (SiC) for use as a refractory armor using a high power plasma arc lamp at powers up to 23.5 MW/m 2 in an argon flow environment. Both tungsten powder and molybdenum powder melted and formed coating layers on silicon carbide within a few seconds. The effect of substrate pre-treatment (vapor deposition of titanium (Ti) and tungsten, and annealing) and sample heating conditions on microstructure of the coating and coating/substrate interface were investigated. The microstructure was observed by scanning electron microscopy (SEM) and optical microscopy (OM). The mechanical properties of the coated materials were evaluated by four-point flexural tests. A strong tungsten coating was successfully applied to the silicon carbide substrate. Tungsten vapor deposition and pre-heating at 5.2 MW/m 2 made for a refractory layer containing no cracks propagating into the silicon carbide substrate. The tungsten coating was formed without the thick reaction layer. For this study, small tungsten carbide grains were observed adjacent to the interface in all conditions. In addition, relatively large, widely scattered tungsten carbide grains and a eutectic structure of tungsten and silicon were observed through the thickness in the coatings formed at lower powers and longer heating times. The strength of the silicon carbide substrate was somewhat decreased as a result of the processing. Vapor deposition of tungsten prior to powder coating helped prevent this degradation. In contrast, molybdenum coating was more challenging than tungsten coating due to the larger coefficient of thermal expansion (CTE) mismatch as compared to tungsten and silicon carbide. From this work it is concluded that refractory armoring of silicon carbide by Infrared Transient Liquid Phase Processing is possible. The tungsten armored silicon carbide samples proved uniform, strong, and capable of withstanding thermal fatigue testing.

Boron carbide coating deposition on tungsten and testing of tungsten layers and coating under intense plasma load

DOE Office of Scientific and Technical Information (OSTI.GOV)

Airapetov, A. A.; Begrambekov, L. B., E-mail: lbb@plasma.mephi.ru; Buzhinskiy, O. I.

2015-12-15

A device intended for boron carbide coating deposition and material testing under high heat loads is presented. A boron carbide coating 5 μm thick was deposited on the tungsten substrate. These samples were subjected to thermocycling loads in the temperature range of 400–1500°C. Tungsten layers deposited on tungsten substrates were tested in similar conditions. Results of the surface analysis are presented.

Mechanical and tribological properties of thermally sprayed tungsten carbide-cobalt coatings

NASA Astrophysics Data System (ADS)

Qiao, Yunfei

Since previous work in our laboratory has shown that very fine microstructures increase the hardness and the resistance to sliding and abrasive wear of bulk, sintered, WC/Co composites, it was decided to explore whether similar benefits can be obtained in coatings of this material deposited by the Thermal Spray Method. The research was a collaborative effort in which a number of companies and universities prepared feedstock powders by a number of methods and deposited coatings by Plasma Spray and High Velocity Oxy Fuel spray techniques. Our role was to study the resistance of these coatings to abrasion and to wear in unlubricated sliding, to relate our findings to the microstructure of the coatings and to the properties of the powder and the parameters of deposition. The results were then used by our partners in the program to modify their processes in order to obtain the best possible performance. The thesis consists of four parts. In the first, we review the literature on WC/Co coatings and present the results of our survey of 45 coatings. This shows that the details of the thermal spray technique determine the tribological performance of the coatings much more than the size of the WC grains in the starting powder. It also shows that abrasive and sliding wear respond differently to the material properties. The remainder of the thesis describes a systematic variation of powders and deposition techniques, based on our earlier findings. In the second part, we describe the microstructures, hardness and toughness of nine coatings deposited by A. Dent at SUNY Stony Brook, with three different powders and three different flame chemistries. We find that the hardness is determined mainly by the flame temperature; hardness is decreased by porosity on the 50-nm size range, and this porosity is produced by insufficient melting of the Co binder. High temperatures and certain powder morphologies cause extensive decarburization, and the latter reduces the adhesion between the deposited material splats. In the third and fourth sections, we examine the abrasive wear resistance of these nine samples. Abrasive wear occurs on a small scale and depends mainly on the adhesion between the WC grains and the Co binder phase. Sliding wear, which occurs chiefly by the removal of entire splats by fatigue, is more sensitive to decarburization. The technological result is that WC/Co coatings made of "multimodal" powders that consist of a mixture of micrometer and nanometer-sized WC are to be preferred for abrasion resistance, and coatings made of a very fine powder with an additive that retards grain growth and decarburization is preferred for sliding wear resistance.

Photoelectrochemical performance of W-doped BiVO4 thin-films deposited by spray pyrolysis

NASA Astrophysics Data System (ADS)

Holland, Stephen K.; Dutter, Melissa R.; Lawrence, David J.; Reisner, Barbara A.; DeVore, Thomas C.

2013-09-01

The effect of tungsten doping and hydrogen annealing treatments on the photoelectrochemical (PEC) performance of bismuth vanadate (BiVO4) photoanodes for solar water splitting was studied. Thin films of BiVO4 were deposited on ITO-coated glass slides by ultrasonic spray pyrolysis of an aqueous solution containing bismuth nitrate and vanadium oxysulfate. Tungsten doping was achieved by adding either silicotungstic acid (STA) or ammonium metatungstate (AMT) in the aqueous precursor. The 1.7 μm - 2.2 μm thick films exhibited a highly porous microstructure. Undoped films that were reduced at 375 ºC in 3% H2 exhibited the largest photocurrent densities under 0.1 W cm-2 AM1.5 illumination. This performance enhancement was believed to be due to the formation of oxygen vacancies, which are shallow electron donors, in the films. Films doped with 1% or 5% tungsten from either STA or AMT exhibited reduced photoelectrochemical performance and greater sample-to-sample performance variations. Powder X-ray diffraction data of the undoped films indicated that they were comprised primarily of the monoclinic scheelite phase while unidentified phases were also present. Scanning electron microscopy showed slightly different morphology characteristics for the Wdoped films. It is surmised that the addition of W in the deposition process promoted the morphology differences and the formation of different phases, thus reducing the PEC performance of the photoanode samples. Significant PEC performance variability was also observed among films deposited using the described process.

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.

Thin coatings for heavy industry: Advanced coatings for pipes and valves

NASA Astrophysics Data System (ADS)

Vernhes, Luc

Pipes and valves are pressure vessels that regulate the flow of materials (liquids, gases, and slurries) by controlling the passageways. To optimize processes, reduce costs, and comply with government regulations, original equipment manufacturers (OEMs) must maintain their products in state-of-the-art condition. The first valves were invented over 3,000 years ago to supply water to farms and cities. They were made with bronze alloys, providing good corrosion resistance and acceptable tribological performance. The industrial revolution drove manufacturers to develop new and improved tribological materials. In the 20th century, innovative alloys such as Monel copper-nickel and Stellite cobalt-chrome as well as hard chrome plating were introduced to better control tribological properties and maximize in-service life. Since then, new materials have been regularly introduced to extend the range of applications for valves. For example, Teflon fluoropolymers are used in corrosive chemical and petrochemical processes, the nickel-based superalloys Hastelloy and Inconel for petrochemical applications, and creep-resistant chromium-rich F91 steel for supercritical power plants. Recently, the valve industry has embraced the use of hard thermal sprayed coatings for the most demanding applications, and is investing heavily in research to develop the most suitable coatings for specific uses. There is increasing evidence that the optimal solution to erosive, corrosive, and fretting wear problems lies in the design and manufacture of multi-layer, graded, and/or nanostructured coatings and coating systems that combine controlled hardness with high elastic modulus, high toughness, and good adhesion. The overall objectives of this thesis were 1) to report on advances in the development of structurally controlled hard protective coatings with tailored mechanical, elastoplastic, and thermal properties; and 2) to describe enhanced wear-, erosion-, and corrosion-resistance and other characteristics suitable for applications such as pipes and valves. From these general objectives, three specific objectives were derived: 1) to select and assess the best candidates for alternatives to hard chromium electroplating, which has been classified by the U.S. Environmental Protection Agency (EPA) as an environmentally unfriendly process; 2) to investigate recurrent failures occurring in the field with thermal sprayed HVOF Cr3C 2-NiCr coating applied to Inconel 718 PH when exposed to supercritical steam lines and thermal shocks in supercritical power plants (determining the root causes of coating failures and assessing potential coating alternatives to alleviate these issues); and 3) to develop new coating architectures, including complex microstructures and interfaces, and to better understand and optimize complex tribomechanical properties. The main results are presented in the form of articles in peer-reviewed journals. In the first article, a variety of chromium-free protective coatings were assessed as alternatives to hard chromium (HC) electroplating, such as nanostructured cobalt-phosphor (NCP) deposited by electroplating and tungsten/tungsten carbide (W/WC) applied by chemical vapor deposition. In order to compare performance across the coatings, a series of laboratory tests were performed, including hardness, microscratch, pin-on-disk, and electrochemical polarization measurements. Mechanical and fatigue resistance were also determined using prototype valves with coated ball under severe tribocorrosion conditions. It was found that W/WC coating exhibits superior wear and corrosion resistance due to high hardness and high pitting resistance, respectively, whereas NCP exhibits better wear resistance than HC with alumina ball as well as low corrosion potential, making it suitable for use as sacrificial protective coating. Both nanostructured coatings exhibited superior tribomechanical and functional characteristics compared to HC. The second article presents an investigation of an HVOF 80/20 Cr 3C2-NiCr coating failure in an on-off metal-seated ball valve (MSBV) used in supercritical steam lines in a power plant, along with an assessment of alternative coating solutions that are less susceptible to this failure mode. HVOF 80/20 Cr3C2-NiCr coating has been used to protect thousands of MSBVs without incident. However, in this case the valves were challenged with exposure to rapid variations in high-pressure flow and temperature, resulting in a unique situation that caused the coating to undergo cracking and cohesive failure. Carbide precipitation was found to be a major factor, resulting in coating embrittlement. Reduced coating toughness and ductility allowed thermal, mechanical, and residual stresses to initiate cracks and propagate them more easily, leading to coating failure with exposure to thermal shock. To alleviate these issues, possible coating alternatives were assessed. The third article presents the mechanical, tribological, and corrosion properties of two novel hybrid coating systems: 1) a tungsten-tungsten carbide (W-WC) top layer and a laser cladded cobalt-chromium (Co-Cr) interlayer (StelliteRTM 6 superalloy) applied to a 316 stainless steel substrate; and 2) the same W-WC top layer and an HVOF spray-and-fused Ni-W-Cr-B interlayer (ColmonoyRTM 88 superalloy) applied to an InconelRTM 718 substrate. X-ray diffraction, energy dispersive spectroscopy, and scanning electron microscopy were used to analyze the microstructure of the coating layers. Microindentation was used to measure surface hardness and the hardness profile of the coating systems. Rockwell indentation was used to assess coating adhesion according to CEN/TS 1071-8. Surface load-carrying capacity was also assessed by measuring micro- and macrohardness at high loads. Tribological properties were assessed with a linear reciprocating ball-on-flat sliding wear test, and corrosion resistance was measured by potentiodynamic polarization and electrochemical impedance spectroscopy.

High-Temperature Crystal-Growth Cartridge Tubes Made by VPS

NASA Technical Reports Server (NTRS)

Holmes, Richard; O'Dell, Scott; McKechnie, Timothy; Power, Christopher

2008-01-01

Cartridge tubes for use in a crystal growth furnace at temperatures as high as 1,600 deg. C have been fabricated by vacuum plasma spraying (VPS). These cartridges consist mainly of an alloy of 60 weight percent molybdenum with 40 weight percent rhenium, made from molybdenum powder coated with rhenium. This alloy was selected because of its high melting temperature (approximately equal.2,550 C) and because of its excellent ductility at room temperature. These cartridges are intended to supplant tungsten/nickel-alloy cartridges, which cannot be used at temperatures above approximately equal 1,300 C.

Method of fabricating thin-walled articles of tungsten-nickel-iron alloy

DOEpatents

Hovis, V.M. Jr.; Northcutt, W.G. Jr.

The present invention relates to a method for fabricating thin-walled high-density structures of tungsten-nickel-iron alloys. A powdered blend of the selected alloy constituents is plasma sprayed onto a mandrel having the desired article configuration. The sprayed deposit is removed from the mandrel and subjected to liquid phase sintering to provide the alloyed structure. The formation of the thin-walled structure by plasma spraying significantly reduces shrinkage, and cracking while increasing physical properties of the structure over that obtainable by employing previously known powder metallurgical procedures.

High-Performance Molybdenum Coating by Wire–HVOF Thermal Spray Process

NASA Astrophysics Data System (ADS)

Tailor, Satish; Modi, Ankur; Modi, S. C.

2018-04-01

Coating deposition on many industrial components with good microstructural, mechanical properties, and better wear resistance is always a challenge for the thermal spray community. A number of thermal spray methods are used to develop such promising coatings for many industrial applications, viz. arc spray, flame spray, plasma, and HVOF. All these processes have their own limitations to achieve porous free, very dense, high-performance wear-resistant coatings. In this work, an attempt has been made to overcome this limitation. Molybdenum coatings were deposited on low-carbon steel substrates using wire-high-velocity oxy-fuel (W-HVOF; WH) thermal spray system (trade name HIJET 9610®). For a comparison, Mo coatings were also fabricated by arc spray, flame spray, plasma spray, and powder-HVOF processes. As-sprayed coatings were analyzed using x-ray diffraction, scanning electron microscopy for phase, and microstructural analysis, respectively. Coating microhardness, surface roughness, and porosity were also measured. Adhesion strength and wear tests were conducted to determine the mechanical and wear properties of the as-sprayed coatings. Results show that the coatings deposited by W-HVOF have better performance in terms of microstructural, mechanical, and wear resistance properties, in comparison with available thermal spray process (flame spray and plasma spray).

Elemental profiling of laser cladded multilayer coatings by laser induced breakdown spectroscopy and energy dispersive X-ray spectroscopy

NASA Astrophysics Data System (ADS)

Lednev, V. N.; Sdvizhenskii, P. A.; Filippov, M. N.; Grishin, M. Ya.; Filichkina, V. A.; Stavertiy, A. Ya.; Tretyakov, R. S.; Bunkin, A. F.; Pershin, S. M.

2017-09-01

Multilayer tungsten carbide wear resistant coatings were analyzed by laser induced breakdown spectroscopy (LIBS) and energy dispersive X-ray (EDX) spectroscopy. Coaxial laser cladding technique was utilized to produce tungsten carbide coating deposited on low alloy steel substrate with additional inconel 625 interlayer. EDX and LIBS techniques were used for elemental profiling of major components (Ni, W, C, Fe, etc.) in the coating. A good correlation between EDX and LIBS data was observed while LIBS provided additional information on light element distribution (carbon). A non-uniform distribution of tungsten carbide grains along coating depth was detected by both LIBS and EDX. In contrast, horizontal elemental profiling showed a uniform tungsten carbide particles distribution. Depth elemental profiling by layer-by-layer LIBS analysis was demonstrated to be an effective method for studying tungsten carbide grains distribution in wear resistant coating without any sample preparation.

Effect of cathodic current density on performance of tungsten coatings on molybdenum prepared by electrodeposition in molten salt

NASA Astrophysics Data System (ADS)

Jiang, Fan

2016-02-01

Smooth tungsten coatings were prepared at current density below 70 mA cm-2 by electrodeposition on molybdenum substrate from Na2WO4-WO3 -melt at 1173 K in air atmosphere. As the current density reached up to 90 mA cm-2, many significant nodules were observed on the surface of the coating. Surface characterization, microstructure and mechanical properties were performed on the tungsten coatings. As the increasing of current density, the preferred orientation of the coatings changed to (2 0 0). All coatings exhibited columnar-grained-crystalline. There was about a 2 μm thick diffusion layer between tungsten coating and molybdenum substrate. The bending test revealed the tungsten coating had -good bonding strength with the molybdenum substrate. There is a down trend of the grain size of the coating on molybdenum as the current density increased from 30 mA cm-2 to 50 mA cm-2. The coating obtained at 50 mA cm-2 had a minimum grain size of 4.57 μm, while the microhardness of this coating reached to a maximum value of 495 HV.

An evaluation of the electric arc spray and (HPPS) processes for the manufacturing of high power plasma spraying MCrAIY coatings

NASA Astrophysics Data System (ADS)

Sacriste, D.; Goubot, N.; Dhers, J.; Ducos, M.; Vardelle, A.

2001-06-01

The high power plasma torch (PlazJet) can be used to spray refractory ceramics with high spray rates and deposition efficiency. It can provide dense and hard coating with high bond strengths. When manufacturing thermal barrier coatings, the PlazJet gun is well adapted to spraying the ceramic top coat but not the MCrAIY materials that are used as bond coat. Arc spraying can compete with plasma spraying for metallic coatings since cored wires can be used to spray alloys and composites. In addition, the high production rate of arc spraying enables a significant decrease in coating cost. This paper discusses the performances of the PlazJet gun, and a twin-wire are spray system, and compares the properties and cost of MCrAIY coatings made with these two processes. For arc spraying, the use of air or nitrogen as atomizing gas is also investigated.

Tungsten Deposition on Graphite using Plasma Enhanced Chemical Vapour Deposition.

NASA Astrophysics Data System (ADS)

Sharma, Uttam; Chauhan, Sachin S.; Sharma, Jayshree; Sanyasi, A. K.; Ghosh, J.; Choudhary, K. K.; Ghosh, S. K.

2016-10-01

The tokamak concept is the frontrunner for achieving controlled thermonuclear reaction on earth, an environment friendly way to solve future energy crisis. Although much progress has been made in controlling the heated fusion plasmas (temperature ∼ 150 million degrees) in tokamaks, technological issues related to plasma wall interaction topic still need focused attention. In future, reactor grade tokamak operational scenarios, the reactor wall and target plates are expected to experience a heat load of 10 MW/m2 and even more during the unfortunate events of ELM's and disruptions. Tungsten remains a suitable choice for the wall and target plates. It can withstand high temperatures, its ductile to brittle temperature is fairly low and it has low sputtering yield and low fuel retention capabilities. However, it is difficult to machine tungsten and hence usages of tungsten coated surfaces are mostly desirable. To produce tungsten coated graphite tiles for the above-mentioned purpose, a coating reactor has been designed, developed and made operational at the SVITS, Indore. Tungsten coating on graphite has been attempted and successfully carried out by using radio frequency induced plasma enhanced chemical vapour deposition (rf -PECVD) for the first time in India. Tungsten hexa-fluoride has been used as a pre-cursor gas. Energy Dispersive X-ray spectroscopy (EDS) clearly showed the presence of tungsten coating on the graphite samples. This paper presents the details of successful operation and achievement of tungsten coating in the reactor at SVITS.

The formation of tungsten doped Al2O3/ZnO coatings on aluminum by plasma electrolytic oxidation and their application in photocatalysis

NASA Astrophysics Data System (ADS)

Stojadinović, Stevan; Vasilić, Rastko; Radić, Nenad; Tadić, Nenad; Stefanov, Plamen; Grbić, Boško

2016-07-01

Tungsten doped Al2O3/ZnO coatings are formed by plasma electrolytic oxidation of aluminum substrate in supporting electrolyte (0.1 M boric acid + 0.05 M borax + 2 g/L ZnO) with addition of different concentrations of Na2WO4·2H2O. The morphology, crystal structure, chemical composition, and light absorption characteristics of formed surface coatings are investigated. The X-ray diffraction and X-ray photoelectron spectroscopy results indicate that formed surface coatings consist of alpha and gamma phase of Al2O3, ZnO, metallic tungsten and WO3. Obtained results showed that incorporated tungsten does not have any influence on the absorption spectra of Al2O3/ZnO coatings, which showed invariable band edge at about 385 nm. The photocatalytic activity of undoped and tungsten doped Al2O3/ZnO coatings is estimated by the photodegradation of methyl orange. The photocatalytic activity of tungsten doped Al2O3/ZnO coatings is higher thanof undoped Al2O3/ZnO coatings; the best photocatalytic activity is ascribed to coatings formed in supporting electrolyte with addition of 0.3 g/L Na2WO4·2H2O. Tungsten in Al2O3/ZnO coatings acts as a charge trap, thus reducing the recombination rate of photogenerated electron-hole pairs. The results of PL measurements are in agreement with photocatalytic activity. Declining PL intensity corresponds to increasing photocatalytic activity of the coatings, indicating slower recombination of electron-hole pairs.

Underwater explosive compaction-sintering of tungsten-copper coating on a copper surface

NASA Astrophysics Data System (ADS)

Chen, Xiang; Li, Xiaojie; Yan, Honghao; Wang, Xiaohong; Chen, Saiwei

2018-01-01

This study investigated underwater explosive compaction-sintering for coating a high-density tungsten-copper composite on a copper surface. First, 50% W-50% Cu tungsten-copper composite powder was prepared by mechanical alloying. The composite powder was pre-compacted and sintered by hydrogen. Underwater explosive compaction was carried out. Finally, a high-density tungsten-copper coating was obtained by diffusion sintering of the specimen after explosive compaction. A simulation of the underwater explosive compaction process showed that the peak value of the pressure in the coating was between 3.0 and 4.8 GPa. The hardness values of the tungsten-copper layer and the copper substrate were in the range of 87-133 and 49 HV, respectively. The bonding strength between the coating and the substrate was approximately 100-105 MPa.

The study of microstructure of wear-resistant coatings applied for protection from abrasive wear of horizontal and tilt drilling drill bits

NASA Astrophysics Data System (ADS)

Markova, I. Yu; Zakharova, E. S.; Maslov, A. L.; Polushin, N. I.; Laptev, A. I.; SOvchinnikova, M.

2017-05-01

Drill bits of the cutting type over the period of their existence have undergone significant changes - from the use of carbide cutters to diamond composite PDC elements, in which the diamond layer is applied to a hardmetal substrate. Using such elements, it was possible to significantly increase the service life of the drill bits, however, during work, there is a significant abrasive deterioration of the bit body, which does not fully realize the advantages of PDC elements. Therefore, to protect the body from wear use special wear-resistant coatings. This work is devoted to research of microstructural coatings, namely coatings brands WokaDur NiA, HR-6750, HR-6750 with sublayer Rock Dur 47 on various steel substrates which applied by the gas-thermal spraying in Ltd “Oerlikon Metko Rus”. They were examined with the use of scanning electron microscopy, X-ray phase analysis and a Vickers micro-hardness tester. It was established that the microhardness of the coating matrix is 590-660 HV, and the microhardness of tungsten carbide particles reinforcing the coating, is 2145-2455 HV.

High density-high purity graphite prepared by hot isostatic pressing in refractory metal containers

DOEpatents

Hoenig, Clarence L.

1994-01-01

Porous graphite in solid form is hot isostatically pressed in a refractory metal container to produce a solid graphite monolith with a bulk density greater than or equal to 2.10 g/cc. The refractory metal container is formed of tantalum, niobium, tungsten, molybdenum or alloys thereof in the form of a canister or alternatively plasma sprayed, chemically vapor deposited, or coated by some other suitable means onto graphite. Hot isostatic pressing at 2200.degree. C. and 30 KSI (206.8 MPa) argon pressure for two hours produces a bulk density of 2.10 g/cc. Complex shapes can be made.

High density-high purity graphite prepared by hot isostatic pressing in refractory metal containers

DOEpatents

Hoenig, C.L.

1994-08-09

Porous graphite in solid form is hot isostatically pressed in a refractory metal container to produce a solid graphite monolith with a bulk density greater than or equal to 2.10 g/cc. The refractory metal container is formed of tantalum, niobium, tungsten, molybdenum or alloys thereof in the form of a canister or alternatively plasma sprayed, chemically vapor deposited, or coated by some other suitable means onto graphite. Hot isostatic pressing at 2,200 C and 30 KSI (206.8 MPa) argon pressure for two hours produces a bulk density of 2.10 g/cc. Complex shapes can be made. 1 fig.

Scanning tunneling microscopy measurements of the spin Hall effect in tungsten films by using iron-coated tungsten tips

NASA Astrophysics Data System (ADS)

Xie, Ting; Dreyer, Michael; Bowen, David; Hinkel, Dan; Butera, R. E.; Krafft, Charles; Mayergoyz, Isaak

2018-05-01

Scanning tunneling microscopy experiments using iron-coated tungsten tips and current-carrying tungsten films have been conducted. An asymmetry of the tunneling current with respect to the change of the direction of the bias current through a tungsten film has been observed. It is argued that this asymmetry is a manifestation of the spin Hall effect in the current-carrying tungsten film. Nanoscale variations of this asymmetry across the tungsten film have been studied by using the scanning tunneling microscopy technique.

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.

Thermal Arc Spray Overview

NASA Astrophysics Data System (ADS)

Hafiz Abd Malek, Muhamad; Hayati Saad, Nor; Kiyai Abas, Sunhaji; Mohd Shah, Noriyati

2013-06-01

Usage of protective coating for corrosion protection was on highly demand during the past decade; and thermal spray coating played a major part during that time. In recent years, the thermal arc spray coating becomes a popular coating. Many big players in oil and gas such as PETRONAS, EXXON MOBIL and SHELL in Malaysia tend to use the coating on steel structure as a corrosion protection. Further developments in coating processes, the devices, and raw materials have led to expansion of functional coatings and applications scope from conventional coating to specialized industries. It is widely used because of its ability to withstand high process temperature, offer advantages in efficiency, lower cost and acts as a corrosion protection. Previous research also indicated that the thermal arc spray offers better coating properties compared to other methods of spray. This paper reviews some critical area of thermal spray coating by discussing the process/parameter of thermal arc spray technology and quality control of coating. Coating performance against corrosion, wear and special characteristic of coating are also described. The field application of arc spray technology are demonstrated and reviewed.

Tungsten coating for improved wear resistance and reliability of microelectromechanical devices

DOEpatents

Fleming, James G.; Mani, Seethambal S.; Sniegowski, Jeffry J.; Blewer, Robert S.

2001-01-01

A process is disclosed whereby a 5-50-nanometer-thick conformal tungsten coating can be formed over exposed semiconductor surfaces (e.g. silicon, germanium or silicon carbide) within a microelectromechanical (MEM) device for improved wear resistance and reliability. The tungsten coating is formed after cleaning the semiconductor surfaces to remove any organic material and oxide film from the surface. A final in situ cleaning step is performed by heating a substrate containing the MEM device to a temperature in the range of 200-600 .degree. C. in the presence of gaseous nitrogen trifluoride (NF.sub.3). The tungsten coating can then be formed by a chemical reaction between the semiconductor surfaces and tungsten hexafluoride (WF.sub.6) at an elevated temperature, preferably about 450.degree. C. The tungsten deposition process is self-limiting and covers all exposed semiconductor surfaces including surfaces in close contact. The present invention can be applied to many different types of MEM devices including microrelays, micromirrors and microengines. Additionally, the tungsten wear-resistant coating of the present invention can be used to enhance the hardness, wear resistance, electrical conductivity, optical reflectivity and chemical inertness of one or more semiconductor surfaces within a MEM device.

Electrical Resistivity of Wire Arc Sprayed Zn and Cu Coatings for In-Mold-Metal-Spraying

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.; Liao, X.; Hopmann, Ch; Ochotta, P.

2018-06-01

Electrical functionalities can be integrated into plastic parts by integrating thermally sprayed metal coatings into the non-conductive base material. Thermally sprayed conducting tracks for power and signal transmission are one example. In this case, the electrical resistance or resistivity of the coatings should be investigated. Therefore, the electrical resistivity of wire arc sprayed Zn and Cu coatings has been investigated. In case of Zn coatings, spray distance, gas pressure and wire diameter could be identified as significant influencing parameters on the electrical resistivity. In contrast, process gas, gas pressure and voltage do have a significant influence on the electrical resistivity of Cu coatings. Through the use of the In-Mold-Metal-Spraying method (IMMS), thermal degradation can be avoided by transferring thermally sprayed coating from a mold insert onto the plastic part. Therefore, the influence of the transfer process on the electrical resistance of the coatings has also been investigated.

Formation of high heat resistant coatings by using gas tunnel type plasma spraying.

PubMed

Kobayashi, A; Ando, Y; Kurokawa, K

2012-06-01

Zirconia sprayed coatings are widely used as thermal barrier coatings (TBC) for high temperature protection of metallic structures. However, their use in diesel engine combustion chamber components has the long run durability problems, such as the spallation at the interface between the coating and substrate due to the interface oxidation. Although zirconia coatings have been used in many applications, the interface spallation problem is still waiting to be solved under the critical conditions such as high temperature and high corrosion environment. The gas tunnel type plasma spraying developed by the author can make high quality ceramic coatings such as Al2O3 and ZrO2 coating compared to other plasma spraying method. A high hardness ceramic coating such as Al2O3 coating by the gas tunnel type plasma spraying, were investigated in the previous study. The Vickers hardness of the zirconia (ZrO2) coating increased with decreasing spraying distance, and a higher Vickers hardness of about Hv = 1200 could be obtained at a shorter spraying distance of L = 30 mm. ZrO2 coating formed has a high hardness layer at the surface side, which shows the graded functionality of hardness. In this study, ZrO2 composite coatings (TBCs) with Al2O3 were deposited on SS304 substrates by gas tunnel type plasma spraying. The performance such as the mechanical properties, thermal behavior and high temperature oxidation resistance of the functionally graded TBCs was investigated and discussed. The resultant coating samples with different spraying powders and thickness are compared in their corrosion resistance with coating thickness as variables. Corrosion potential was measured and analyzed corresponding to the microstructure of the coatings. High Heat Resistant Coatings, Gas Tunnel Type Plasma Spraying, Hardness,

NASA Astrophysics Data System (ADS)

Kadyrov, E.; Evdokimenko, Y.; Kisel, V.; Kadyrov, V.; Worzala, F.

1994-12-01

Several designs of high-velocity oxygen fuel (HVOF) thermal spray systems have been created during the last decade. The most advanced systems are now producing coatings comparable in quality to detonation (D-gun) coatings. This paper presents numerical analysis of the interaction of dispersive particles with the carrying gas flow for three different HVOF systems, along with a method to calculate the parameters of sprayed particles that highlights the advantages and limitations of each design. The method includes gas dynamical calculations of the gas flow in an accelerating channel and calculations of the injected par-motion and thermal state (temperature and melted mass fraction). The calculations were performed for particles of tungsten carbide, aluminum oxide, and zirconium oxide with size distributions of 10 to 80 μm. Two conventional types of HVOF systems were considered: those with a supersonic accelerating channel and those with a subsonic accelerating channel (without a de Laval nozzle). A novel design is pro-posed that contains a combined gas dynamical path with functionally separated regions of heating and acceleration. The regularities and distinctions in the behavior of the metallic and ceramic oxide particles are discussed for different jet configurations. The results obtained indicate that it is possible to signifi-cantly affect particle parameters by using the new configuration solutions without creating construction complications.

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.

Plasma Sprayed Hydroxyapatite Coatings: Influence of Spraying Power on Microstructure

NASA Astrophysics Data System (ADS)

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

2010-03-01

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.

Effect of Post-spray Shot Peening Treatment on the Corrosion Behavior of NiCr-Mo Coating by Plasma Spraying of the Shell-Core-Structured Powders

NASA Astrophysics Data System (ADS)

Tian, Jia-Jia; Wei, Ying-Kang; Li, Cheng-Xin; Yang, Guan-Jun; Li, Chang-Jiu

2018-01-01

Corrosion of metal plays a detrimental role in service lifetime of parts or systems. Therefore, coating a protective film which is fully dense and defects free on the base metal is an effective approach to protect the base metal from corrosion. In this study, a dense NiCr-20Mo coating with excellent lamellar interface bonding was deposited by plasma spraying of the novel shell-core-structured Mo-clad-NiCr powders, and then post-spray shot peening treatment by cold spraying of steel shots was applied to the plasma-sprayed NiCr-20Mo coating to obtain a fully dense coating through eliminating possibly existed pores and un-bonded interfaces within the NiCr-20Mo coating. Corrosion behaviors of the NiCr-20Mo coatings before and after shot peening were tested to investigate the effect of the post-spray shot peening on the corrosion behavior of the NiCr-20Mo coating. Results showed that a much dense and uniform plasma-sprayed NiCr-20Mo coating with perfect lamellar bonding at most of interfaces was deposited. However, the electrochemical tests revealed the existence of through-thickness pores in the as-plasma-sprayed NiCr-20Mo coating. Through the post-spray shot peening treatment, a completely dense top layer in the coating was formed, and with the increase in the shot peening intensity from one pass to three passes, the dense top layer became thicker from 100 μm to reach 300 μm of the whole coating thickness. Thus, a fully dense bulk-like coating was obtained. Corrosion test results showed that the dense coating layer resulting from densification of shot peening can act as an effective barrier coating to prevent the penetration of the corrosive medium and consequently protect the substrate from corrosion effectively. Therefore, a fully dense bulk-like NiCr-20Mo coating with excellent corrosion resistance can be achieved through the plasma spraying of Mo-clad-NiCr powders followed by appropriate post-spray shot peening treatment.

Microstructural Characteristics and Oxidation Behavior of Low-Pressure Cold-Sprayed CoNiCrAlY Coatings

NASA Astrophysics Data System (ADS)

Zhang, Lin-wei; Lu, Lei; Wang, Lu; Ning, Xian-jin; Wang, Quan-sheng; Wang, Ri-xin

2017-10-01

CoNiCrAlY coatings were deposited by low-pressure cold spraying and subsequently heat-treated at 1050 °C for 4 h in a vacuum environment. The microstructural characteristics and oxidation behavior of CoNiCrAlY coatings were investigated. The as-sprayed coating exhibited low porosity and oxygen content. The high plastic deformation of the sprayed particles led to significant refinement of γ-matrix and dissolution of β-(Ni,Co)Al phase in the as-sprayed coating. After heat treatment, the single phase (γ) in the as-sprayed coating was converted into a γ/β microstructure, and a continuous single α-Al2O3 scale was formed on the coating surface. Vacuum heat treatment can postpone the formation of spinel oxides within 100 h. After being oxidized at 1050 °C for 400 h, the heat-treated coating exhibited better oxidation resistance than the as-sprayed coating. The reduced growth rate of the oxide scale and the suppression of the formation of spinel oxides can be attributed to the vacuum heat treatment, as well as the intrinsic microstructure of the cold-sprayed coating. Finally, the effects of the microstructural changes induced during the cold spraying process on the growth of the thermally grown oxide and the oxidation mechanisms of the CoNiCrAlY coatings were discussed.

Coating of tips for electrochemical scanning tunneling microscopy by means of silicon, magnesium, and tungsten oxides

NASA Astrophysics Data System (ADS)

Salerno, Marco

2010-09-01

Different combinations of metal tips and oxide coatings have been tested for possible operation in electrochemical scanning tunneling microscopy. Silicon and magnesium oxides have been thermally evaporated onto gold and platinum-iridium tips, respectively. Two different thickness values have been explored for both materials, namely, 40 and 120 nm for silicon oxide and 20 and 60 nm for magnesium oxide. Alternatively, tungsten oxide has been grown on tungsten tips via electrochemical anodization. In the latter case, to seek optimal results we have varied the pH of the anodizing electrolyte between one and four. The oxide coated tips have been first inspected by means of scanning electron microscopy equipped with microanalysis to determine the morphological results of the coating. Second, the coated tips have been electrically characterized ex situ for stability in time by means of cyclic voltammetry in 1 M aqueous KCl supporting electrolyte, both bare and supplemented with K3[Fe(CN)6] complex at 10 mM concentration in milliQ water as an analyte. Only the tungsten oxide coated tungsten tips have shown stable electrical behavior in the electrolyte. For these tips, the uncoated metal area has been estimated from the electrical current levels, and they have been successfully tested by imaging a gold grating in situ, which provided stable results for several hours. The successful tungsten oxide coating obtained at pH=4 has been assigned to the WO3 form.

Coating of tips for electrochemical scanning tunneling microscopy by means of silicon, magnesium, and tungsten oxides.

PubMed

Salerno, Marco

2010-09-01

Different combinations of metal tips and oxide coatings have been tested for possible operation in electrochemical scanning tunneling microscopy. Silicon and magnesium oxides have been thermally evaporated onto gold and platinum-iridium tips, respectively. Two different thickness values have been explored for both materials, namely, 40 and 120 nm for silicon oxide and 20 and 60 nm for magnesium oxide. Alternatively, tungsten oxide has been grown on tungsten tips via electrochemical anodization. In the latter case, to seek optimal results we have varied the pH of the anodizing electrolyte between one and four. The oxide coated tips have been first inspected by means of scanning electron microscopy equipped with microanalysis to determine the morphological results of the coating. Second, the coated tips have been electrically characterized ex situ for stability in time by means of cyclic voltammetry in 1 M aqueous KCl supporting electrolyte, both bare and supplemented with K(3)[Fe(CN)(6)] complex at 10 mM concentration in milliQ water as an analyte. Only the tungsten oxide coated tungsten tips have shown stable electrical behavior in the electrolyte. For these tips, the uncoated metal area has been estimated from the electrical current levels, and they have been successfully tested by imaging a gold grating in situ, which provided stable results for several hours. The successful tungsten oxide coating obtained at pH=4 has been assigned to the WO(3) form.

Direct morphological comparison of vacuum plasma sprayed and detonation gun sprayed hydroxyapatite coatings for orthopaedic applications.

PubMed

Gledhill, H C; Turner, I G; Doyle, C

1999-02-01

Hydroxyapatite coatings on titanium substrates were produced using two thermal spray techniques vacuum plasma spraying and detonation gun spraying. X-ray diffraction was used to compare crystallinity and residual stresses in the coatings. Porosity was measured using optical microscopy in conjunction with an image analysis system. Scanning electron microscopy and surface roughness measurements were used to characterise the surface morphologies of the coatings. The vacuum plasma sprayed coatings were found to have a lower residual stress, a higher crystallinity and a higher level of porosity than the detonation gun coatings. It is concluded that consideration needs to be given to the significance of such variations within the clinical context.

Effect of particle in-flight behavior on the composition of thermal barrier coatings

NASA Astrophysics Data System (ADS)

Zhao, L.; Bai, Y.; Tang, J. J.; Liu, K.; Ding, C. H.; Yang, J. F.; Han, Z. H.

2013-12-01

In this work, 6 to 11 mol% YO1.5-stabilized zirconia (YSZ) coatings were deposited by supersonic and conventional atmospheric plasma spraying. During spraying, the surface temperature and velocity of in-flight particles were monitored by Spray Watch 2i on-line system. The phase composition of as-sprayed coatings was analyzed by X-ray diffractometry (XRD). Lattice parameters, tetragonality and the content of YO1.5 (mol%) of as-sprayed coatings were calculated according to the position of (0 0 4) and (4 0 0) diffraction peaks. It was found that the as-sprayed coatings were composed of metastable non-transformable tetragonal phase (t‧). However, the amount of YO1.5 (mol%) in the as-sprayed coatings decreased with the increase of melting index of in-flight particles due to the partial evaporation of YO1.5 during spraying.

Two feasible approaches to enhance the wear behaviors of NiCrBSi coating in atmosphere and aqueous environments

NASA Astrophysics Data System (ADS)

Ye, Yuwei; Wang, Chunting; Zheng, Wenru; Xiong, Wei; Wang, Yongxin; Li, Xiaogang

2017-09-01

NiCrBSi coating was deposited successfully on the surface of 316 stainless steel substrate by means of plasma spraying. The microstructures and mechanical property were analyzed by scanning electron microscopy, x-ray diffraction, and a Vickers hardness tester. The wear performances of the coatings sliding against the GCr15 ball under ambient air and water conditions were investigated, and two feasible approaches (tungsten carbide (WC)-doping and heat treatment) were used to improve the tribological performance. Results showed that the hardness of the NiCrBSi coating increased by 12.5% and 28.5% and the porosity decreased by 26.1% and 47.8%, respectively, after WC-doping and heat treatment. During dry friction, the friction coefficient and wear rate of the NiCrBSi coating were about 0.47 and 1.4  ×  10-5 mm3 N-1 m-1, respectively. These values were higher than those obtained on other coatings. In water conditions, all coatings showed a lower friction and wear rate than that in ambient air, which was as a result of the lubrication effect of water. Significantly, with WC-doping and heat treatment, the friction coefficients of both coatings were about 18.5% and 36.7%, respectively, lower than that of the NiCrBSi coating. Furthermore, the wear rates of both coatings were about 20% and 70%, respectively, lower than that of the NiCrBSi coating.

40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

Code of Federal Regulations, 2013 CFR

2013-07-01

... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... recreational boat surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of...

40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

Code of Federal Regulations, 2012 CFR

2012-07-01

... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... recreational boat surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of...

40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

Code of Federal Regulations, 2014 CFR

2014-07-01

... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... recreational boat surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of...

40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

Code of Federal Regulations, 2011 CFR

2011-07-01

... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of paragraph (a) or...

40 CFR 63.5755 - How do I demonstrate compliance with the aluminum recreational boat surface coating spray gun...

Code of Federal Regulations, 2010 CFR

2010-07-01

... the aluminum recreational boat surface coating spray gun cleaning work practice standards? 63.5755... surface coating spray gun cleaning work practice standards? You must demonstrate compliance with the aluminum coating spray gun cleaning work practice standards by meeting the requirements of paragraph (a) or...

Effect of Spray Distance on Microstructure and Tribological Performance of Suspension Plasma-Sprayed Hydroxyapatite-Titania Composite Coatings

NASA Astrophysics Data System (ADS)

Zhang, Chao; Xu, Haifeng; Geng, Xin; Wang, Jingjing; Xiao, Jinkun; Zhu, Peizhi

2016-10-01

Hydroxyapatite (HA)-titania (TiO2) composite coatings prepared on Ti6Al4V alloy surface can combine the excellent mechanical property of the alloy substrate and the good biocompatibility of the coating material. In this paper, HA-TiO2 composite coatings were deposited on Ti6Al4V substrates using suspension plasma spray (SPS). X-ray diffraction, scanning electron microscopy, Fourier infrared absorption spectrometry and friction tests were used to analyze the microstructure and tribological properties of the obtained coatings. The results showed that the spray distance had an important influence on coating microstructure and tribological performance. The amount of decomposition phases decreased as the spray distance increased. The increase in spray distance from 80 to 110 mm improved the crystalline HA content and decreased the wear performance of the SPS coatings. In addition, the spray distance had a big effect on the coating morphology due to different substrate temperature resulting from different spray distance. Furthermore, a significant presence of OH- and CO3 2- was observed, which was favorable for the biomedical applications.

Spray process for in situ synthesizing Ti(C,N)-TiB2-Al2O3 composite ceramic coatings

NASA Astrophysics Data System (ADS)

Zhou, Jian; Liu, Hongwei; Sun, Sihao

2017-12-01

Using core wires with Ti-B4C-C as core and Al as strip materials, Ti(C,N)-TiB2-Al2O3 composite ceramic coatings were prepared on 45 steel substrates by the reactive arc spray technology. The influence of spray voltage, current, gas pressure and distance on the coatings was discussed. The spray parameters were optimized with porosity of the coatings as evaluation standard. The results showed that the most important factor which influences the quality of the coatings was spray distance. Then spray gas pressure, current and voltage followed in turn. The optimum process was spray current of 120A, voltage of 36, gas pressure of 0.7MPa and distance of 160mm. The porosity of coatings prepared in this spray process was only 2.11%. The coatings were composed of TiB2, TiC0.3N0.7, TiN, Al2O3 and AlN. Good properties and uniform distribution of these ceramic phases made the coatings have excellent comprehensive performances.

Thermal Spraying of Bioactive Polymer Coatings for Orthopaedic Applications

NASA Astrophysics Data System (ADS)

Chebbi, A.; Stokes, J.

2012-06-01

Flame sprayed biocompatible polymer coatings, made of biodegradable and non-biodegradable polymers, were investigated as single coatings on titanium and as top coatings on plasma sprayed Hydroxyapatite. Biocompatible polymers can act as drug carriers for localized drug release following implantation. The polymer matrix consisted of a biodegradable polymer, polyhydroxybutyrate 98%/ polyhydroxyvalerate 2% (PHBV) and a non-biodegradable polymer, polymethylmethacrylate (PMMA). Screening tests were performed to determine the suitable range of spraying parameters, followed by a Design of Experiments study to determine the effects of spraying parameters on coating characteristics (thickness, roughness, adhesion, wettability), and to optimize the coating properties accordingly. Coatings characterization showed that optimized flame sprayed biocompatible polymers underwent little chemical degradation, did not produce acidic by-products in vitro, and that cells proliferated well on their surface.

Rapidly curable electrically conductive clear coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bowman, Mark P.; Anderson, Lawrence G.; Post, Gordon L.

2018-01-16

Rapidly curable electrically conductive clear coatings are applied to substrates. The electrically conductive clear coating includes to clear layer having a resinous binder with ultrafine non-stoichiometric tungsten oxide particles dispersed therein. The clear coating may be rapidly cured by subjecting the coating to infrared radiation that heats the tungsten oxide particles and surrounding resinous binder. Localized heating increases the temperature of the coating to thereby thermally cure the coating, while avoiding unwanted heating of the underlying substrate.

Liquid-Solid Self-Lubricated Coatings

NASA Astrophysics Data System (ADS)

Armada, S.; Schmid, R.; Equey, S.; Fagoaga, I.; Espallargas, N.

2013-02-01

Self-lubricated coatings have been a major topic of interest in thermal spray in the last decades. Self-lubricated coatings obtained by thermal spray are exclusively based on solid lubricants (PTFE, h-BN, graphite, MoS2, etc.) embedded in the matrix. Production of thermal spray coatings containing liquid lubricants has not yet been achieved because of the complexity of keeping a liquid in a solid matrix during the spraying process. In the present article, the first liquid-solid self-lubricating thermal spray coatings are presented. The coatings are produced by inserting lubricant-filled capsules inside a polymeric matrix. The goal of the coating is to release lubricant to the system when needed. The first produced coatings consisted solely of capsules for confirming the feasibility of the process. For obtaining such a coating, the liquid-filled capsules were injected in the thermal spray flame without any other feedstock material. Once the concept and the idea were proven, a polymer was co-sprayed together with the capsules to obtain a coating containing the lubricant-filled capsules distributed in the solid polymeric matrix. The coatings and the self-lubricated properties have been investigated by means of optical microscopy, Scanning Electron Microscopy, and tribological tests.

Studies on corrosion resistance and bio-activity of plasma spray deposited hydroxylapatite (HA) based TiO2 and ZrO2 dispersed composite coatings on titanium alloy (Ti-6Al-4V) and the same after post spray heat treatment

NASA Astrophysics Data System (ADS)

Kumari, Renu; Majumdar, Jyotsna Dutta

2017-10-01

In the present study, the effect of plasma spray deposited hydroxylapatite (HA) based TiO2 dispersed (HA + 50 wt.% TiO2), coating and post spray heat treatment to be referred as HA-TiO2 (heat treated at 650 °C for 2 h) and ZrO2 dispersed (HA + 10 wt.% ZrO2), to be referred as HA-ZrO2 coating (heat treated at 750 °C for 2 h) on corrosion resistance and bioactivity of Ti-6Al-4V substrate has been undertaken. There is partial decomposition of HA to tri-calcium-phosphate (Ca3(PO4)2) and formation of CaTiO3 phase in HA-TiO2 coating and CaZrO3 phase in the HA-ZrO2 coating. Corrosion study in Hank's solution shows that there is shifting of corrosion potential (Ecorr) towards active potential (-1.1 V(SCE) for as-sprayed and post spray heat treated HA-TiO2 coating, -1.1 V(SCE) for as-sprayed HA-ZrO2 coating and -1 V(SCE) for HA-ZO2 coating after post spray heat treatment), and deterioration in pitting corrosion (Epit) resistance in as-sprayed coatings and the same after heat treatment (-0.7 V(SCE) for both HA-TiO2 and HA-ZrO2 coating as compared to as received substrate (-0.3 V(SCE)). The corrosion rate was increased for both the coatings with a maximum increase in HA-ZrO2 coating. Bioactivity test shows a higher degree of apatite deposition in as-sprayed coating and the same after heat treatment as compared to as received Ti-6Al-4V though the as-sprayed one showed a superior behavior.

Plasma-sprayed CaTiSiO5 ceramic coating on Ti-6Al-4V with excellent bonding strength, stability and cellular bioactivity.

PubMed

Wu, Chengtie; Ramaswamy, Yogambha; Liu, Xuanyong; Wang, Guocheng; Zreiqat, Hala

2009-02-06

Novel Ca-Si-Ti-based sphene (CaTiSiO5) ceramics possess excellent chemical stability and cytocompatibility. The aim of this study was to prepare sphene coating on titanium alloy (Ti-6Al-4V) for orthopaedic applications using the plasma spray method. The phase composition, surface and interface microstructure, coating thickness, surface roughness and bonding strength of the plasma-sprayed sphene coating were analysed using X-ray diffraction, scanning electron microscopy, atomic force microscopy and the standard mechanical testing of the American Society for Testing and Materials, respectively. The results indicated that sphene coating was obtained with a uniform and dense microstructure at the interface of the Ti-6Al-4V surface and the thickness and surface roughness of the coating were approximately 150 and 10 microm, respectively. Plasma-sprayed sphene coating on Ti-6Al-4V possessed a significantly improved bonding strength and chemical stability compared with plasma-sprayed hydroxyapatite (HAp) coating. Plasma-sprayed sphene coating supported human osteoblast-like cell (HOB) attachment and significantly enhanced HOB proliferation and differentiation compared with plasma-sprayed HAp coating and uncoated Ti-6Al-4V. Taken together, plasma-sprayed sphene coating on Ti-6Al-4V possessed excellent bonding strength, chemical stability and cellular bioactivity, indicating its potential application for orthopaedic implants.

Plasma-sprayed CaTiSiO5 ceramic coating on Ti-6Al-4V with excellent bonding strength, stability and cellular bioactivity

PubMed Central

Wu, Chengtie; Ramaswamy, Yogambha; Liu, Xuanyong; Wang, Guocheng; Zreiqat, Hala

2008-01-01

Novel Ca-Si-Ti-based sphene (CaTiSiO5) ceramics possess excellent chemical stability and cytocompatibility. The aim of this study was to prepare sphene coating on titanium alloy (Ti-6Al-4V) for orthopaedic applications using the plasma spray method. The phase composition, surface and interface microstructure, coating thickness, surface roughness and bonding strength of the plasma-sprayed sphene coating were analysed using X-ray diffraction, scanning electron microscopy, atomic force microscopy and the standard mechanical testing of the American Society for Testing and Materials, respectively. The results indicated that sphene coating was obtained with a uniform and dense microstructure at the interface of the Ti-6Al-4V surface and the thickness and surface roughness of the coating were approximately 150 and 10 μm, respectively. Plasma-sprayed sphene coating on Ti-6Al-4V possessed a significantly improved bonding strength and chemical stability compared with plasma-sprayed hydroxyapatite (HAp) coating. Plasma-sprayed sphene coating supported human osteoblast-like cell (HOB) attachment and significantly enhanced HOB proliferation and differentiation compared with plasma-sprayed HAp coating and uncoated Ti-6Al-4V. Taken together, plasma-sprayed sphene coating on Ti-6Al-4V possessed excellent bonding strength, chemical stability and cellular bioactivity, indicating its potential application for orthopaedic implants. PMID:18664431

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.

DOE Office of Scientific and Technical Information (OSTI.GOV)

MANI,SEETHAMBAL S.; FLEMING,JAMES G.; WALRAVEN,JEREMY A.

Two major problems associated with Si-based MEMS (MicroElectroMechanical Systems) devices are stiction and wear. Surface modifications are needed to reduce both adhesion and friction in micromechanical structures to solve these problems. In this paper, the authors present a CVD (Chemical Vapor Deposition) process that selectively coats MEMS devices with tungsten and significantly enhances device durability. Tungsten CVD is used in the integrated-circuit industry, which makes this approach manufacturable. This selective deposition process results in a very conformal coating and can potentially address both stiction and wear problems confronting MEMS processing. The selective deposition of tungsten is accomplished through the siliconmore » reduction of WF{sub 6}. The self-limiting nature of the process ensures consistent process control. The tungsten is deposited after the removal of the sacrificial oxides to minimize stress and process integration problems. The tungsten coating adheres well and is hard and conducting, which enhances performance for numerous devices. Furthermore, since the deposited tungsten infiltrates under adhered silicon parts and the volume of W deposited is less than the amount of Si consumed, it appears to be possible to release adhered parts that are contacted over small areas such as dimples. The wear resistance of tungsten coated parts has been shown to be significantly improved by microengine test structures.« less

Use of Iba Techniques to Characterize High Velocity Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Trompetter, W.; Markwitz, A.; Hyland, M.

Spray coatings are being used in an increasingly wide range of industries to improve the abrasive, erosive and sliding wear of machine components. Over the past decade industries have moved to the application of supersonic high velocity thermal spray techniques. These coating techniques produce superior coating quality in comparison to other traditional techniques such as plasma spraying. To date the knowledge of the bonding processes and the structure of the particles within thermal spray coatings is very subjective. The aim of this research is to improve our understanding of these materials through the use of IBA techniques in conjunction with other materials analysis techniques. Samples were prepared by spraying a widely used commercial NiCr powder onto substrates using a HVAF (high velocity air fuel) thermal spraying technique. Detailed analysis of the composition and structure of the power particles revealed two distinct types of particles. The majority was NiCr particles with a significant minority of particles composing of SiO2/CrO3. When the particles were investigated both as raw powder and in the sprayed coating, it was surprising to find that the composition of the coating meterial remained unchanged during the coating process despite the high velocity application.

Design Optimization of Liquid Fueled High Velocity Oxy- Fuel Thermal Spraying Technique for Durable Coating for Fossil Power Systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Choudhuri, Ahsan; Love, Norman

High-velocity oxy–fuel (HVOF) thermal spraying was developed in 1930 and has been commercially available for twenty-five years. HVOF thermal spraying has several benefits over the more conventional plasma spray technique including a faster deposition rate which leads to quicker turn-around, with more durable coatings and higher bond strength, hardness and wear resistance due to a homogeneous distribution of the sprayed particles. HVOF thermal spraying is frequently used in engineering to deposit cermets, metallic alloys, composites and polymers, to enhance product life and performance. HVOF thermal spraying system is a highly promising technique for applying durable coatings on structural materials formore » corrosive and high temperature environments in advanced ultra-supercritical coal- fired (AUSC) boilers, steam turbines and gas turbines. HVOF thermal spraying is the preferred method for producing coatings with low porosity and high adhesion. HVOF thermal spray process has been shown to be one of the most efficient techniques to deposit high performance coatings at moderate cost. Variables affecting the deposit formation and coating properties include hardware characteristics such as nozzle geometry and spraying distance and process parameters such as equivalence ratio, gas flow density, and powder feedstock. In the spray process, the powder particles experience very high speeds combined with fast heating to the powder material melting point or above. This high temperature causes evaporation of the powder, dissolution, and phase transformations. Due to the complex nature of the HVOF technique, the control and optimization of the process is difficult. In general, good coating quality with suitable properties and required performance for specific applications is the goal in producing thermal spray coatings. In order to reach this goal, a deeper understanding of the spray process as a whole is needed. Although many researchers studied commercial HVOF thermal spray systems, there exists a lack of fundamental understanding of the effect of hardware characteristics and operating parameters on HVOF thermally sprayed coatings. Motivated by these issues, this study is devoted to investigate the effect of hardware characteristics (e.g. spraying distance) and operating parameters (e.g. combustion chamber pressure, equivalence ratio, and total gas flow rate) on HVOF sprayed coatings using Inconel 718 alloy. The current study provides extensive understanding of several key operating and process parameters to optimize the next generation of HVOF thermally sprayed coatings for high temperature and harsh environment applications. A facility was developed to support this endeavor in a safe and efficient way, including a HVOF thermal spray system with a Data Acquisition and Remote Controls system (DARCS). The coatings microstructure and morphology were examined using X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Nanoindentation.« less

Corrosion behavior of magnetic ferrite coating prepared by plasma spraying

DOE Office of Scientific and Technical Information (OSTI.GOV)

Liu, Yi; Wei, Shicheng, E-mail: wsc33333@163.com; Tong, Hui

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 surfacemore » 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.« less

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

K.H. Kim; C.T. Lee; C.B. Lee

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 mostmore » promising characteristics among HfN, TiC, ZrC, and Y2O3 coating.« less

The Influence of Spray Parameters on the Characteristics of Hydroxyapatite In-Flight Particles, Splats and Coatings by Micro-plasma Spraying

NASA Astrophysics Data System (ADS)

Liu, Xiao-mei; He, Ding-yong; Wang, Yi-ming; Zhou, Zheng; Wang, Guo-hong; Tan, Zhen; Wang, Zeng-jie

2018-04-01

Hydroxyapatite (HA) is one of the most important bioceramic materials used in medical implants. The structure of HA coatings is closely related to their manufacturing process. In the present study, HA coatings were deposited on Ti-6Al-4V substrate by micro-plasma spraying. Results show that three distinct HA coatings could be obtained by changing the spraying power from 0.5 to 1.0 kW and spraying stand-off distance from 60 to 110 mm: (1) high crystallinity (93.3%) coatings with porous structure, (2) high crystallinity coatings (86%) with columnar structure, (3) higher amorphous calcium phosphate (ACP, 50%) coatings with dense structure. The in-flight particles melting state and splat topography was analyzed to better understand the formation mechanism of three distinct HA coatings. Results show that HA coatings sprayed at low spraying power and short stand-off distance exhibit high crystallinity and porosity is attributed to the presence of partially melted particles. High crystallinity HA coatings with (002) crystallographic texture could be deposited due to the complete melting of the in-flight particles and low cooling rate of the disk shape splats under higher spraying power and shorter SOD. However, splashed shape splats with relative high cooling can be provided by increasing SOD, which leads to the formation of ACP.

Biofouling of Cr-Nickel Spray Coated Films on Steel Surfaces

NASA Astrophysics Data System (ADS)

Yoshida, Kento; Kanematsu, Hideyuki; Kuroda, Daisuke; Ikigai, Hajime; Kogo, Takeshi; Yokoyama, Seiji

2012-03-01

Nowadays, corrosion of metals brings us serious economic loss and it often reaches several percentage of GNP. Particularly the marine corrosion was serious and the counter measure was very hard to be established, since the number of factors is huge and complicated. One of the complicated factors in marine corrosion is biofouling. Biofouling was classified into two main categories, microfouling and macrofouling. The former is composed of biofilm formation mainly. Marine bacteria are attached to material surfaces, seeking for nutrition in oligotrophic environment and they excrete polysaccharide to form biofilm on metal surfaces. Then larger living matters are attached on the biofilms to develop biofouling on metal surfaces, which often lead loss and failures of metals in marine environments. From the viewpoint of corrosion protection and maintenance of marine structures, biofouling should be mitigated as much as possible. In this study, we applied spray coating to steels and investigated if chromium-nickel spray coating could mitigate the biofouling, being compared with the conventional aluminium-zinc spray coating in marine environments. The specimens used for this investigation are aluminium, zinc, aluminium-zinc, stacked chromium/nickel and those films were formed on carbon steel (JIS SS400). And the pores formed by spray coating were sealed by a commercial reagent for some specimens. All of those specimens were immersed into sea water located at Marina Kawage (854-3, Chisato, Tsu, Mie Prefecture) in Ise Bay for two weeks. The depth of the specimen was two meter from sea water surface and the distance was always kept constant, since they were suspended from the floating pier. The temperature in sea water changed from 10 to 15 degrees Celsius during the immersion test. The biofouling behavior was investigated by low vacuum SEM (Hitachi Miniscope TM1000) and X-ray fluorescent analysis. When the spray coated specimens with and without sealing agents were compared, the former showed higher antifouling properties generally. Aluminium-zinc alloy spray coated films had higher antifouling property. And the anti-property decreased in this order: Al-Zn alloy spray coating > Zinc spray coating > Aluminium spray coating > Stacked chromium/nickel spray coating. Aluminium and zinc spray coating has been evaluated high conventionally for anti-biofouling in marine environment. However, the Cr/Ni spray coating showed pretty high anti-fouling property.

Systems and methods for coating conduit interior surfaces utilizing a thermal spray gun with extension arm

DOEpatents

Moore, Karen A.; Zatorski, Raymond A.

2005-07-12

Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Methods for coating conduit interior surfaces utilizing a thermal spray gun with extension arm

DOEpatents

Moore, Karen A.; Zatorski, Raymond A.

2007-10-02

Systems and methods for applying a coating to an interior surface of a conduit. In one embodiment, a spray gun configured to apply a coating is attached to an extension arm which may be inserted into the bore of a pipe. The spray gun may be a thermal spray gun adapted to apply a powder coating. An evacuation system may be used to provide a volume area of reduced air pressure for drawing overspray out of the pipe interior during coating. The extension arm as well as the spray gun may be cooled to maintain a consistent temperature in the system, allowing for more consistent coating.

Microstructure, Mechanical Properties, and Two-Body Abrasive Wear Behavior of Cold-Sprayed 20 vol.% Cubic BN-NiCrAl Nanocomposite Coating

NASA Astrophysics Data System (ADS)

Luo, Xiao-Tao; Yang, Er-Juan; Shang, Fu-Lin; Yang, Guan-Jun; Li, Chen-Xin; Li, Chang-Jiu

2014-10-01

20 vol.% cubic boron nitride (cBN) dispersoid reinforced NiCrAl matrix nanocomposite coating was prepared by cold spray using mechanically alloyed nanostructured composite powders. The as-sprayed nanocomposite coating was annealed at a temperature of 750 °C to enhance the inter-particle bonding. Microstructure of spray powders and coatings was characterized. Vickers microhardness of the coatings was measured. Two-body abrasive wear behavior of the coatings was examined on a pin-on-disk test. It was found that, in mechanically alloyed composite powders, nano-sized and submicro-sized cBN particles are uniformly distributed in nanocrystalline NiCrAl matrix. Dense coating was deposited by cold spray at a gas temperature of 650 °C with the same phases and grain size as those of the starting powder. Vickers hardness test yielded a hardness of 1063 HV for the as-sprayed 20 vol.% cBN-NiCrAl coating. After annealed at 750 °C for 5 h, unbonded inter-particle boundaries were partially healed and evident grain growth of nanocrystalline NiCrAl was avoided. Wear resistance of the as-sprayed 20 vol.% cBN-NiCrAl nanocomposite coating was comparable to the HVOF-sprayed WC-12Co coating. Annealing of the nanocomposite coating resulted in the improvement of wear resistance by a factor of ~33% owing to the enhanced inter-particle bonding. Main material removal mechanisms during the abrasive wear are also discussed.

Microstructure and Mechanical Properties of Microwave Post-processed Ni Coating

NASA Astrophysics Data System (ADS)

Zafar, Sunny; Sharma, Apurbba Kumar

2017-03-01

Flame-sprayed coatings are widely used in the industries attributed to their low cost and simple processing. However, the presence of porosity and poor adhesion with the substrate requires suitable post-processing of the as-sprayed deposits. In the present work, post-processing of the flame-sprayed Ni-based coating has been successfully attempted using microwave hybrid heating. Microwave post-processing of the flame-sprayed coatings was carried out at 2.45 GHz in a 1 kW multimode industrial microwave applicator. The microwave-processed and as-sprayed deposits were characterized for their microstructure, porosity, fracture toughness and surface roughness. The properties of the coatings were correlated with their abrasive wear behavior using a sliding abrasion test on a pin-on-disk tribometer. Microwave post-processing led to healed micropores and microcracks, thus causing homogenization of the microstructure in the coating layer. Therefore, microwave post-processed coating layer exhibits improved mechanical and tribological properties compared to the as-sprayed coating layer.

Method for preparing corrosion-resistant ceramic shapes

DOEpatents

Arons, R.M.; Dusek, J.T.

1979-12-07

Ceramic shapes having impermeable tungsten coatings can be used for containing highly corrosive molten alloys and salts. The shapes are prepared by coating damp green ceramic shapes containing a small amount of yttria with a tungsten coating slip which has been adjusted to match the shrinkage rate of the green ceramic and which will fire to a theoretical density of at least 80% to provide an impermeable coating.

Method for preparing corrosion-resistant ceramic shapes

DOEpatents

Arons, Richard M.; Dusek, Joseph T.

1983-09-13

Ceramic shapes having impermeable tungsten coatings can be used for containing highly corrosive molten alloys and salts. The shapes are prepared by coating damp green ceramic shapes containing a small amount of yttria with a tungsten coating slip which has been adjusted to match the shrinkage rate of the green ceramic and which will fire to a theoretical density of at least 80% to provide a impermeable coating.

High temperature surface effects of He + implantation in ICF fusion first wall materials

NASA Astrophysics Data System (ADS)

Zenobia, Samuel J.; Radel, R. F.; Cipiti, B. B.; Kulcinski, Gerald L.

2009-06-01

The first wall armor of the inertial confinement fusion reactor chambers must withstand high temperatures and significant radiation damage from target debris and neutrons. The resilience of multiple materials to one component of the target debris has been investigated using energetic (20-40 keV) helium ions generated in the inertial electrostatic confinement device at the University of Wisconsin. The materials studied include: single-crystalline, and polycrystalline tungsten, tungsten-coated tantalum-carbide 'foams', tungsten-rhenium alloy, silicon carbide, carbon-carbon velvet, and tungsten-coated carbon-carbon velvet. Steady-state irradiation temperatures ranged from 750 to 1250 °C with helium fluences between 5 × 10 17 and 1 × 10 20 He +/cm 2. The crystalline, rhenium alloyed, carbide foam, and powder metallurgical tungsten specimens each experienced extensive pore formation after He + irradiation. Flaking and pore formation occurred on silicon carbide samples. Individual fibers of carbon-carbon velvet specimens sustained erosion and corrugation, in addition to the roughening and rupturing of tungsten coatings after helium ion implantation.

The Corrosion Behavior of Cold Sprayed Zinc Coatings on Mild Steel Substrate

NASA Astrophysics Data System (ADS)

Chavan, Naveen Manhar; Kiran, B.; Jyothirmayi, A.; Phani, P. Sudharshan; Sundararajan, G.

2013-04-01

Zinc and its alloy coatings have been used extensively for the cathodic protection of steel. Zinc coating corrodes in preference to the steel substrate due to its negative corrosion potential. Numerous studies have been conducted on the corrosion behavior of zinc and its alloy coatings deposited using several techniques viz., hot dip galvanizing, electrodeposition, metalizing or thermal spray etc. Cold spray is an emerging low temperature variant of thermal spray family which enables deposition of thick, dense, and pure coatings at a rapid rate with an added advantage of on-site coating of steel structures. In the present study, the corrosion characteristics of cold sprayed zinc coatings have been investigated for the first time. In addition, the influence of heat treatment of zinc coating at a temperature of 150 °C on its corrosion behavior has also been addressed.

Influence of coating defects on the corrosion behavior of cold sprayed refractory metals

NASA Astrophysics Data System (ADS)

Kumar, S.; Rao, A. Arjuna

2017-02-01

The defects in the cold sprayed coatings are critical in the case of corrosion performances of the coatings in aggressive conditions. To understand the influence of coating defects on corrosion, immersion tests have been carried out in HF solution for the cold sprayed and heat treated Titanium, Tantalum and Niobium coatings. Long duration immersion tests reveal inhomogeneous weight losses of the samples prepared at different heat treatment conditions. The weight loss for different coatings has been well corroborated with the coating defects and microstructures. Chemical and micro structural analysis elucidates the reason behind the inhomogeneous performance of different type of cold sprayed coatings in corrosion medium. In the case of cold sprayed titanium, formation of stable oxide along the inter-splat boundary hinders the aggressive attack of the corrosion medium which is not so in other cases.

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.

Effect of layer thickness on the properties of nickel thermal sprayed steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nurisna, Zuhri, E-mail: zuhri-nurisna@yahoo.co.id; Triyono,, E-mail: triyonomesin@uns.ac.id; Muhayat, Nurul, E-mail: nurulmuhayat@staff.uns.ac.id

Thermal arc spray nickel coating is widely used for decorative and functional applications, by improving corrosion resistance, wear resistance, heat resistence or by modifying other properties of the coated materials. There are several properties have been studied. Layer thickness of nickel thermal sprayed steel may be make harder the substrate surface. In this study, the effect of layer thickness of nickel thermal sprayed steel has been investigated. The rectangular substrate specimens were coated by Ni–5 wt.% Al using wire arc spray method. The thickness of coating layers were in range from 0.4 to 1.0 mm. Different thickness of coating layers weremore » conducted to investigate their effect on hardness and morphology. The coating layer was examined by using microvickers and scanning electron microscope with EDX attachment. Generally, the hardness at the interface increased with increasing thickness of coating layers for all specimens due to higher heat input during spraying process. Morphology analysis result that during spraying process aluminum would react with surrounding oxygen and form aluminum oxide at outer surface of splat. Moreover, porosity was formed in coating layers. However, presence porosity is not related to thickness of coating material. The thicker coating layer resulted highesr of hardness and bond strength.« less

Improvement of wear resistance of plasma-sprayed molybdenum blend coatings

NASA Astrophysics Data System (ADS)

Ahn, Jeehoon; Hwang, Byoungchul; Lee, Sunghak

2005-06-01

The wear resistance of plasma sprayed molybdenum blend coatings applicable to synchronizer rings or piston rings was investigated in this study. Four spray powders, one of which was pure molybdenum and the others blended powders of bronze and aluminum-silicon alloy powders mixed with molybdenum powders, were sprayed on a low-carbon steel substrate by atmospheric plasma spraying. Microstructural analysis of the coatings showed that the phases formed during spraying were relatively homogeneously distributed in the molybdenum matrix. The wear test results revealed that the wear rate of all the coatings increased with increasing wear load and that the blended coatings exhibited better wear resistance than the pure molybdenum coating, although the hardness was lower. In the pure molybdenum coatings, splats were readily fractured, or cracks were initiated between splats under high wear loads, thereby leading to the decrease in wear resistance. On the other hand, the molybdenum coating blended with bronze and aluminum-silicon alloy powders exhibited excellent wear resistance because hard phases such as CuAl2 and Cu9Al4 formed inside the coating.

Tungsten nitride coatings obtained by HiPIMS as plasma facing materials for fusion applications

NASA Astrophysics Data System (ADS)

Tiron, Vasile; Velicu, Ioana-Laura; Porosnicu, Corneliu; Burducea, Ion; Dinca, Paul; Malinský, Petr

2017-09-01

In this work, tungsten nitride coatings with nitrogen content in the range of 19-50 at% were prepared by reactive multi-pulse high power impulse magnetron sputtering as a function of the argon and nitrogen mixture and further exposed to a deuterium plasma jet. The elemental composition, morphological properties and physical structure of the samples were investigated by Rutherford backscattering spectrometry, atomic force microscopy and X-ray diffraction. Deuterium implantation was performed using a deuterium plasma jet and its retention in nitrogen containing tungsten films was investigated using thermal desorption spectrometry. Deuterium retention and release behaviour strongly depend on the nitrogen content in the coatings and the films microstructure. All nitride coatings have a polycrystalline structure and retain a lower deuterium level than the pure tungsten sample. Nitrogen content in the films acts as a diffusion barrier for deuterium and leads to a higher desorption temperature, therefore to a higher binding energy.

Durability testing of medium speed diesel engine components designed for operating on coal/water slurry fuel

NASA Astrophysics Data System (ADS)

McDowell, R. E.; Giammarise, A. W.; Johnson, R. N.

1994-01-01

Over 200 operating cylinder hours were run on critical wearing engine parts. The main components tested included cylinder liners, piston rings, and fuel injector nozzles for coal/water slurry fueled operation. The liners had no visible indication of scoring nor major wear steps found on their tungsten carbide coating. While the tungsten carbide coating on the rings showed good wear resistance, some visual evidence suggests adhesive wear mode was present. Tungsten carbide coated rings running against tungsten carbide coated liners in GE 7FDL engines exhibit wear rates which suggest an approximate 500 to 750 hour life. Injector nozzle orifice materials evaluated were diamond compacts, chemical vapor deposited diamond tubes, and thermally stabilized diamond. Based upon a total of 500 cylinder hours of engine operation (including single-cylinder combustion tests), diamond compact was determined to be the preferred orifice material.

Emission characteristics of dispenser cathodes with a fine-grained tungsten top layer

NASA Astrophysics Data System (ADS)

Kimura, S.; Higuchi, T.; Ouchi, Y.; Uda, E.; Nakamura, O.; Sudo, T.; Koyama, K.

1997-02-01

In order to improve the emission stability of the Ir-coated dispenser cathode under ion bombardment, a fine-grained tungsten top layer was applied on the substrate porous tungsten plug before Ir coating. The emission characteristics were studied after being assembled in a CRT gun. Cathode current was measured under pulse operation in a range of 0.1-9% duty. Remarkable anti-ion bombardment characteristics were observed over the range of 1-6% duty. The improved cathode showed 1.5 times higher emission current than that of a conventional Ir-coated dispenser cathode at 4% duty. AES analysis showed that the recovering rates of surface Ba and O atoms after ion bombardment were 2.5 times higher. From these results it is confirmed that the Ir coated cathode with a fine-grained tungsten top layer is provided with a good tolerance against the ion bombardment.

Effects of laser remelting on microstructures and immersion corrosion performance of arc sprayed Al coating in 3.5% NaCl solution

NASA Astrophysics Data System (ADS)

Sun, Ze; Zhang, Donghui; Yan, Baoxu; Kong, Dejun

2018-02-01

An arc sprayed aluminum (Al) coating on S355 steel was processed using a laser remelting (LR). The microstructures, chemical element composition, and phases of the obtained Al coating were analyzed using a field mission scanning electronic microscope (FESEM), energy dispersive spectrometer (EDS), and X-ray diffractometer (XRD), respectively, and the residual stresses were measured using an X-ray diffraction stress tester. The immersion corrosion tests and potentiodynamic polarization of Al coating in 3.5% NaCl solution were performed to investigate the effects of LR on its immersion corrosion behaviors, and the corrosion mechanism of Al coating was also discussed. The results show that the arc sprayed Al coating is composed of Al phase, while that by LR is composed of Al-Fe and AlO4FeO6 phases, and the porosities and cracks in the arc sprayed Al coating are eliminated by LR, The residual stress of arc sprayed Al coating is -5.6 ± 18 MPa, while that after LR is 137.9 ± 12 MPa, which deduces the immersion corrosion resistance of Al coating. The corrosion mechanism of arc sprayed Al coating is pitting corrosion and crevice corrosion, while that by LR is uniform corrosion and pitting corrosion. The corrosion potential of arc sprayed Al coating by LR shifts positively, which improves its immersion corrosion resistance.

Process Of Bonding Copper And Tungsten

DOEpatents

Slattery, Kevin T.; Driemeyer, Daniel E.

1999-11-23

Process for bonding a copper substrate to a tungsten substrate by providing a thin metallic adhesion promoting film bonded to a tungsten substrate and a functionally graded material (FGM) interlayer bonding the thin metallic adhesion promoting film to the copper substrate. The FGM interlayer is formed by thermal plasma spraying mixtures of copper powder and tungsten powder in a varied blending ratio such that the blending ratio of the copper powder and the tungsten powder that is fed to a plasma torch is intermittently adjusted to provide progressively higher copper content/tungsten content, by volume, ratio values in the interlayer in a lineal direction extending from the tungsten substrate towards the copper substrate. The resulting copper to tungsten joint well accommodates the difference in the coefficient of thermal expansion of the materials.

Preheating temperature effect on tritium retention in VPS-W

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sato, M.; Uchimura, H.; Toda, K.

The W coating by Vacuum Plasma Spraying (VPS) technology is thought to be reasonable for most plasma facing components in future fusion reactors. In this paper the deuterium retention behavior for the Vacuum Plasma Spraying (VPS) tungsten (W) coating has been studied to demonstrate the tritium retention as a function of heating temperature. It has been found that two major deuterium desorption stages were observed at the temperature regions of 400 - 700 K (Stage 1) and 900 - 1100 K (Stage 2), considering that Stage 1 has been linked to the desorption of deuterium trapped by near surface andmore » intrinsic defects, and Stage 2 has been related to the desorption of deuterium bound to impurities as C-D bonds. By heating the sample above 673 K, the major peak of C-1s shifted from C-O bond to C-C bond, where the retention of deuterium as Stage 2 has increased. Therefore it indicates that the hydrogen isotope retention was controlled by the amount of C-C bond in VPS, most of which was contaminated during the VPS coating process. The comparison of several samples (VPS-W with shading, VPS-W without shading and Polycrystalline W (PCW)) shows that the carbon impurity has a large affinity with deuterium and makes stable trapping states compared to that with intrinsic defects and grain boundaries. However, most of them was reduced by heating at 1173 K. Therefore, heating treatment is quite important to get rid of carbon impurities and refrain higher tritium retention in VPS. (authors)« less

Development & characterization of alumina coating by atmospheric plasma spraying

NASA Astrophysics Data System (ADS)

Sebastian, Jobin; Scaria, Abyson; Kurian, Don George

2018-03-01

Ceramic coatings are applied on metals to prevent them from oxidation and corrosion at room as well as elevated temperatures. The service environment, mechanisms of protection, chemical and mechanical compatibility, application method, control of coating quality and ability of the coating to be repaired are the factors that need to be considered while selecting the required coating. The coatings based on oxide materials provides high degree of thermal insulation and protection against oxidation at high temperatures for the underlying substrate materials. These coatings are usually applied by the flame or plasma spraying methods. The surface cleanliness needs to be ensured before spraying. Abrasive blasting can be used to provide the required surface roughness for good adhesion between the substrate and the coating. A pre bond coat like Nickel Chromium can be applied on to the substrate material before spraying the oxide coating to avoid chances of poor adhesion between the oxide coating and the metallic substrate. Plasma spraying produces oxide coatings of greater density, higher hardness, and smooth surface finish than that of the flame spraying process Inert gas is often used for generation of plasma gas so as to avoid the oxidation of the substrate material. The work focuses to develop, characterize and optimize the parameters used in Al2O3 coating on transition stainless steel substrate material for minimizing the wear rate and maximizing the leak tightness using plasma spray process. The experiment is designed using Taguchi’s L9 orthogonal array. The parameters that are to be optimized are plasma voltage, spraying distance and the cooling jet pressure. The characterization techniques includes micro-hardness and porosity tests followed by Grey relational analysis of the results.

Ceramic coatings on smooth surfaces

NASA Technical Reports Server (NTRS)

Miller, R. A. (Inventor); Brindley, W. J. (Inventor); Rouge, C. J. (Inventor)

1991-01-01

A metallic coating is plasma sprayed onto a smooth surface of a metal alloy substitute or on a bond coating. An initial thin ceramic layer is low pressure sprayed onto the smooth surface of the substrate or bond coating. Another ceramic layer is atmospheric plasma sprayed onto the initial ceramic layer.

Cold Spray Coating of Submicronic Ceramic Particles on Poly(vinyl alcohol) in Dry and Hydrogel States

NASA Astrophysics Data System (ADS)

Moreau, David; Borit, François; Corté, Laurent; Guipont, Vincent

2017-06-01

We report an approach using cold spray technology to coat poly(vinyl alcohol) (PVA) in polymer and hydrogel states with hydroxyapatite (HA). Using porous aggregated HA powder, we hypothesized that fragmentation of the powder upon cold spray could lead to formation of a ceramic coating on the surface of the PVA substrate. However, direct spraying of this powder led to complete destruction of the swollen PVA hydrogel substrate. As an alternative, HA coatings were successfully produced by spraying onto dry PVA substrates prior to swelling in water. Dense homogeneous HA coatings composed of submicron particles were obtained using rather low-energy spraying parameters (temperature 200-250 °C, pressure 1-3 MPa). Coated PVA substrates could swell in water without removal of the ceramic layer to form HA-coated hydrogels. Microscopic observations and in situ measurements were used to explain how local heating and impact of sprayed aggregates induced surface roughening and strong binding of HA particles to the molten PVA substrate. Such an approach could lead to design of ceramic coatings whose roughness and crystallinity can be finely adjusted to improve interfacing with biological tissues.

Cadmium Coating Alternatives for High- Strength Steel JTP - Phase 2

DTIC Science & Technology

2009-09-03

Substrate 4130 Washer 17 - 4PH Washer CuBe Washer AlNiBr Washer Salt Spray Cyclic Salt Spray Cyclic Salt Spray Cyclic Salt Spray Cyclic No coating...2009, Westminster, CO. Sponsored by SERDP/ESTCP. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17 . LIMITATION OF ABSTRACT Same...Passed Appearance Testing U.S. AIR FORCE Primary Coating Bend Adhesion Test Results Coating Bend Adhesion Results 4130 steel substrate 17 -4 PH stainless

NASA Astrophysics Data System (ADS)

Mohanty, M.; Smith, R. W.

1995-12-01

Lightweight coatings based on titanium and titanium carbides produced by plasma spraying can be used to improve and modify the tribomechanical properties of aerospace structural materials. Although plasma-sprayed WC/Co coatings have been applied with success in many cases, such as primary wear-re-sistant materials, their high densities preclude their use in applications that mandate reduction in weight. In the present investigation, the sliding wear resistance of plasma-sprayed, metal-bonded TiC coatings on AI 7075 substrates was studied. Coatings containing 50, 70, and 90 vol% TiC in a Ti matrix produced from physically blended powders of Ti and TiC were compared. Metallographie evaluations showed that dense coatings with good bonding to AI 7075 substrates can be obtained. Coatings from commercial pu-rity (CP) Ti powders sprayed in air under atmospheric conditions, however, indicated considerable oxi-dation of the particles. Under dry sliding conditions, the coefficient of friction (COF) values of the Ti/TiC containing/Al 7075 substrate system were lower than high-velocity oxygen fuel (HVOF) sprayed 75% Cr3C2/25%NiCr coatings on steel and were comparable to coatings of WC/Co. Vacuum plasma-sprayed TiC/Ti coatings with 90 vol% TiC also exhibited better wear resistance than HVOF sprayed 75%Cr3C2/25%NiCr.

Microstructural inhomogeneity in plasma-sprayed hydroxyapatite coatings and effect of post-heat treatment

NASA Astrophysics Data System (ADS)

Lu, Yu-Peng; Xiao, Gui-Yong; Li, Shi-Tong; Sun, Rui-Xue; Li, Mu-Sen

2006-01-01

The microstructural inhomogeneity in the plasma-sprayed hydroxyapatite (HA) coatings was characterized by using electron probe microanalyser (EPMA). A simple and artful method was developed to detect the interface characteristics. All the samples for observation were ground and polished along the direction parallel to the coating surfaces. The BSE images directly and clearly showed the inhomogeneity in the as-sprayed coatings with the amorphous regions being bright gray and crystalline regions being dark gray. X-ray diffractometer (XRD) patterns indicated that after immersion in deionized water for 20 days, bone-like apatite and α-Ca 2P 2O 7 precipitated on the polished surfaces of the as-sprayed HA coatings. The post-heat treatment could eliminate the microstructural inhomogeneity in the coatings. Only β-Ca 2P 2O 7 precipitated on the surfaces of the heat-treated HA coatings. The immersed samples were re-polished till tiny substrate was bared to investigate the effect of immersion on interface. It was shown that the immersion decreased the cohesive strength of the as-sprayed coatings. There were more and broader cracks in the splats that came into contact with the substrate and amorphous phase increased toward the coating-substrate interface. Post-heat treatment was proved to reduce the peeling off of coating during re-polishing operation. It was proposed that the distributions of amorphous phase and cracks in as-sprayed coatings are detrimental to coating properties and should be modified through improving the plasma spraying processing.

Ceramic Coatings for Corrosion Resistant Nuclear Waste Container Evaluated in Simulated Ground Water at 90?C

DOE Office of Scientific and Technical Information (OSTI.GOV)

Haslam, J J; Farmer, J C

2004-03-31

Ceramic materials have been considered as corrosion resistant coatings for nuclear waste containers. Their suitability can be derived from the fully oxidized state for selected metal oxides. Several types of ceramic coatings applied to plain carbon steel substrates by thermal spray techniques have been exposed to 90 C simulated ground water for nearly 6 years. In some cases no apparent macroscopic damage such as coating spallation was observed in coatings. Thermal spray processes examined in this work included plasma spray, High Velocity Oxy Fuel (HVOF), and Detonation Gun. Some thermal spray coatings have demonstrated superior corrosion protection for the plainmore » carbon steel substrate. In particular the HVOF and Detonation Gun thermal spray processes produced coatings with low connected porosity, which limited the growth rate of corrosion products. It was also demonstrated that these coatings resisted spallation of the coating even when an intentional flaw (which allowed for corrosion of the carbon steel substrate underneath the ceramic coating) was placed in the coating. A model for prediction of the corrosion protection provided by ceramic coatings is presented. The model includes the effect of the morphology and amount of the porosity within the thermal spray coating and provides a prediction of the exposure time needed to produce a crack in the ceramic coating.« less

Engineering a new class of thermal spray nano-based microstructures from agglomerated nanostructured particles, suspensions and solutions: an invited review

NASA Astrophysics Data System (ADS)

Fauchais, P.; Montavon, G.; Lima, R. S.; Marple, B. R.

2011-03-01

From the pioneering works of McPherson in 1973 who identified nanometre-sized features in thermal spray conventional alumina coatings (using sprayed particles in the tens of micrometres size range) to the most recent and most advanced work aimed at manufacturing nanostructured coatings from nanometre-sized feedstock particles, the thermal spray community has been involved with nanometre-sized features and feedstock for more than 30 years. Both the development of feedstock (especially through cryo-milling, and processes able to manufacture coatings structured at the sub-micrometre or nanometre sizes, such as micrometre-sized agglomerates made of nanometre-sized particles for feedstock) and the emergence of thermal spray processes such as suspension and liquid precursor thermal spray techniques have been driven by the need to manufacture coatings with enhanced properties. These techniques result in two different types of coatings: on the one hand, those with a so-called bimodal structure having nanometre-sized zones embedded within micrometre ones, for which the spray process is similar to that of conventional coatings and on the other hand, sub-micrometre or nanostructured coatings achieved by suspension or solution spraying. Compared with suspension spraying, solution precursor spraying uses molecularly mixed precursors as liquids, avoiding a separate processing route for the preparation of powders and enabling the synthesis of a wide range of oxide powders and coatings. Such coatings are intended for use in various applications ranging from improved thermal barrier layers and wear-resistant surfaces to thin solid electrolytes for solid oxide fuel cell systems, among other numerous applications. Meanwhile these processes are more complex to operate since they are more sensitive to parameter variations compared with conventional thermal spray processes. Progress in this area has resulted from the unique combination of modelling activities, the evolution of diagnostic tools and strategies, and experimental advances that have enabled the development of a wide range of coating structures exhibiting in numerous cases unique properties. Several examples are detailed. In this paper the following aspects are presented successively (i) the two spray techniques used for manufacturing such coatings: thermal plasma and HVOF, (ii) sensors developed for in-flight diagnostics of micrometre-sized particles and the interaction of a liquid and hot gas flow, (iii) three spray processes: conventional spraying using micrometre-sized agglomerates of nanometre-sized particles, suspension spraying and solution spraying and (iv) the emerging issues resulting from the specific structures of these materials, particularly the characterization of these coatings and (v) the potential industrial applications. Further advances require the scientific and industrial communities to undertake new research and development activities to address, understand and control the complex mechanisms occurring, in particular, thermal flow—liquid drops or stream interactions when considering suspension and liquid precursor thermal spray techniques. Work is still needed to develop new measurement devices to diagnose in-flight droplets or particles below 2 µm average diameter and to validate that the assumptions made for liquid-hot gas interactions. Efforts are also required to further develop some of the characterization protocols suitable to address the specificities of such nanostructured coatings, as some existing 'conventional' protocols usually implemented on thermal spray coatings are not suitable anymore, in particular to address the void network architectures from which numerous coatings properties are derived.

Optimization of the inter-tablet coating uniformity for an active coating process at lab and pilot scale.

PubMed

Just, Sarah; Toschkoff, Gregor; Funke, Adrian; Djuric, Dejan; Scharrer, Georg; Khinast, Johannes; Knop, Klaus; Kleinebudde, Peter

2013-11-30

The objective of this study was to enhance the inter-tablet coating uniformity in an active coating process at lab and pilot scale by statistical design of experiments. The API candesartan cilexetil was applied onto gastrointestinal therapeutic systems containing the API nifedipine to obtain fixed dose combinations of these two drugs with different release profiles. At lab scale, the parameters pan load, pan speed, spray rate and number of spray nozzles were examined. At pilot scale, the parameters pan load, pan speed, spray rate, spray time, and spray pressure were investigated. A low spray rate and a high pan speed improved the coating uniformity at both scales. The number of spray nozzles was identified as the most influential variable at lab scale. With four spray nozzles, the highest CV value was equal to 6.4%, compared to 13.4% obtained with two spray nozzles. The lowest CV of 4.5% obtained with two spray nozzles was further reduced to 2.3% when using four spray nozzles. At pilot scale, CV values between 2.7% and 11.1% were achieved. Since the test of uniformity of dosage units accepts CV values of up to 6.25%, this active coating process is well suited to comply with the pharmacopoeial requirements. Copyright © 2013 Elsevier B.V. All rights reserved.

Granulometric characterization of airborne particulate release during spray application of nanoparticle-doped coatings

NASA Astrophysics Data System (ADS)

Göhler, Daniel; Stintz, Michael

2014-08-01

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

Comparative examination of the microstructure and high temperature oxidation performance of NiCrBSi flame sprayed and pack cementation coatings

NASA Astrophysics Data System (ADS)

Chaliampalias, D.; Vourlias, G.; Pavlidou, E.; Skolianos, S.; Chrissafis, K.; Stergioudis, G.

2009-01-01

Coatings formed from NiCrBSi powder were deposited by thermal spray and pack cementation processes on low carbon steel. The microstructure and morphology of the coatings were studied by scanning electron microscopy (SEM) and X-ray diffraction analysis (XRD). Flame sprayed coatings exhibited high porosity and were mechanically bonded to the substrate while pack cementation coatings were more compact and chemically bonded to the substrate. The microhardness and the high temperature oxidation resistance of the coated samples were evaluated by a Vickers microhardness tester and by thermogravimetric measurements (TG), respectively. Pack cementation coatings showed higher hardness and were more protective to high temperature environments than the flame sprayed coatings.

Tribological Properties of HVOF-Sprayed TiB2-NiCr Coatings with Agglomerated Feedstocks

NASA Astrophysics Data System (ADS)

Zhao, Zichun; Li, Hui; Yang, Tianlong; Zhu, Hongbin

2018-04-01

Boride materials have drawn great attention in surface engineering field, owing to their high hardness and good wear resistance. In our previous work, a plasma-sprayed TiB2-based cermet coating was deposited, but the coating toughness was significantly influenced by the formation of a brittle ternary phase (Ni20Ti3B6) derived from the reaction between TiB2 and metal binder. In order to suppress such a reaction occurred in the high-temperature spraying process, the high-velocity oxygen-fuel spraying technique was applied to prepare the TiB2-NiCr coating. Emphasis was paid on the microstructure, the mechanical properties, and the sliding wearing performance of the coating. The result showed that the HVOF-sprayed coating mainly consisted of hard ceramic particles including TiB2, CrB, and the binder phase. No evidence of Ni20Ti3B6 phase was found in the coating. The mechanical properties of HVOF-sprayed TiB2-NiCr coating were comparable to the conventional Cr3C2-NiCr coating. The frictional coefficient of the TiB2-NiCr coating was lower than the Cr3C2-NiCr coating when sliding against a bearing steel ball.

Ultrasonic technique for measuring porosity of plasma-sprayed alumina coatings

NASA Astrophysics Data System (ADS)

Parthasarathi, S.; Tittmann, B. R.; Onesto, E. J.

1997-12-01

Porosity is an important factor in plasma-sprayed coatings, especially ceramic coatings. Excessive poros-ity can adversely affect the performance of the coated component in various ways. An ultrasonic nonde-structive measurement technique has been developed to measure porosity in plasma-sprayed alumina coatings. The technique is generic and can be extended to other ceramic coating systems. To test the tech-nique, freestanding alumina coatings with varying levels of porosity were fabricated via plasma spray. Samples with varying porosity, obtained through innovative fabrication techniques, were used to gener-ate a calibration curve. The ultrasonic velocity in the low-frequency range was found to be dependent on the density of freestanding coatings (measured via Archimedian techniques). This dependence is the basis of the development of a technique to measure the density of coatings.

Deposition of tungsten metal by an immersion process

DOE PAGES

Small, Leo J.; Brumbach, Michael T.; Clem, Paul G.; ...

2017-03-23

A new multi-step, solution-phase method for the spontaneous deposition of tungsten from a room temperature ethereal solution is reported. This immersion process relies on the deposition of a sacrificial zinc coating which is galvanically displaced by the ether-mediated reduction of oxophilic WCl 6. Subsequent thermal treatment renders a crystalline, metallic tungsten film. The chemical evolution of the surface and formation of a complex intermediate tungsten species is characterized by X-ray diffraction, infrared spectroscopy, and X-ray photoelectron spectroscopy. Efficient metallic tungsten deposition is first characterized on a graphite substrate and then demonstrated on a functional carbon foam electrode. The resulting electrochemicalmore » performance of the modified electrode is interrogated with the canonical aqueous ferricyanide system. A tungsten-coated carbon foam electrode showed that both electrode resistance and overall electrochemical cell resistance were reduced by 50%, resulting in a concomitant decrease in redox peak separation from 1.902 V to 0.783 V. Furthermore, this process promises voltage efficiency gains in electrodes for energy storage technologies and demonstrates the viability of a new route to tungsten coating for technologies and industries where high conductivity and chemical stability are paramount.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Small, Leo J.; Brumbach, Michael T.; Clem, Paul G.

A new multi-step, solution-phase method for the spontaneous deposition of tungsten from a room temperature ethereal solution is reported. This immersion process relies on the deposition of a sacrificial zinc coating which is galvanically displaced by the ether-mediated reduction of oxophilic WCl 6. Subsequent thermal treatment renders a crystalline, metallic tungsten film. The chemical evolution of the surface and formation of a complex intermediate tungsten species is characterized by X-ray diffraction, infrared spectroscopy, and X-ray photoelectron spectroscopy. Efficient metallic tungsten deposition is first characterized on a graphite substrate and then demonstrated on a functional carbon foam electrode. The resulting electrochemicalmore » performance of the modified electrode is interrogated with the canonical aqueous ferricyanide system. A tungsten-coated carbon foam electrode showed that both electrode resistance and overall electrochemical cell resistance were reduced by 50%, resulting in a concomitant decrease in redox peak separation from 1.902 V to 0.783 V. Furthermore, this process promises voltage efficiency gains in electrodes for energy storage technologies and demonstrates the viability of a new route to tungsten coating for technologies and industries where high conductivity and chemical stability are paramount.« less

Tungsten-yttria carbide coating for conveying copper

DOEpatents

Rothman, Albert J.

1993-01-01

A method is provided for providing a carbided-tungsten-yttria coating on the interior surface of a copper vapor laser. The surface serves as a wick for the condensation of liquid copper to return the condensate to the interior of the laser for revolatilization.

Corrosion behavior of HVOF coated sheets

NASA Astrophysics Data System (ADS)

Yilbas, B. S.; Abdul-Aleem, B. J.; Khalid, M.

2003-12-01

High velocity oxygen-fuel (HVOF) thermal spray coating finds application in industry due to its superior resistance to corrosion and thermal loading. In the HVOF process, the metallic powders at elevated temperature are sprayed at supersonic speed onto a substrate material. The powder granules sprayed impact onto each other, forming a mechanical bonding across the coating layer. In most of the cases, the distances among the particles (powder granules sprayed) are not the same, which in turn results in inhomogeneous structure across the coating layer. Moreover, the rate of oxidation of the powder granules during the spraying process varies. Consequently, the electrochemical response of the coating layer surfaces next to the base material and free to atmosphere differs. In the current study, the electrochemical response of a coating sheet formed during HVOF thermal spraying was investigated. NiCrMoNb alloy (similar to Inconel 625) wass used for the powder granules. Thermal spraying was carried out onto a smooth surface of stainless steel workpiece (without grid blasting), and later the coating layer was removed from the surface to obtain the coating sheet for the electrochemical tests. It was found that the corrosion rate of the smooth surface (surface next to the stainless steel surface before its removal) is considerably larger than that corresponding to the rough surface (free surface) of the coating sheet, and no specific patterns were observed for the pit sites.

Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 2: Effect of spray parameters on the performance of several hafnia-yttria and zirconia-yttria coatings

NASA Technical Reports Server (NTRS)

Miller, Robert A.; Leissler, George W.

1993-01-01

This is the second of two reports which discuss initial experiments on thermal barrier coatings prepared and tested in newly upgraded plasma spray and burner rig test facilities at LeRC. The first report, part 1, describes experiments designed to establish the spray parameters for the baseline zirconia-yttria coating. Coating quality was judged primarily by the response to burner rig exposure, together with a variety of other characterization approaches including thermal diffusivity measurements. That portion of the study showed that the performance of the baseline NASA coating was not strongly sensitive to processing parameters. In this second part of the study, new hafnia-yttria coatings were evaluated with respect to both baseline and alternate zirconia-yttria coatings. The hafnia-yttria and the alternate zirconia-yttria coatings were very sensitive to plasma-spray parameters in that high-quality coatings were obtained only when specific parameters were used. The reasons for this important observation are not understood.

Thermal spray for commercial shipbuilding

NASA Astrophysics Data System (ADS)

Rogers, F. S.

1997-09-01

Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum. This extends the service life of the coating and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanizing. With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal- sprayed aluminum coating system has proved the most cost- effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Arc spray technology has reduced the application cost of thermal spraying of aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

A simulation technique for predicting thickness of thermal sprayed coatings

NASA Technical Reports Server (NTRS)

Goedjen, John G.; Miller, Robert A.; Brindley, William J.; Leissler, George W.

1995-01-01

The complexity of many of the components being coated today using the thermal spray process makes the trial and error approach traditionally followed in depositing a uniform coating inadequate, thereby necessitating a more analytical approach to developing robotic trajectories. A two dimensional finite difference simulation model has been developed to predict the thickness of coatings deposited using the thermal spray process. The model couples robotic and component trajectories and thermal spraying parameters to predict coating thickness. Simulations and experimental verification were performed on a rotating disk to evaluate the predictive capabilities of the approach.

Investigation to develop a method to apply diffusion barrier to high strength fibers

NASA Technical Reports Server (NTRS)

Veltri, R. D.; Paradis, R. D.; Douglas, F. C.

1975-01-01

A radio frequency powered ion plating process was used to apply the diffusion barriers of aluminum oxide, yttrium oxide, hafnium oxide and titanium carbide to a substrate tungsten fiber. Each of the coatings was examined as to its effect on both room temperature strength and tensile strength of the base tungsten fiber. The coated fibers were then overcoated with a nickel alloy to become single cell diffusion couples. These diffusion couples were exposed to 1093 C for 24 hours, cycled between room temperature and 1093 C, and given a thermal anneal for 100 hours at 1200 C. Tensile testing and metallographic examinations determined that the hafnium oxide coating produced the best high temperature diffusion barrier for tungsten of the four coatings.

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.

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.

Improvements in Microstructure and Wear Resistance of Plasma-Sprayed Fe-Based Amorphous Coating by Laser-Remelting

NASA Astrophysics Data System (ADS)

Jiang, Chaoping; Chen, Hong; Wang, Gui; Chen, Yongnan; Xing, Yazhe; Zhang, Chunhua; Dargusch, Matthew

2017-04-01

Amorphous coating technology is an attractive way of taking advantage of the superior properties of amorphous alloys for structural applications. However, the limited bonds between splats within the plasma-sprayed coatings result in a typically lamellar and porous coating structure. To overcome these limitations, the as-sprayed coating was treated by a laser-remelting process. The microstructure and phase composition of two coatings were analyzed using scanning electron microscopy with energy-dispersive spectroscopy, transmission electron microscopy, and x-ray diffraction. The wear resistance of the plasma-sprayed coating and laser-remelted coating was studied comparatively using a pin-on-disc wear test under dry friction conditions. It was revealed that the laser-remelted coating exhibited better wear resistance because of its defect-free and amorphous-nanocrystalline composited structure.

The influence of pore formers on the microstructure of plasma-sprayed NiO-YSZ anodes

NASA Astrophysics Data System (ADS)

Poon, Michael; Kesler, Olivera

2012-07-01

Four types of pore formers: high-density polyethylene (HDPE), polyether-ether-ketone (PEEK), mesocarbon-microbead (MCMB) carbon powder, and baking flour, are processed and characterized, then incorporated with NiO-YSZ nano-agglomerate powder to produce plasma sprayed SOFC anode coatings. Scanning electron microscopy (SEM) of the coating microstructure, gas permeability measurements, and porosity determinations by image analysis are used to evaluate the effectiveness of each potential pore former powder. Under the spray conditions studied, the flour and MCMB pore former powders are effective as plasma sprayed pore formers, increasing the permeability of the coatings by factors of four and two, respectively, compared to a similarly sprayed NiO-YSZ coating without pore formers. The HDPE powder is unable to survive the plasma spray process and does not contribute to the final coating porosity. The PEEK pore former, though ineffective with the current powder characteristics and spray parameters, exhibits the highest relative deposition efficiency and the most favorable thermal characteristics.

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

NASA Technical Reports Server (NTRS)

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

1998-01-01

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

Hydrogen transport behavior of metal coatings for plasma-facing components

NASA Astrophysics Data System (ADS)

Anderl, R. A.; Holland, D. F.; Longhurst, G. R.

1990-12-01

Plasma-facing components for experimental and commercial fusion reactor studies may include cladding or coatings of refractory metals like tungsten on metallic structural substrates such as copper, vanadium alloys and austenitic stainless steel. Issues of safety and fuel economy include the potential for inventory buildup and permeation of tritium implanted into the plasma-facing surface. This paper reports on laboratory-scale studies with 3 keV D +3 ion beams to investigate the hydrogen transport behavior in tungsten coatings on substrates of copper. These experiments entailed measurements of the deuterium re-emission and permeation rates for tungsten, copper, and tungsten-coated copper specimens at temperatures ranging from 638 to 825 K and implanting particle fluxes of approximately 5 × 10 19 D/m 2 s. Diffusion constants and surface recombination coefficients with enhancement factors due to sputtering were obtained from these measurements. These data may be used in calculations to estimate permeation rates and inventory buildups for proposed diverter designs.

Role of Oxides and Porosity on High-Temperature Oxidation of Liquid-Fueled HVOF Thermal-Sprayed Ni50Cr Coatings

NASA Astrophysics Data System (ADS)

Song, B.; Bai, M.; Voisey, K. T.; Hussain, T.

2017-02-01

High chromium content in Ni50Cr thermally sprayed coatings can generate a dense and protective scale at the surface of coating. Thus, the Ni50Cr coating is widely used in high-temperature oxidation and corrosion applications. A commercially available gas atomized Ni50Cr powder was sprayed onto a power plant steel (ASME P92) using a liquid-fueled high velocity oxy-fuel thermal spray with three processing parameters in this study. Microstructure of as-sprayed coatings was examined using oxygen content analysis, mercury intrusion porosimetry, scanning electron microscope (SEM), energy-dispersive x-ray spectroscopy (EDX) and x-ray diffraction (XRD). Short-term air oxidation tests (4 h) of freestanding coatings (without boiler steel substrate) in a thermogravimetric analyzer at 700 °C were performed to obtain the kinetics of oxidation of the as-sprayed coating. Long-term air oxidation tests (100 h) of the coated substrates were performed at same temperature to obtain the oxidation products for further characterization in detail using SEM/EDX and XRD. In all samples, oxides of various morphologies developed on top of the Ni50Cr coatings. Cr2O3 was the main oxidation product on the surface of all three coatings. The coating with medium porosity and medium oxygen content has the best high-temperature oxidation performance in this study.

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

High velocity pulsed wire-arc spray

NASA Technical Reports Server (NTRS)

Kincaid, Russell W. (Inventor); Witherspoon, F. Douglas (Inventor); Massey, Dennis W. (Inventor)

1999-01-01

Wire arc spraying using repetitively pulsed, high temperature gas jets, usually referred to as plasma jets, and generated by capillary discharges, substantially increases the velocity of atomized and entrained molten droplets. The quality of coatings produced is improved by increasing the velocity with which coating particles impact the coated surface. The effectiveness of wire-arc spraying is improved by replacing the usual atomizing air stream with a rapidly pulsed high velocity plasma jet. Pulsed power provides higher coating particle velocities leading to improved coatings. 50 micron aluminum droplets with velocities of 1500 m/s are produced. Pulsed plasma jet spraying provides the means to coat the insides of pipes, tubes, and engine block cylinders with very high velocity droplet impact.

Mechanical Performance of Cold-Sprayed A357 Aluminum Alloy Coatings for Repair and Additive Manufacturing

NASA Astrophysics Data System (ADS)

Petráčková, K.; Kondás, J.; Guagliano, M.

2017-12-01

Cold-sprayed coatings made of A357 aluminum alloy, a casting alloy widely used in aerospace, underwent set of standard tests as well as newly developed fatigue test to gain an information about potential of cold spray for repair and additive manufacturing of loaded parts. With optimal spray parameters, coating deposition on substrate with smooth surface resulted in relatively good bonding, which can be further improved by application of grit blasting on substrate's surface. However, no enhancement of adhesion was obtained for shot-peened surface. Process temperature, which was set either to 450 or 550 °C, was shown to have an effect on adhesion and cohesion strength, but it does not influence residual stress in the coating. To assess cold spray perspectives for additive manufacturing, flat tensile specimens were machined from coating and tested in as-sprayed and heat-treated (solution treatment and aging) condition. Tensile properties of the coating after the treatment correspond to properties of the cast A357-T61 aluminum alloy. Finally, fatigue specimen was proposed to test overall performance of the coating and coating's fatigue limit is compared to the results obtained on cast A357-T61 aluminum alloy.

Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy

NASA Astrophysics Data System (ADS)

Caliari, F. R.; Miranda, F. S.; Reis, D. A. P.; Essiptchouk, A. M.; Filho, G. P.

2017-06-01

Plasma spray is a versatile technology used for production of environmental and thermal barrier coatings, mainly in the aerospace, gas turbine, and automotive industries, with potential application in the renewable energy industry. New plasma spray technologies have been developed recently to produce high-quality coatings as an alternative to the costly low-pressure plasma-spray process. In this work, we studied the properties of as-sprayed CoNiCrAlY coatings deposited on Ti-6Al-4V substrate with smooth surface ( R a = 0.8 μm) by means of a plasma torch operating in supersonic regime at atmospheric pressure. The CoNiCrAlY coatings were evaluated in terms of their surface roughness, microstructure, instrumented indentation, and phase content. Static and dynamic depositions were investigated to examine their effect on coating characteristics. Results show that the substrate surface velocity has a major influence on the coating properties. The sprayed CoNiCrAlY coatings exhibit low roughness ( R a of 5.7 μm), low porosity (0.8%), excellent mechanical properties ( H it = 6.1 GPa, E it = 155 GPa), and elevated interface toughness (2.4 MPa m1/2).

Microstructure and mechanical properties of plasma sprayed HA/YSZ/Ti-6Al-4V composite coatings.

PubMed

Khor, K A; Gu, Y W; Pan, D; Cheang, P

2004-08-01

Plasma sprayed hydroxyapatite (HA) coatings on titanium alloy substrate have been used extensively due to their excellent biocompatibility and osteoconductivity. However, the erratic bond strength between HA and Ti alloy has raised concern over the long-term reliability of the implant. In this paper, HA/yttria stabilized zirconia (YSZ)/Ti-6Al-4V composite coatings that possess superior mechanical properties to conventional plasma sprayed HA coatings were developed. Ti-6Al-4V powders coated with fine YSZ and HA particles were prepared through a unique ceramic slurry mixing method. The so-formed composite powder was employed as feedstock for plasma spraying of the HA/YSZ/Ti-6Al-4V coatings. The influence of net plasma energy, plasma spray standoff distance, and post-spray heat treatment on microstructure, phase composition and mechanical properties were investigated. Results showed that coatings prepared with the optimum plasma sprayed condition showed a well-defined splat structure. HA/YSZ/Ti-6Al-4V solid solution was formed during plasma spraying which was beneficial for the improvement of mechanical properties. There was no evidence of Ti oxidation from the successful processing of YSZ and HA coated Ti-6Al-4V composite powders. Small amount of CaO apart from HA, ZrO(2) and Ti was present in the composite coatings. The microhardness, Young's modulus, fracture toughness, and bond strength increased significantly with the addition of YSZ. Post-spray heat treatment at 600 degrees C and 700 degrees C for up to 12h was found to further improve the mechanical properties of coatings. After the post-spray heat treatment, 17.6% increment in Young's modulus (E) and 16.3% increment in Vicker's hardness were achieved. The strengthening mechanisms of HA/YSZ/Ti-6Al-4V composite coatings were related to the dispersion strengthening by homogeneous distribution of YSZ particles in the matrix, the good mechanical properties of Ti-6Al-4V and the formation of solid solution among HA, Ti alloy and YSZ components.

Laser modification of thermally sprayed coatings

NASA Astrophysics Data System (ADS)

Uglov, A. A.; Fomin, A. D.; Naumkin, A. O.; Pekshev, P. Iu.; Smurov, I. Iu.

1987-08-01

Experimental results are reported on the modification of thermally sprayed coatings on steels and aluminum alloys using pulsed YAG and CW CO2 lasers. In particular, results obtained for self-fluxing Ni9CrBSi powders, ZRO2 ceramic, and titanium are examined. It is shown that the laser treatment of thermally sprayed coatings significantly improves their physicomechanical properties; it also makes it possible to obtain refractory coatings on low-melting substrates with good coating-substrate adhesion.

Review of Thermal Spray Coating Applications in the Steel Industry: Part 2—Zinc Pot Hardware in the Continuous Galvanizing Line

NASA Astrophysics Data System (ADS)

Matthews, S.; James, B.

2010-12-01

This two-part article series reviews the application of thermal spray coating technology in the production of steel and steel sheet products. Part 2 of this article series is dedicated to coating solutions in the continuous galvanizing line. The corrosion mechanisms of Fe- and Co-based bulk materials are briefly reviewed as a basis for the development of thermal spray coating solutions. WC-Co thermal spray coatings are commonly applied to low Al-content galvanizing hardware due to their superior corrosion resistance compared to Fe and Co alloys. The effect of phase degradation, carbon content, and WC grain size are discussed. At high Al concentrations, the properties of WC-Co coatings degrade significantly, leading to the application of oxide-based coatings and corrosion-resistant boride containing coatings. The latest results of testing are summarized, highlighting the critical coating parameters.

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

PubMed

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

2007-11-01

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

Cold Spray for Repair of Magnesium Components

DTIC Science & Technology

2011-11-01

powder material. Other advantages of the Cold Spray process include:  It provides extremely dense coatings with virtually no inclusions or cracks ... crack on insertion of Rosan fitting and does not reclaim the mechanical properties of the Mg alloy. It is expected that the use of Cold Spray coating...Spray process include:  Extremely dense coatings with virtually no inclusions or cracks .  Retains properties and microstructure of initial powder

Evaluation Report of the Double Wall Air Inflated MUST Shelter Made from Three Dimensional Fabric

DTIC Science & Technology

1975-10-22

II Natick laboratory Test Results on Spray Coated 3-D Woven Fabric iWST Shelter Casing Material ......... 29 11 3-D Casing Fabric D1mensions, as Woven...of yarns shoi . be achieved before spraying. 3.1.3 The casing surface should be inspected afhir each of the first several spray coats for pinholes in...Coated Fabric Casing Material After two days of drying time, a three-foot-wide portion was cut off from one end of a sprayed casing . Part of this coated

Spray-coated carbon nanotube thin-film transistors with striped transport channels

NASA Astrophysics Data System (ADS)

Jeong, Minho; Lee, Kunhak; Choi, Eunsuk; Kim, Ahsung; Lee, Seung-Beck

2012-12-01

We present results for the transfer characteristics of carbon nanotube thin-film transistors (CNT-TFTs) that utilize single-walled carbon nanotube thin-films prepared by direct spray-coating on the substrate. By varying the number of spray-coatings (Nsp) and the concentration of nanotubes in solution (CNT), it was possible to control the conductivity of the spray-coated nanotube thin-film from 129 to 0.1 kΩ/□. Also, by introducing stripes into the channel of the CNT-TFT, and thereby reducing the number of metallic percolation paths between source and drain, it was possible to enhance the on/off current ratio 1000-fold, from 10 to 104, demonstrating that it may be possible to utilize spray-coating as a method to fabricate CNT-TFTs for large area switching array applications.

Warm spraying-a novel coating process based on high-velocity impact of solid particles.

PubMed

Kuroda, Seiji; Kawakita, Jin; Watanabe, Makoto; Katanoda, Hiroshi

2008-07-01

In recent years, coating processes based on the impact of high-velocity solid particles such as cold spraying and aerosol deposition have been developed and attracting much industrial attention. A novel coating process called 'warm spraying' has been developed, in which coatings are formed by the high-velocity impact of solid powder particles heated to appropriate temperatures below the melting point of the powder material. The advantages of such process are as follows: (1) the critical velocity needed to form a coating can be significantly lowered by heating, (2) the degradation of feedstock powder such as oxidation can be significantly controlled compared with conventional thermal spraying where powder is molten, and (3) various coating structures can be realized from porous to dense ones by controlling the temperature and velocity of the particles. The principles and characteristics of this new process are discussed in light of other existing spray processes such as high-velocity oxy-fuel spraying and cold spraying. The gas dynamics of particle heating and acceleration by the spraying apparatus as well as the high-velocity impact phenomena of powder particles are discussed in detail. Several examples of depositing heat sensitive materials such as titanium, metallic glass, WC-Co cermet and polymers are described with potential industrial applications.

EVALUATION OF CONVERGENT SPRAY TECHNOLOGYTM SPRAY PROCESS FOR ROOF COATING APPLICATION

EPA Science Inventory

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

Effect of Sodium Dodecyl Sulphate and Sodium Bromide Additives on Ni–W Nanocoatings.

PubMed

Das, Malay Kumar; Qin, Jiaqian; Zhang, Xinyu; Li, Rongxia; Thueploy, Adisak; Limpanart, Sarintorn; Boonyongmaneerat, Yuttanat; Ma, Mingzhen; Liu, Riping

2017-02-01

Nickel-tungsten (Ni–W) coatings were fabricated by electrodeposition method with varying quantities of sodium dodecyl sulphate and sodium bromide to examine the effects of the aforesaid additives on the coatings. The obtained nanocoatings were studied by X-ray diffraction, scanning electron microscopy, energy dispersive X-ray spectroscopy, and hardness tester. The hardness, tungsten content and grain size attained a maximum value at current density of 0.15 A/cm²,0.1 A/cm² and 0.1 A/cm², respectively. There was a pronounced impact of both the additives on the microstructure and morphology of the coatings. According to results, there are considerable difference in terms of the impact caused by the additives to the tungsten content, hardness and grain size of the coatings. The obtained results suggest that hardness of coatings is mainly contributed by W content in the deposits.

Structure and microhardness of the plasma sprayed composite coatings after combined treatment

NASA Astrophysics Data System (ADS)

Ivannikov, A. Yu; Kalita, V. I.; Komlev, D. I.; Radyuk, A. A.; Bagmutov, V. P.; Zakharov, I. N.; Parshev, S. N.; Denisevich, D. S.

2018-04-01

The principal aim of this study was to evaluate the effect of combination of electromechanical treatment (EMT) and ultrasonic treatment on structure and microhardness of air plasma sprayed composite coatings from Ni–20Cr alloy and R6M5 high speed steel (HSS). The results of the microstructural studies showed fundamental changes of the treated by the EMT plasma sprayed coating with the formation of nanostructured crystalline phases. As a consequence of the coating thus formed, the number of pores in the coating structure reduced from 10.0±1.5% to 2.0±0.5%, the surface microhardness increased from 3100±500 MPa to 7900±400 MPa. Additional ultrasonic treatment on the selected mode decreased surface waviness, which was formed on the surface of the plasma sprayed composite coatings after the EMT. The obtained results revealed the high potential of the combined treatment for post-treatment of the plasma sprayed coatings.

Characterization of commercially cold sprayed copper coatings and determination of the effects of impacting copper powder velocities

NASA Astrophysics Data System (ADS)

Jakupi, P.; Keech, P. G.; Barker, I.; Ramamurthy, S.; Jacklin, R. L.; Shoesmith, D. W.; Moser, D. E.

2015-11-01

Copper coated steel containers are being developed for the disposal of high level nuclear waste using processes such as cold spray and electrodeposition. Electron Back-Scatter Diffraction has been used to determine the microstructural properties and the quality of the steel-copper coating interface. The influence of the nature of the cold-spray carrier gas as well as its temperature and pressure (velocity) on the coating's plastic strain and recrystallization behaviour have been investigated, and one commercially-produced electrodeposited coating characterized. The quality of the coatings was assessed using the coincident site lattice model to analyse the properties of the grain boundaries. For cold spray coatings the grain size and number of coincident site lattice grain boundaries increased, and plastic strain decreased, with carrier gas velocity. In all cases annealing improved the quality of the coatings by increasing texture and coincidence site-lattices, but also increased the number of physical voids, especially when a low temperature cold spray carrier gas was used. Comparatively, the average grain size and number of coincident site-lattices was considerably larger for the strongly textured electrodeposited coating. Tensile testing showed the electrodeposited coating was much more strongly adherent to the steel substrate.

Plasma sprayed coatings on crankshaft used steels

NASA Astrophysics Data System (ADS)

Mahu, G.; Munteanu, C.; Istrate, B.; Benchea, M.

2017-08-01

Plasma spray coatings may be an alternative to conventional heat treatment of main journals and crankpins of the crankshaft. The applications of plasma coatings are various and present multiple advantages compared to electric arc wire spraying or flame spraying. The study examines the layers sprayed with the following powders: Cr3C2- 25(Ni 20Cr), Al2O3- 13TiO2, Cr2O3-SiO2- TiO2 on the surface of steels used in the construction of a crankshaft (C45). The plasma spray coatings were made with the Spray wizard 9MCE facility at atmospheric pressure. The samples were analyzed in terms of micro and morphological using optical microscopy, scanning electron microscopy and X-ray diffraction. Wear tests on samples that have undergone simulates extreme working conditions of the crankshafts. In order to emphasize adherence to the base material sprayed layer, were carried out tests of microscratches and micro-indentation. Results have showed a relatively compact morphological aspect given by the successive coatings with splat-like specific structures. Following the microscratch analysis it can be concluded that Al2O3-13TiO2 coating has a higher purpose in terms of hardness compared to Cr3C2-(Ni 20Cr) and Cr2O3-SiO2- TiO2 powders. Thermal coatings of the deposited powders have increased the mechanical properties of the material. The results stand to confirm that plasma sprayed Al2O3-13TiO2 powder is in fact a efficient solution for preventing mechanical wear, even with a faulty lubrication system.

Gas Dynamic Spray Technology Demonstration Project Management. Joint Test Report

NASA Technical Reports Server (NTRS)

Lewis, Pattie

2011-01-01

The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are sUbject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by Air Force Space Command (AFSPC) and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GOS) technology (also known as Cold Spray) was evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GOS coatings also have no VOCs and are environmentally preferable coatings. The primary objective of this effort was to demonstrate GDS technology as a repair method for TSCs. The aim was that successful completion of this project would result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations to improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Suppression of agglomeration in fluidized bed coating. II. Measurement of mist size in a fluidized bed chamber and effect of sodium chloride addition on mist size.

PubMed

Yuasa, H; Nakano, T; Kanaya, Y

1999-02-01

It has been reported that the degree of particle agglomeration in fluidized bed coating is greatly affected by the spray mist size of coating solution. However, the mist size has generally been measured in open air, and few reports have described the measurement of the mist size in a chamber of the fluidized bed, in which actual coating is carried out. Therefore, using hydroxypropylmethyl cellulose (HPMC) aqueous solution as a coating solution, the spray mist size of the coating solution in a chamber of the fluidized bed was measured under various coating conditions, such as the distance from the spray nozzle, fluidization air volume, inlet air temperature and addition of sodium chloride (NaCl) into the coating solution. The mist size in the fluidized bed was compared with that in open air at various distances from the spray nozzle. Further, the relationship between the spray mist size and the degree of suppression of agglomeration at various NaCl concentrations during fluidized bed coating was studied. The mist size distribution showed a logarithmic normal distribution in both cases of the fluidized bed and open air. The number-basis median diameter of spray mist (D50) in the fluidized bed was smaller compared with that in open air. D50 increased with the increasing distance from the spray nozzle in both cases. In the fluidized bed, D50 decreased with the increasing fluidization air volume and inlet air temperature. The effect of NaCl concentration on the mist size was hardly observed, but the degree of suppression of agglomeration during coating increased with the increasing NaCl concentration in the coating solution.

Erosion resistance of arc-sprayed coatings to iron ore at 25 and 315 °C

NASA Astrophysics Data System (ADS)

Dallaire, S.; Levert, H.; Legoux, J.-G.

2001-06-01

Iron ore pellets are sintered and reduced in large continuous industrial oil-fired furnaces. From the furnace, powerful fans extract large volumes of hot gas. Being exposed to gas-borne iron ore particles and temperatures ranging between 125 and 328 °C, fan components are rapidly eroded. Extensive part repair or replacement is required for maintaining a profitable operation. The arc spraying technique has been suggested for repair provided it could produce erosion-resistant coatings. Conventional and cored wires (1.6 mm diameter) were arc sprayed using various spray parameters to produce 250 to 300 µm thick coatings. Arc-sprayed coatings and reference specimens were erosion tested at 25 and 315 °C and impact angles of 25 and 90° in a laboratory gas-blast erosion rig. This device was designed to impact materials with coarse (32 to 300 µm) iron ore particles at a speed of 100 m/s. The coating volume loss due to erosion was measured with a laser profilometer built by National Research Council Canada several years ago. Few arc-sprayed coatings exhibited erosion resistance comparable with structural steel at low impact angles. Erosion of arc-sprayed coatings and reference specimens dramatically increases at 315 °C for both 25° and 90° impact angles. Erosion-enhanced oxidation was found to be responsible for the increase in volume loss above room temperature. Though arc spraying can be appropriate for on-site repair, the development of more erosion-resistant coatings is required for intermediate temperatures.

Systematic Investigation on the Influence of Spray Parameters on the Mechanical Properties of Atmospheric Plasma-Sprayed YSZ Coatings

NASA Astrophysics Data System (ADS)

Mutter, Markus; Mauer, Georg; Mücke, Robert; Guillon, Olivier; Vaßen, Robert

2018-04-01

In the atmospheric plasma spray (APS) process, micro-sized ceramic powder is injected into a thermal plasma where it is rapidly heated and propelled toward the substrate. The coating formation is characterized by the subsequent impingement of a large number of more or less molten particles forming the so-called splats and eventually the coating. In this study, a systematic investigation on the influence of selected spray parameters on the coating microstructure and the coating properties was conducted. The investigation thereby comprised the coating porosity, the elastic modulus, and the residual stress evolution within the coating. The melting status of the particles at the impingement on the substrate in combination with the substrate surface condition is crucial for the coating formation. Single splats were collected on mirror-polished substrates for selected spray conditions and evaluated by identifying different types of splats (ideal, distorted, weakly bonded, and partially molten) and their relative fractions. In a previous study, these splat types were evaluated in terms of their effect on the above-mentioned coating properties. The particle melting status, which serves as a measure for the particle spreading behavior, was determined by in-flight particle temperature measurements and correlated to the coating properties. It was found that the gun power and the spray distance have a strong effect on the investigated coating properties, whereas the feed rate and the cooling show minor influence.

Ceramic Top Coats of Plasma-Sprayed Thermal Barrier Coatings: Materials, Processes, and Properties

NASA Astrophysics Data System (ADS)

Bakan, Emine; Vaßen, Robert

2017-08-01

The ceramic top coat has a major influence on the performance of the thermal barrier coating systems (TBCs). Yttria-partially-stabilized zirconia (YSZ) is the top coat material frequently used, and the major deposition processes of the YSZ top coat are atmospheric plasma spraying and electron beam physical vapor deposition. Recently, also new thermal spray processes such as suspension plasma spraying or plasma spray-physical vapor deposition have been intensively investigated for TBC top coat deposition. These new processes and particularly the different coating microstructures that can be deposited with them will be reviewed in this article. Furthermore, the properties and the intrinsic-extrinsic degradation mechanisms of the YSZ will be discussed. Following the TBC deposition processes and standard YSZ material, alternative ceramic materials such as perovskites and hexaaluminates will be summarized, while properties of pyrochlores with regard to their crystal structure will be discussed more in detail. The merits of the pyrochlores such as good CMAS resistance as well as their weaknesses, e.g., low fracture toughness, processability issues, will be outlined.

Nuclear Rocket Ceramic Metal Fuel Fabrication Using Tungsten Powder Coating and Spark Plasma Sintering

NASA Technical Reports Server (NTRS)

Barnes, M. W.; Tucker, D. S.; Hone, L.; Cook, S.

2017-01-01

Nuclear thermal propulsion is an enabling technology for crewed Mars missions. An investigation was conducted to evaluate spark plasma sintering (SPS) as a method to produce tungsten-depleted uranium dioxide (W-dUO2) fuel material when employing fuel particles that were tungsten powder coated. Ceramic metal fuel wafers were produced from a blend of W-60vol% dUO2 powder that was sintered via SPS. The maximum sintering temperatures were varied from 1,600 to 1,850 C while applying a 50-MPa axial load. Wafers exhibited high density (>95% of theoretical) and a uniform microstructure (fuel particles uniformly dispersed throughout tungsten matrix).

Cold spray NDE for porosity and other process anomalies

NASA Astrophysics Data System (ADS)

Glass, S. W.; Larche, M. R.; Prowant, M. S.; Suter, J. D.; Lareau, J. P.; Jiang, X.; Ross, K. A.

2018-04-01

This paper describes a technology review of nondestructive evaluation (NDE) methods that can be applied to cold spray coatings. Cold spray is a process for depositing metal powder at high velocity so that it bonds to the substrate metal without significant heating that would be likely to cause additional residual tensile stresses. Coatings in the range from millimeters to centimeters are possible at relatively high deposition rates. Cold spray coatings that may be used for hydroelectric components that are subject to erosion, corrosion, wear, and cavitation damage are of interest. The topic of cold spray NDE is treated generally, however, but may be considered applicable to virtually any cold spray application except where there are constraints of the hydroelectric component application that bear special consideration. Optical profilometry, eddy current, ultrasound, and hardness tests are shown for one set of good, fair, and poor nickel-chrome (NiCr) on 304 stainless steel (304SS) cold spray samples to demonstrate inspection possibilities. The primary indicator of cold spray quality is the cold spray porosity that is most directly measured with witness-sample destructive examinations (DE)—mostly photo-micrographs. These DE-generated porosity values are correlated with optical profilometry, eddy current, ultrasound, and hardness test NDE methods to infer the porosity and other information of interest. These parameters of interest primarily include: • Porosity primarily caused by improper process conditions (temperature, gas velocity, spray standoff, spray angle, powder size, condition, surface cleanliness, surface oxide, etc.) • Presence/absence of the cold spray coating including possible over-sprayed voids • Coating thicknessOptical profilometry measurements of surface roughness trended with porosity plus, if compared with a reference measurement or reference drawing, would provide information on the coating thickness. Ultrasound could provide similar surface profile information plus attenuation measurements trended with porosity. The ultrasound measurements, however, may be limited to geometries where the substrate back-wall is normal to the cold spray surface and not too thick. Eddy current showed a strong correlation with porosity. Eddy currents can also be sensitive to cracks and do not need fluid coupling to make measurements, but are not sensitive to coating thicknesses in most cases. Vickers hardness measurements also tracked well with porosity; however, these types of hardness measurements are also not sensitive to coating thickness. An NDE program may include multiple measurements.

Thermal barrier coating life prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J. F.; Tasooji, A.

1985-01-01

This program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system is composed of a low pressure, plasma sprayed applied, oxidation resistant NiCrAlY bond coating. The other system is an air plasma sprayed yttria (8 percent) partially stabilized zirconia insulative layer.

Wear and Corrosion Properties of 316L-SiC Composite Coating Deposited by Cold Spray on Magnesium Alloy

NASA Astrophysics Data System (ADS)

Chen, Jie; Ma, Bing; Liu, Guang; Song, Hui; Wu, Jinming; Cui, Lang; Zheng, Ziyun

2017-08-01

In order to improve the wear and corrosion resistance of commonly used magnesium alloys, 316L stainless steel coating and 316L-SiC composite coating have been deposited directly on commercial AZ80 magnesium alloy using cold spraying technology (CS). The microstructure, hardness and bonding strength of as-sprayed coatings were studied. Their tribological properties sliding against Si3N4 and GCr15 steel under unlubricated conditions were evaluated by a ball-on-disk tribometer. Corrosion behaviors of coated samples were also evaluated and compared to that of uncoated magnesium alloy substrate in 3.5 wt.% NaCl solution by electrochemical measurements. Scanning electron microscopy was used to characterize the corresponding wear tracks and corroded surfaces to determine wear and corrosion mechanisms. The results showed that the as-sprayed coatings possessed higher microhardness and more excellent wear resistance than magnesium alloy substrate. Meanwhile, 316L and 316L-SiC coating also reduced the corrosion current density of magnesium alloy and the galvanic corrosion of the substrates was not observed after 200-h neutral salt spray exposure, which demonstrated that corrosion resistance of a magnesium alloy substrate could be greatly improved by cold-sprayed stainless steel-based coatings.

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

NASA Astrophysics Data System (ADS)

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

2016-02-01

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

Hydroxyapatite coatings deposited by liquid precursor plasma spraying: controlled dense and porous microstructures and osteoblastic cell responses.

PubMed

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

2010-12-01

Hydroxyapatite coatings were deposited on Ti-6Al-4V substrates by a novel plasma spraying process, the liquid precursor plasma spraying (LPPS) process. X-ray diffraction results showed that the coatings obtained by the LPPS process were mainly composed of hydroxyapatite. The LPPS process also showed excellent control on the coating microstructure, and both nearly fully dense and highly porous hydroxyapatite coatings were obtained by simply adjusting the solid content of the hydroxyapatite liquid precursor. Scanning electron microscope observations indicated that the porous hydroxyapatite coatings had pore size in the range of 10-200 µm and an average porosity of 48.26 ± 0.10%. The osteoblastic cell responses to the dense and porous hydroxyapatite coatings were evaluated with human osteoblastic cell MG-63, in respect of the cell morphology, proliferation and differentiation, with the hydroxyapatite coatings deposited by the atmospheric plasma spraying (APS) process as control. The cell experiment results indicated that the heat-treated LPPS coatings with a porous structure showed the best cell proliferation and differentiation among all the hydroxyapatite coatings. Our results suggest that the LPPS process is a promising plasma spraying technique for fabricating hydroxyapatite coatings with a controllable microstructure, which has great potential in bone repair and replacement applications.

Microstructural characteristics of plasma sprayed nanostructured partially stabilized zirconia

NASA Astrophysics Data System (ADS)

Lima, Rogerio Soares

Thermal barrier coatings have been extensively applied in the aerospace industry in turbines and rocket engines as an insulation system. Partially stabilized zirconia, due to its high thermal stability and low thermal conductivity at high temperatures has been traditionally employed as the ceramic element of the thermal barrier coating system. Different approaches have been taken in order to improve the performance of these coatings. Nanostructured materials are promising an interesting future in the beginning of the 21st century. Due to its enhanced strain to failure and superplasticity new applications may be accomplished or the limits of materials utilization may be placed at higher levels. Single nanostructured particles can not be thermal sprayed by conventional thermal spray equipment. Due to its low mass, they would be deviated to the periphery of the thermal spray jet. To overcome this characteristic, single nanostructured particles were successively agglomerated into large microscopic particles, with particle size distribution similar to the conventional feedstocks for thermal spray equipment. Agglomerated nanostructured particles of partially stabilized zirconia were plasma sprayed in air with different spray parameters. According to traditional thermal spray procedure, the feedstock has to be melted in the thermal spray jet in order to achieve the necessary conditions for adhesion and cohesion on the substrate. Due to the nature of the nanostructured particles, a new step has to be taken in the thermal spray processing; particle melting has to be avoided in order to preserve the feedstock nanostructure in the coating overall microstructure. In this work, the adhesion/cohesion system of nanostructured coatings is investigated and clarified. A percentage of molten particles will retain and hold the non-molten agglomerated nanostructured particles in the coating overall microstructure. Controlling the spray parameters it was possible to produce coatings with different levels of non-molten particles in the coating microstructure; from 25 to 50%. The presence of non-molten and molten phases in the coating microstructure, results in an unique mechanical behavior. The nanostructured coatings present a bimodal distribution with respect to the mechanical properties; each mode has origin from one of the phases. The phases were carefully mapped via scanning electron microscopy and microhardness measurements. These results enabled us to create a model for mechanical properties prediction. This finding is considered one of the most important achievements of this work.

Oven rack having integral lubricious, dry porcelain surface

DOEpatents

Ambrose, Jeffrey A; Mackiewicz-Ludtka, Gail; Sikka, Vinod K; Qu, Jun

2014-06-03

A lubricious glass-coated metal cooking article capable of withstanding repeated heating and cooling between room temperature and at least 500.degree. F. without chipping or cracking the glass coating, wherein the glass coating includes about 0.1 to about 20% by weight of a homogeneously distributed dry refractory lubricant material having a particle size less than about 200 .mu.m. The lubricant material is selected from the group consisting of carbon; graphite; boron nitride; cubic boron nitride; molybdenum (FV) sulfide; molybdenum sulfide; molybdenum (IV) selenide; molybdenum selenide, tungsten (IV) sulfide; tungsten disulfide; tungsten sulfide; silicon nitride (Si.sub.3N.sub.4); TiN; TiC; TiCN; TiO.sub.2; TiAlN; CrN; SiC; diamond-like carbon; tungsten carbide (WC); zirconium oxide (ZrO.sub.2); zirconium oxide and 0.1 to 40 weight % aluminum oxide; alumina-zirconia; antimony; antimony oxide; antimony trioxide; and mixtures thereof.

Effect of spark plasma sintering on the microstructure and in vitro behavior of plasma sprayed HA coatings.

PubMed

Yu, L-G; Khor, K A; Li, H; Cheang, P

2003-07-01

The crystalline phases and degree of crystallinity in plasma sprayed calcium phosphate coatings on Ti substrates are crucial factors that influence the biological interactions of the materials in vivo. In this study, plasma sprayed hydroxyapatite (HA) coatings underwent post-spray treatment by the spark plasma sintering (SPS) technique at 500 degrees C, 600 degrees C, and 700 degrees C for duration of 5 and 30 min. The activity of the HA coatings before and after SPS are evaluated in vitro in a simulated body fluid. The surface microstructure, crystallinity, and phase composition of each coating is characterized by scanning electron microscopy and X-ray diffractometry before, and after in vitro incubation. Results show that the plasma sprayed coatings treated for 5 min in SPS demonstrated increased proportion of beta-TCP phase with a preferred-orientation in the (214) plane, and the content of beta-TCP phase corresponded to SPS temperature, up to 700 degrees C. SPS treatment at 700 degrees C for 30 min enhanced the HA content in the plasma spray coating as well. The HA coatings treated in SPS for 5 min revealed rapid surface morphological changes during in vitro incubation (up to 12 days), indicating that the surface activity is enhanced by the SPS treatment. The thickest apatite layer was found in the coating treated by SPS at 700 degrees C for 5 min.

Effects of Traverse Scanning Speed of Spray Nozzle on the Microstructure and Mechanical Properties of Cold-Sprayed Ti6Al4V Coatings

NASA Astrophysics Data System (ADS)

Tan, Adrian Wei-Yee; Sun, Wen; Phang, Yun Peng; Dai, Minghui; Marinescu, Iulian; Dong, Zhili; Liu, Erjia

2017-10-01

Cold spray has the potential to restore damaged aerospace components made from titanium alloy, Ti6Al4V at low temperature (200-400 °C). Traverse scanning speed during deposition is one of the key factors that affect the quality of the Ti6Al4V coatings as it influences the thermal build-up and coating thickness per pass. As there are fewer reported studies on this, this work investigated the effects of different traverse scanning speeds (100, 300 and 500 mm/s) of cold spray nozzle on the microstructure and mechanical properties of cold-sprayed Ti6Al4V coatings. The cross-sectional analysis showed coating porosities reduces with slower traverse speed, from 3.2 to 0.5%. In addition, the microhardness of the coatings increased from about 361-385 HV due to strain hardening. However, the adhesion strength of the coatings to the substrates significantly decreased with reduced traverse speed from about 60 MPa (glue failure) at 500 mm/s to 2.5 MPa (interface failure) at 100 mm/s. Therefore, this study revealed that the control of heat build-up and thickness per pass during the cold spray deposition of the Ti6Al4V coatings is crucial to attain the desirable properties of the coatings.

Wear and Adhesive Failure of Al2O3 Powder Coating Sprayed onto AISI H13 Tool Steel Substrate

NASA Astrophysics Data System (ADS)

Amanov, Auezhan; Pyun, Young-Sik

2016-07-01

In this study, an alumina (Al2O3) ceramic powder was sprayed onto an AISI H13 hot-work tool steel substrate that was subjected to sanding and ultrasonic nanocrystalline surface modification (UNSM) treatment processes. The significance of the UNSM technique on the adhesive failure of the Al2O3 coating and on the hardness of the substrate was investigated. The adhesive failure of the coating sprayed onto sanded and UNSM-treated substrates was investigated by a micro-scratch tester at an incremental load. It was found, based on the obtained results, that the coating sprayed onto the UNSM-treated substrate exhibited a better resistance to adhesive failure in comparison with that of the coating sprayed onto the sanded substrate. Dry friction and wear property of the coatings sprayed onto the sanded and UNSM-treated substrates were assessed by means of a ball-on-disk tribometer against an AISI 52100 steel ball. It was demonstrated that the UNSM technique controllably improved the adhesive failure of the Al2O3 coating, where the critical load was improved by about 31%. Thus, it is expected that the application of the UNSM technique to an AISI H13 tool steel substrate prior to coating may delay the adhesive failure and improve the sticking between the coating and the substrate thanks to the modified and hardened surface.

Modeling of Thickness and Profile Uniformity of Thermally Sprayed Coatings Deposited on Cylinders

NASA Astrophysics Data System (ADS)

Yanjun, Zhang; Wenbo, Li; Dayu, Li; Jinkun, Xiao; Chao, Zhang

2018-02-01

In thermal spraying processes, kinematic parameters of the robot play a decisive role in the coating thickness and profile. In this regard, some achievements have been made to optimize the spray trajectory on flat surfaces. However, few reports have focused on nonholonomic or variable-curvature cylindrical surfaces. The aim of this study is to investigate the correlation between the coating profile, coating thickness, and scanning step, which is determined by the radius of curvature and scanning angle. A mathematical simulation model was developed to predict the thickness of thermally sprayed coatings. Experiments were performed on cylinders with different radiuses of curvature to evaluate the predictive ability of the model.

HVOF-Sprayed Nano TiO2-HA Coatings Exhibiting Enhanced Biocompatibility

NASA Astrophysics Data System (ADS)

Lima, R. S.; Dimitrievska, S.; Bureau, M. N.; Marple, B. R.; Petit, A.; Mwale, F.; Antoniou, J.

2010-01-01

Biomedical thermal spray coatings produced via high-velocity oxy-fuel (HVOF) from nanostructured titania (n-TiO2) and 10 wt.% hydroxyapatite (HA) (n-TiO2-10wt.%HA) powders have been engineered as possible future alternatives to HA coatings deposited via air plasma spray (APS). This approach was chosen due to (i) the stability of TiO2 in the human body (i.e., no dissolution) and (ii) bond strength values on Ti-6Al-4V substrates more than two times higher than those of APS HA coatings. To explore the bioperformance of these novel materials and coatings, human mesenchymal stem cells (hMSCs) were cultured from 1 to 21 days on the surface of HVOF-sprayed n-TiO2 and n-TiO2-10 wt.%HA coatings. APS HA coatings and uncoated Ti-6Al-4V substrates were employed as controls. The profiles of the hMSCs were evaluated for (i) cellular proliferation, (ii) biochemical analysis of alkaline phosphatase (ALP) activity, (iii) cytoskeleton organization (fluorescent/confocal microscopy), and (iv) cell/substrate interaction via scanning electron microscopy (SEM). The biochemical analysis indicated that the hMSCs cultured on n-TiO2-10 wt.%HA coatings exhibited superior levels of bioactivity than hMSCs cultured on APS HA and pure n-TiO2 coatings. The cytoskeleton organization demonstrated a higher degree of cellular proliferation on the HVOF-sprayed n-TiO2-10wt.%HA coatings when compared to the control coatings. These results are considered promising for engineering improved performance in the next generation of thermally sprayed biomedical coatings.

On the Interplay Between Adhesion Strength and Tensile Properties of Thermal Spray Coated Laminates—Part II: Low-Velocity Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Luo, Xiaotao; Smith, Gregory M.; Sampath, Sanjay

2018-02-01

In this two-part study, uniaxial tensile testing was used to evaluate coating/substrate bonding and compared with traditional ASTM C633 bond pull test results for thermal spray (TS) coated steel laminates. In Part I, the rationale, methodology, and applicability of the test to high-velocity TS coatings were demonstrated. In this Part II, the method was investigated for low-velocity TS processes (air plasma spray and arc spray) on equivalent materials. Ni and Ni-5wt.%Al coatings were deposited on steel substrates with three different roughness levels and tested using both uniaxial tensile and ASTM C633 methods. The results indicate the uniaxial tensile approach provides useful information about the nature of the coating/substrate bonding and goes beyond the traditional bond pull test in providing insightful information on the load sharing processes across the interface. Additionally, this proposed methodology alleviates some of the longstanding shortcomings and potentially reduces error associated with the traditional ASTM C633 test. The mechanisms governing the load transfer between the substrate and the coating were investigated, and the influence of Al in the coating material evaluated.

Investigations on the Behavior of HVOF and Cold Sprayed Ni-20Cr Coating on T22 Boiler Steel in Actual Boiler Environment

NASA Astrophysics Data System (ADS)

Bala, Niraj; Singh, Harpreet; Prakash, Satya; Karthikeyan, J.

2012-01-01

High temperature corrosion accompanied by erosion is a severe problem, which may result in premature failure of the boiler tubes. One countermeasure to overcome this problem is the use of thermal spray protective coatings. In the current investigation high velocity oxy-fuel (HVOF) and cold spray processes have been used to deposit commercial Ni-20Cr powder on T22 boiler steel. To evaluate the performance of the coatings in actual conditions the bare as well as the coated steels were subjected to cyclic exposures, in the superheater zone of a coal fired boiler for 15 cycles. The weight change and thickness loss data were used to establish kinetics of the erosion-corrosion. X-ray diffraction, surface and cross-sectional field emission scanning electron microscope/energy dispersive spectroscopy (FE-SEM/EDS) and x-ray mapping techniques were used to analyse the as-sprayed and corroded specimens. The HVOF sprayed coating performed better than its cold sprayed counterpart in actual boiler environment.

Relationships between spray parameters, microstructures and ultrasonic cavitation erosion behavior of HVOF sprayed Fe-based amorphous/nanocrystalline coatings.

PubMed

Qiao, Lei; Wu, Yuping; Hong, Sheng; Zhang, Jianfeng; Shi, Wei; Zheng, Yugui

2017-11-01

Fe-based amorphous/nanocrystalline coatings were prepared on the AISI 321 steel substrate by the high-velocity oxygen-fuel (HVOF) thermal spraying technology. The effect of selected parameters (oxygen flow, kerosene flow and spray distance) on the cavitation erosion resistance (denoted as Rc) of the coating were investigated by using the Taguchi method. Statistical tools such as design of experiments (DOE), signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were used to meet the expected objective. It was concluded that the kerosene flow had greater influence on the Rc of the coating and followed by the spray distance and the oxygen flow, respectively. The optimum spray parameters (OSP) were 963L/min for the oxygen flow, 28L/h for the kerosene flow, and 330mm for the spray distance. The Rc of the coating increased with the increase of hardness or the decrease of porosity, and the hardness had a greater influence on Rc than the porosity. The Fe-based coating deposited under the OSP exhibited the best cavitation erosion resistance in distilled water. The cracks initiated at the edge of the pores and the interfaces between the un-melted or half-melted particles, and finally leaded to the delamination of the coating. Copyright © 2017 Elsevier B.V. All rights reserved.

Pd/Ni-WO3 anodic double layer gasochromic device

DOEpatents

Lee, Se-Hee; Tracy, C. Edwin; Pitts, J. Roland; Liu, Ping

2004-04-20

An anodic double layer gasochromic sensor structure for optical detection of hydrogen in improved response time and with improved optical absorption real time constants, comprising: a glass substrate; a tungsten-doped nickel oxide layer coated on the glass substrate; and a palladium layer coated on the tungsten-doped nickel oxide layer.

Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review

NASA Astrophysics Data System (ADS)

Feuerstein, Albert; Knapp, James; Taylor, Thomas; Ashary, Adil; Bolcavage, Ann; Hitchman, Neil

2008-06-01

The most advanced thermal barrier coating (TBC) systems for aircraft engine and power generation hot section components consist of electron beam physical vapor deposition (EBPVD) applied yttria-stabilized zirconia and platinum modified diffusion aluminide bond coating. Thermally sprayed ceramic and MCrAlY bond coatings, however, are still used extensively for combustors and power generation blades and vanes. This article highlights the key features of plasma spray and HVOF, diffusion aluminizing, and EBPVD coating processes. The coating characteristics of thermally sprayed MCrAlY bond coat as well as low density and dense vertically cracked (DVC) Zircoat TBC are described. Essential features of a typical EBPVD TBC coating system, consisting of a diffusion aluminide and a columnar TBC, are also presented. The major coating cost elements such as material, equipment and processing are explained for the different technologies, with a performance and cost comparison given for selected examples.

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.

A Comparative Study on Ni-Based Coatings Prepared by HVAF, HVOF, and APS Methods for Corrosion Protection Applications

NASA Astrophysics Data System (ADS)

Sadeghimeresht, E.; Markocsan, N.; Nylén, P.

2016-12-01

Selection of the thermal spray process is the most important step toward a proper coating solution for a given application as important coating characteristics such as adhesion and microstructure are highly dependent on it. In the present work, a process-microstructure-properties-performance correlation study was performed in order to figure out the main characteristics and corrosion performance of the coatings produced by different thermal spray techniques such as high-velocity air fuel (HVAF), high-velocity oxy fuel (HVOF), and atmospheric plasma spraying (APS). Previously optimized HVOF and APS process parameters were used to deposit Ni, NiCr, and NiAl coatings and compare with HVAF-sprayed coatings with randomly selected process parameters. As the HVAF process presented the best coating characteristics and corrosion behavior, few process parameters such as feed rate and standoff distance (SoD) were investigated to systematically optimize the HVAF coatings in terms of low porosity and high corrosion resistance. The Ni and NiAl coatings with lower porosity and better corrosion behavior were obtained at an average SoD of 300 mm and feed rate of 150 g/min. The NiCr coating sprayed at a SoD of 250 mm and feed rate of 75 g/min showed the highest corrosion resistance among all investigated samples.

On the Interplay Between Adhesion Strength and Tensile Properties of Thermal Spray Coated Laminates—Part I: High Velocity Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Luo, Xiaotao; Smith, Gregory M.; Sampath, Sanjay

2018-02-01

Adhesion of thermal spray (TS) coatings is an important system level property in coating design and application. Adhesive-based pull testing (ASTM C633) has long been used to evaluate coating/substrate bonding. However, this approach is not always suitable for high velocity spray coatings, for example, where adhesion strengths are routinely greater than the strength of the adhesive bonding agent used in the testing. In this work, a new approach has been proposed to evaluate the adhesion of TS coatings. A systematic investigation of the effects of substrate roughness on both the uniaxial tensile yield strength and traditional bond pull adhesive strength of HVOF Ni and Ni-5wt.%Al, as well as cold-sprayed Ni-coated laminates revealed a strong correlation between these two test methodologies for the respective materials and processes. This approach allows measurement of the adhesion response even where the adhesive method is not applicable, overcoming many of the issues in the traditional ASTM C633. Analysis of cracking patterns of the coatings after 10.5% strain was used to assess the adhesion and cohesion properties. The mechanisms which determine the load transfer between the substrate and the coating are also briefly discussed.

Evolution of the plasma-sprayed microstructure in 7 wt% yttria-stabilized zirconia thermal barrier coatings during uniaxial stress relaxation and the concomitant changes in material properties

NASA Astrophysics Data System (ADS)

Petorak, Christopher

The understanding of failure mechanisms in plasma sprayed 7 wt% yttria stabilized zirconia (YSZ) is a key step toward optimizing thermal barrier coating (TBC) usage, design, and life prediction. The purpose of the present work is to characterize and understand the stress relaxation behavior occurring in plasma-sprayed YSZ coatings, so that the correlating magnitude of unfavorable tensile stress, which coatings experienced upon cooling, may be reduced through microstructural design. The microstructure and properties of as-sprayed coatings changes immensely during service at high temperature, and therefore the effects of long heat-treatment times, and the concomitant change within the microstructure, on the time-dependent mechanical behavior of stand-alone YSZ coatings was studied in parallel with the as-sprayed coating condition. Aside from influencing the mechanical properties, stress relaxation also affects the insulating efficiency of plasma-sprayed 7wt% YSZ coatings. Directionally dependent changes in microstructure due to stress relaxation of a uniaxially applied stress at 1200°C were observed in plasma-sprayed coatings. Small angle neutron scattering (SANS) investigation of coatings after stress relaxation displayed a 46% reduction in the specific surface area connected to the load-orientation dependent closure of void surface area perpendicular to the applied load when compared to coatings sintered in air, i.e. no applied load. These anisotropic microstructural changes were linked to the thermal properties of the coating. For example, a coating stress relaxed from 60 MPa for 5-min at 1200°C exhibited a thermal conductivity of 2.1 W/m-K. A coating that was only heat-treated for 5-min at 1200°C (i.e. no stress applied) exhibited a thermal conductivity of 1.7 W/m·K. In the current study, uniaxial stress relaxation in plasma-sprayed 7wt% YSZ coatings was determined the result of: (1) A more uniform distribution of the applied load with time, (2) A reduction in the SSA associated with void systems due to sintering, specifically the closing and healing of intralamellar cracks perpendicular to the applied stress, and (3) A compaction and closure of void systems under the applied load. These anisotropic changes in microstructure result in distinguishable changes in thermo-mechanical properties, with very minute changes to the overall bulk density.

Assessment of thermal spray coatings for wear and abrasion resistance applications

NASA Astrophysics Data System (ADS)

Karode, Ishaan Nitin

Thermal spray cermet and metallic coatings are extensively used for wear, abrasion and corrosion control in a variety of industries. The first part of the thesis focuses mainly on testing of sand erosion resistance of thermal spray coatings on carbon composites used in the manufacture of helicopter rotor blades. The test set-up employed is a sand blasting machine and is an effort to duplicate the in-flight conditions especially those encountered in hot arid conditions. The technique adopted follows the Department of Defence test method standard. Carbon Composites have excellent stiffness, strength and low weight/density. The strength to weight ratio is high. Hence, these are used in aerospace applications to a large extent. However, the biggest problem encountered with carbon composites is its low abrasion resistance as its surface is very weak. Hence, thermal spray coatings are used to improve the surface properties of CFRP. Zinc bond coats and WC-Co coatings were tested. However, high amount of thermal stresses were developed between the substrate and the coating due to large differences in the CTE's of the both, leading to high mass losses within two minutes and just 130 grams of sand sprayed on to the coatings with the sand blasting machine built; and hence the coatings with CC as a substrate could not qualify for the application. The second part of the thesis focuses on the assessment of different thermal spray coatings used for manufacture of mechanical seals in pumps and analyze the best coating material for the wear resistance application through detail quantification of material loss by block-on-ring test set-up. A machine based on Block-on-ring test set-up following ASTM G77 (Measurement of Adhesive wear resistance of thermal spray coatings) standards was built to duplicate the pump conditions. Thermally sprayed coated materials were tested in different conditions (Load, time, abrasive). WC-Co had the highest wear resistance (lower volume losses) and proved to be the best coating amongst all the other ones followed by Cr2O3 and Al2O3 in deionized water. In the presence of abrasive alumina slurry WC-Co offered the highest abrasive resistance with the lowest volume losses followed by Al2O3 and Cr2O3. In both the testing conditions B4C coating showed lower wear/abrasion resistance giving the highest volume losses.

Systematization of material consumption norms in spray-coating

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lelyukh, I.M.

1995-03-01

Regulating the consumption of materials is particularly important in the economics and organization of spray-coating operations. Three main factors are taken into account when establishing norms for the consumption of the materials of the coating: the physicomechanical and chemical properties of the particles; the shape of the substrate; the dimensions of the substrate. The most important parameters of the spraying regime are the velocity and temperature of the particles. Given the same velocity, the optimum particle kinetic energy for producing a strong bond with the substrate depends on particle shape and size and the density of the materials being spray-coated.more » These parameters determine the heating of the particles in the plasma jet or, in the case of the use of a detonation gun, during collision with the surface of the part. Powders of fragmented or drop shape are used to obtain coatings by spraying.« less

Combined slurry and cavitation erosion resistance of surface modified SS410 stainless steel

NASA Astrophysics Data System (ADS)

Amarendra, H. J.; Pratap, M. S.; Karthik, S.; Punitha Kumara, M. S.; Rajath, H. C.; Ranjith, H.; Shubhatunga, S. V.

2018-03-01

Slurry erosion and combined slurry and cavitation erosion resistance of thermal spray coatings are studied and compared with the as-received martensitic stainless steel material. 70Ni-Cr coatings are deposited on SS 410 material through plasma thermal spray process. The synergy effect of the combined slurry and cavitation erosion resistance of plasma thermal spray coatings were investigated in a slurry pot tester in the presence of bluff bodies known as Cavitation Inducers. Results showed the combined slurry and cavitation erosion resistance of martensitic stainless steel - 410 can be improved by plasma thermal spray coating. It is observed that the plasma spray coated specimens are better erosion resistant than the as- received material, subjected to erosion test under similar conditions. As-received and the surface modified steels are mechanically characterized for its hardness, bending. Morphological studies are conducted through scanning electron microscope.

Preparation and Bond Properties of Thermal Barrier Coatings on Mg Alloy with Sprayed Al or Diffused Mg-Al Intermetallic Interlayer

NASA Astrophysics Data System (ADS)

Fan, Xizhi; Wang, Ying; Zou, Binglin; Gu, Lijian; Huang, Wenzhi; Cao, Xueqiang

2014-02-01

Sprayed Al or diffused Mg-Al layer was designed as interlayer between the thermal barrier coatings (TBCs) and Mg alloy substrate. The effects of the interlayer on the bond properties of the coats were investigated. Al layers were prepared by arc spraying and atmospheric plasma spraying (APS), respectively. Mg-Al diffused layer was obtained after the heat treatment of the sprayed sample (Mg alloy with APS Al coat) at 400 °C. The results show that sprayed Al interlayer does not improve the bond stability of TBCs. The failure of the TBCs on Mg alloy with Al interlayer occurs mainly due to the low strength of Al layer. Mg-Al diffused layer improves corrosion resistance of substrate and the bond interface. The TBCs on Mg alloy with Mg-Al diffused interlayer shows better bond stability than the sample of which the TBCs is directly sprayed on Mg alloy substrate by APS.

In vitro fatigue behaviour of vacuum plasma and detonation gun sprayed hydroxyapatite coatings.

PubMed

Gledhill, H C; Turner, I G; Doyle, C

2001-06-01

The fatigue behaviour of vacuum plasma sprayed (VPS) and detonation gun sprayed (DGUN) hydroxyapatite coatings on titanium substrates has been compared in air and in buffered Ringer's solution. There was an increase in the surface microcracking and bulk porosity of both types of coating tested in air. After 1 million cycles in Ringer's solution the VPS coatings had completely delaminated from their substrates. In contrast the DGUN coatings retained their integrity when tested up to 10 million cycles but were beginning to show signs of delamination at the interface.

Plasma Spraying of Ceramics with Particular Difficulties in Processing

NASA Astrophysics Data System (ADS)

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

2015-01-01

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

Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers

NASA Astrophysics Data System (ADS)

Oksa, M.; Metsäjoki, J.; Kärki, J.

2015-01-01

There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. Many of them encounter serious problems with high-temperature corrosion due to detrimental elements such as chlorides, alkali metals, and heavy metals. By HVOF spraying, it is possible to produce very dense and well-adhered coatings, which can be applied for corrosion protection of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation for 5900 h at 550 and 750 °C. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo, and Ni-Cr-Ti. CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-Cr coating structures. Reference materials were ferritic steel T92 and nickel super alloy A263. The circulating fluidized bed boiler burnt a mixture of wood, peat and coal. The coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

Argon Shrouded Plasma Spraying of Tantalum over Titanium for Corrosion Protection in Fluorinated Nitric Acid Media

NASA Astrophysics Data System (ADS)

Vetrivendan, E.; Jayaraj, J.; Ningshen, S.; Mallika, C.; Kamachi Mudali, U.

2018-02-01

Argon shrouded plasma spraying (ASPS) was used to deposit a Ta coating on commercially pure Ti (CP-Ti) under inert argon, for dissolver vessel application in the aqueous spent fuels reprocessing plant with high plutonium content. Oxidation during plasma spraying was minimized by shrouding argon system. Porosity and oxide content were controlled by optimizing the spraying parameters, to obtain a uniform and dense Ta coating. The Ta particle temperature and velocity were optimized by judiciously controlling the spray parameters, using a spray diagnostic charge-coupled device camera. The corrosion resistance of the Ta coatings developed by ASPS was investigated by electrochemical studies in 11.5 M HNO3 and 11.5 M HNO3 + 0.05 M NaF. Similarly, the durability of the ASPS Ta coating/substrate was evaluated as per ASTM A262 Practice-C test in boiling nitric acid and fluorinated nitric acid for 240 h. The ASPS Ta coating exhibited higher corrosion resistance than the CP-Ti substrate, as evident from electrochemical studies, and low corrosion rate with excellent coating stability in boiling nitric, and fluorinated nitric acid. The results of the present study revealed that tantalum coating by ASPS is a promising strategy for improving the corrosion resistance in the highly corrosive reprocessing environment.

Macroscale and Nanoscale Morphology Evolution during in Situ Spray Coating of Titania Films for Perovskite Solar Cells.

PubMed

Su, Bo; Caller-Guzman, Herbert A; Körstgens, Volker; Rui, Yichuan; Yao, Yuan; Saxena, Nitin; Santoro, Gonzalo; Roth, Stephan V; Müller-Buschbaum, Peter

2017-12-20

Mesoporous titania is a cheap and widely used material for photovoltaic applications. To enable a large-scale fabrication and a controllable pore size, we combined a block copolymer-assisted sol-gel route with spray coating to fabricate titania films, in which the block copolymer polystyrene-block-poly(ethylene oxide) (PS-b-PEO) is used as a structure-directing template. Both the macroscale and nanoscale are studied. The kinetics and thermodynamics of the spray deposition processes are simulated on a macroscale, which shows a good agreement with the large-scale morphology of the spray-coated films obtained in practice. On the nanoscale, the structure evolution of the titania films is probed with in situ grazing incidence small-angle X-ray scattering (GISAXS) during the spray process. The changes of the PS domain size depend not only on micellization but also on solvent evaporation during the spray coating. Perovskite (CH 3 NH 3 PbI 3 ) solar cells (PSCs) based on sprayed titania film are fabricated, which showcases the suitability of spray-deposited titania films for PSCs.

Effect of Nozzle Geometry on the Microstructure and Properties of HVAF-Sprayed WC-10Co4Cr and Cr3C2-25NiCr Coatings

NASA Astrophysics Data System (ADS)

Matikainen, V.; Koivuluoto, H.; Vuoristo, P.; Schubert, J.; Houdková, Š.

2018-04-01

Thermally sprayed hard metal coatings are the industrial standard solution for numerous demanding applications to improve wear resistance. In the aim of improving coating quality by utilising finer particle size distributions, several approaches have been studied to control the spray temperature. The most viable solution is to use the modern high velocity air-fuel (HVAF) spray process, which has already proven to produce high-quality coatings with dense structures. In HVAF spray process, the particle heating and acceleration can be efficiently controlled by changing the nozzle geometry. In this study, fine WC-10Co4Cr and Cr3C2-25NiCr powders were sprayed with three nozzle geometries to investigate their effect on the particle temperature, velocity and coating microstructure. The study demonstrates that the particle melting and resulting carbide dissolution can be efficiently controlled by changing the nozzle geometry from cylindrical to convergent-divergent. Moreover, the average particle velocity was increased from 780 to over 900 m/s. The increase in particle velocity significantly improved the coating structure and density. Further evaluation was carried out to resolve the effect of particle in-flight parameters on coating structure and cavitation erosion resistance, which was significantly improved in the case of WC-10Co4Cr coatings with the increasing average particle velocity.

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.

Flame Spray Strain Gages with Improved Durability and Lifetimes

NASA Technical Reports Server (NTRS)

Fralick, Gustave (Technical Monitor); Gregory, Otto

2003-01-01

The focus of this APP research program was to improve the bond coats used in the fabrication of flame sprayed instrumentation. Typically. a bond coat is applied to a superalloy surface prior to the application of a thin dielectric coating onto which instrumentation is placed. After affixing the instrumentation, a much thicker ceramic topcoat is typically applied to protect the instrumentation from harsh environments. The fatigue life of NiCoCrAlY coated superalloys was extended beyond current state-of-the-art by relatively simple and cost effective means. Heat treatment in reduced oxygen partial pressures at 1750 to 1800 F effectively doubled the fatigue life of NiCoCrAlY coated substrates relative to as-sprayed substrates and when used in conjunction with platinum diffusion barriers yielded a four fold increase in the fatigue life of NiCoCrAlY coated substrates. Further improvements in the fatigue life of thermally sprayed coatings were made by employing intermediate coatings, which minimized thermal expansion differences between the bond coat and top coat. Combinatorial chemistry experiments yielded an optimum composition for an intermediate TCE matching coating that showed considerable promise in extending the fatigue life of thermal spray instrumentation. The intermediate coating had two functions: to reduce the surface roughness of the peaks and valleys associated with the as-sprayed NiCoCrAlY bond coat, and to produce a thin layer of a mixture of Al2O3 and NiCoCrAlY that exhibited an intermediate TCE. The optimal composition of the intermediate coating consisted of 60 wt% Al2O3 and 40 wt% NiCoCrAlY, as determined by energy dispersive analysis of x-rays (EDS). Intermediate coatings having this composition were prepared by physical vapor deposition and the resulting coating systems are being evaluated in our test facility.

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

DOE PAGES

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

2015-04-20

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

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

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

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

Mathematical simulation of surface heating during plasma spraying

NASA Astrophysics Data System (ADS)

Bogdanovich, V. I.; Giorbelidze, M. G.

2017-02-01

A mathematical model of temperature distribution over the flat ‘coating-substrate’ system section during plasma spraying, taking into account a plasma gun travel and coating buildup has been developed. It has been shown that the temperature value in the near-surface layer of the sprayed coating during the plasma gun passage can significantly exceed the temperature values in underlayers.

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.

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.

Advances in Thermal Spray Coatings for Gas Turbines and Energy Generation: A Review

NASA Astrophysics Data System (ADS)

Hardwicke, Canan U.; Lau, Yuk-Chiu

2013-06-01

Functional coatings are widely used in energy generation equipment in industries such as renewables, oil and gas, propulsion engines, and gas turbines. Intelligent thermal spray processing is vital in many of these areas for efficient manufacturing. Advanced thermal spray coating applications include thermal management, wear, oxidation, corrosion resistance, sealing systems, vibration and sound absorbance, and component repair. This paper reviews the current status of materials, equipment, processing, and properties' aspects for key coatings in the energy industry, especially the developments in large-scale gas turbines. In addition to the most recent industrial advances in thermal spray technologies, future technical needs are also highlighted.

In Situ Acoustic Monitoring of Thermal Spray Process Using High-Frequency Impulse Measurements

NASA Astrophysics Data System (ADS)

Tillmann, Wolfgang; Walther, Frank; Luo, Weifeng; Haack, Matthias; Nellesen, Jens; Knyazeva, Marina

2018-01-01

In order to guarantee their protective function, thermal spray coatings must be free from cracks, which expose the substrate surface to, e.g., corrosive media. Cracks in thermal spray coatings are usually formed because of tensile residual stresses. Most commonly, the crack occurrence is determined after the thermal spraying process by examination of metallographic cross sections of the coating. Recent efforts focus on in situ monitoring of crack formation by means of acoustic emission analysis. However, the acoustic signals related to crack propagation can be absorbed by the noise of the thermal spraying process. In this work, a high-frequency impulse measurement technique was applied to separate different acoustic sources by visualizing the characteristic signal of crack formation via quasi-real-time Fourier analysis. The investigations were carried out on a twin wire arc spraying process, utilizing FeCrBSi as a coating material. The impact of the process parameters on the acoustic emission spectrum was studied. Acoustic emission analysis enables to obtain global and integral information on the formed cracks. The coating morphology and coating defects were inspected using light microscopy on metallographic cross sections. Additionally, the resulting crack patterns were imaged in 3D by means of x-ray microtomography.

Milestones in Functional Titanium Dioxide Thermal Spray Coatings: A Review

NASA Astrophysics Data System (ADS)

Gardon, M.; Guilemany, J. M.

2014-04-01

Titanium dioxide has been the most investigated metal oxide due to its outstanding performance in a wide range of applications, chemical stability and low cost. Coating processes that can produce surfaces based on this material have been deeply studied. Nevertheless, the necessity of coating large areas by means of rapid manufacturing processes renders laboratory-scale techniques unsuitable, leading to a noteworthy interest from the thermal spray (TS) community in the development of significant intellectual property and a large number of scientific publications. This review unravels the relationship between titanium dioxide and TS technologies with the aim of providing detailed information related to the most significant achievements, lack of knowhow, and performance of TS TiO2 functional coatings in photocatalytic, biomedical, and other applications. The influence of thermally activated techniques such as atmospheric plasma spray and high-velocity oxygen fuel spray on TiO2 feedstock based on powders and suspensions is revised; the influence of spraying parameters on the microstructural and compositional changes and the final active behavior of the coating have been analyzed. Recent findings on titanium dioxide coatings deposited by cold gas spray and the capacity of this technology to prevent loss of the nanostructured anatase metastable phase are also reviewed.

Corrosion Protection of Nd-Fe Magnets via Phophatization, Silanization and Electrostatic Spraying with Organic Resin Composite Coatings

NASA Astrophysics Data System (ADS)

Ding, Xia; Li, Jingjie; Li, Musen; Ge, Shengsong; Wang, Xiuchun; Ding, Kaihong; Cui, Shengli; Sun, Yongcong

2014-09-01

Nd-Fe-B permanent magnets possess excellent properties. However, they are highly sensitive to the attack of corrosive environment. The aim of this work is to improve the corrosion resistance of the magnets by phosphatization, silanization, and electrostatic spraying with organic resin composite coatings. Field emission scanning electron microscope (FE-SEM) and energy dispersive spectrometer (EDS) tests showed that uniform phosphate conversion coatings and spray layers were formed on the surface of the Nd-Fe-B magnets. Neutral salt spray tests exhibited that, after treated by either phosphating, silanization or electrostatic spraying, the protectiveness of Nd-Fe-B alloys was apparently increased. And corrosion performance of magnets treated with silane only was slightly inferior to those of phosphatized ones. However, significant improvement in corrosion protection was achieved after two-step treatments, i.e. by top-coating spray layer with phosphate or silane films underneath. Grid test indicated that the phosphate and silane coating were strongly attached to the substrate while silane film was slightly weaker than the phosphate-treated ones. Magnetic property analysis revealed phosphatization, silanization, and electrostatic spraying caused decrease in magnetism, but silanization had the relatively smaller effect.

Ternary ceramic thermal spraying powder and method of manufacturing thermal sprayed coating using said powder

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vogli, Evelina; Sherman, Andrew J.; Glasgow, Curtis P.

The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance againstmore » corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.« less

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.

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.

Effect of epoxy resin sealing on corrosion resistance of arc spraying aluminium coating using cathode electrophoresis method

NASA Astrophysics Data System (ADS)

Pang, Xuming; Wang, Runqiu; Wei, Qian; Zhou, Jianxin

2018-01-01

Arc-sprayed Al coating was sealed with epoxy resin using the cathode electrophoresis method. The anti-corrosion performance of the coatings sealed with epoxy resin was studied by means of a 3.5 wt.% NaCl solution test at 40 °C. For comparison, the anti-corrosion performance of Al coating sealed with boiling water was also performed under the same conditions. The results show that epoxy resin with a thickness of about 20 microns can entirely cover open pores and decreases the surface roughness of the as-sprayed Al coating, and the epoxy resin even permeates into the gaps among lamellar splats from open pores. After corrosion, the thickness of the epoxy resin layer is unchanged and can still cover the as-sprayed Al coating entirely. However, the thickness of Al coating sealed with boiling water decreases from 100 to 40 microns, which indicates that the arc-sprayed Al coating has much better corrosion resistance than the Al coating sealed with boiling water. Meanwhile, the content of substituted benzene ring in the epoxy resin increases, but aromatic ring decreases according to the fourier transform infrared spectra, which will cause the rigidity of the epoxy resin to increase, but the toughness slightly decreases after corrosion.

A critical assessment of in-flight particle state during plasma spraying of YSZ and its implications on coating properties and process reliability

NASA Astrophysics Data System (ADS)

Srinivasan, Vasudevan

Air plasma spray is inherently complex due to the deviation from equilibrium conditions, three dimensional nature, multitude of interrelated (controllable) parameters and (uncontrollable) variables involved, and stochastic variability at different stages. The resultant coatings are complex due to the layered high defect density microstructure. Despite the widespread use and commercial success for decades in earthmoving, automotive, aerospace and power generation industries, plasma spray has not been completely understood and prime reliance for critical applications such as thermal barrier coatings on gas turbines are yet to be accomplished. This dissertation is aimed at understanding the in-flight particle state of the plasma spray process towards designing coatings and achieving coating reliability with the aid of noncontact in-flight particle and spray stream sensors. Key issues such as the phenomena of optimum particle injection and the definition of spray stream using particle state are investigated. Few strategies to modify the microstructure and properties of Yttria Stabilized Zirconia coatings are examined systematically using the framework of process maps. An approach to design process window based on design relevant coating properties is presented. Options to control the process for enhanced reproducibility and reliability are examined and the resultant variability is evaluated systematically at the different stages in the process. The 3D variability due to the difference in plasma characteristics has been critically examined by investigating splats collected from the entire spray footprint.

Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 1: Effect of spray parameters on the performance of several lots of partially stabilized zirconia-yttria powder

NASA Technical Reports Server (NTRS)

Miller, Robert A.; Leissler, George W.; Jobe, J. Marcus

1993-01-01

Initial experiments conducted on thermal barrier coatings prepared in the newly upgraded research plasma spray facility and the burner rig test facilities are discussed. Part 1 discusses experiments which establish the spray parameters for three baseline zirconia-yttria coatings. The quality of five similar coating lots was judged primarily by their response to burner rig exposure supplemented by data from other sources such as specimen characterizations and thermal diffusivity measurements. After allowing for burner rig variability, although there appears to be an optimum density (i.e., optimum microstructure) for maximum burner rig life, the distribution tends to be rather broad about the maximum. In Part 2, new hafnia-yttria-based coatings were evaluated against both baseline and alternate zirconia-yttria coatings. The hafnia-yttria coatings and the zirconia-yttria coatings that were prepared by an alternate powder vendor were very sensitive to plasma spray parameters, in that high-quality coatings were only obtained when certain parameters were employed. The reasons for this important observation are not understood. Also not understood is that the first of two replicate specimens sprayed for Part 1 consistently performed better than the second specimen. Subsequent experiments did not display this spray order affect, possibly because a chiller was installed in the torch cooling water circuit. Also, large changes in coating density were observed after switching to a new lot of electrodes. Analyses of these findings were made possible, in part, because of the development of a sensitive density measurement technique described herein in detail. The measured thermal diffusivities did not display the expected strong relationship with porosity. This surprising result was believed to have been caused by increased microcracking of the denser coatings on the stainless steel substrates.

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.

Influence of Feedstock Materials and Spray Parameters on Thermal Conductivity of Wire-Arc-Sprayed Coatings

NASA Astrophysics Data System (ADS)

Yao, H. H.; Zhou, Z.; Wang, G. H.; He, D. Y.; Bobzin, K.; Zhao, L.; Öte, M.; Königstein, T.

2017-03-01

To manufacture a protective coating with high thermal conductivity on drying cylinders in paper production machines, a FeCrB-cored wire was developed, and the spraying parameters for wire-arc spraying were optimized in this study. The conventional engineering materials FeCrAl and FeCrMo coatings were produced as the reference coatings under the same experimental condition. It has been shown that the oxide content in coating influences the thermal conductivity of coating significantly. The FeCrB coating exhibits a relative higher thermal conductivity due to the lower oxide content in comparison with conventional FeCrAl and FeCrMo coatings. Moreover, the oxidation of in-flight particles can be reduced by decreasing the standoff distance contributing to the increase in the thermal conductivity of coating. Total energy consumption of a papermaking machine can be significantly reduced if the coatings applied to dryer section exhibit high thermal conductivity. Therefore, the FeCrB coating developed in this study is a highly promising coating system for drying cylinders regarding the improved thermal conductivity and low operation costs in paper production industry.

Improving Erosion Resistance of Plasma-Sprayed Ceramic Coatings by Elevating the Deposition Temperature Based on the Critical Bonding Temperature

NASA Astrophysics Data System (ADS)

Yao, Shu-Wei; Yang, Guan-Jun; Li, Cheng-Xin; Li, Chang-Jiu

2018-01-01

Interlamellar bonding within plasma-sprayed coatings is one of the most important factors dominating the properties and performance of coatings. The interface bonding between lamellae significantly influences the erosion behavior of plasma-sprayed ceramic coatings. In this study, TiO2 and Al2O3 coatings with different microstructures were deposited at different deposition temperatures based on the critical bonding temperature concept. The erosion behavior of ceramic coatings was investigated. It was revealed that the coatings prepared at room temperature exhibit a typical lamellar structure with numerous unbonded interfaces, whereas the coatings deposited at the temperature above the critical bonding temperature present a dense structure with well-bonded interfaces. The erosion rate decreases sharply with the improvement of interlamellar bonding when the deposition temperature increases to the critical bonding temperature. In addition, the erosion mechanisms of ceramic coatings were examined. The unbonded interfaces in the conventional coatings act as pre-cracks accelerating the erosion of coatings. Thus, controlling interlamellar bonding formation based on the critical bonding temperature is an effective approach to improve the erosion resistance of plasma-sprayed ceramic coatings.

Understanding the effects of process parameters on the properties of cold gas dynamic sprayed pure titanium coatings

NASA Astrophysics Data System (ADS)

Wong, Wilson

The cold gas dynamic spraying of commercially pure titanium coatings was investigated. Specifically, the relationship between several key cold spray parameters on the quality of the resulting coatings was studied in order to gain a more thorough understanding of the cold spray process. To achieve this goal, three distinct investigations were performed. The first part of the investigation focussed on the effect of propelling gas, particularly helium and nitrogen, during the cold spraying of titanium coatings. Coatings were characterised by SEM and were evaluated for their deposition efficiency (DE), microhardness, and porosity. In selected conditions, three particle velocities were investigated such that for each condition, the propelling gasses temperature and pressure were attuned to attain similar particle velocities for each gas. In addition, a thick and fully dense cold sprayed titanium coating was achieved with optimised spray parameters and nozzle using helium. The corresponding average particle velocity was 1173 m/s. The second part of the investigation studied the effect of particle morphology (spherical, sponge, and irregular) and size distributions (mean particle sizes of 20, 29, and 36 mum) of commercially pure titanium on the mechanical properties of the resulting cold sprayed coatings. Numerous powder and coating characterisations were performed. From these data, semi-empirical flow (stress-strain) curves were generated based on the Johnson-Cook plasticity model which could be used as a measure of cold sprayability. Cold sprayability can be defined as the ease with which a powder can be cold sprayed. It was found that the sponge and irregular commercially pure titanium powders had higher oxygen content, poorer powder flowability, higher compression ratio, lower powder packing factor, and higher average particle impact velocities compared to the spherical powders. XRD results showed no new phases present when comparing the various feedstock powders to their corresponding coatings. For all feedstock powder morphologies, it was observed that the larger the particle size, the higher the temperature generated on impact. For the spherical powders, the higher the temperature generated on impact, the lower the stress needed to deform the particle. In addition, as the kinetic energy of the impacting particle increased, the flow peak stress decreased while the final strain increased. Furthermore, higher final flow strains were associated with higher coating DeltaHV 10 (between the coatings and the feedstock powders). Similar relationships are expected to exist for the sponge and irregular feedstock powders. Based on porosity, the spherical medium powder was found to have the best cold sprayability. The final part of the investigation focussed on the effect of substrate surface roughness and coating thickness on the adhesion strength of commercially pure titanium cold sprayed coatings onto Steel 1020, Al 6061, and Ti substrates. Adhesion strength was measured by tensile/pull tests according to ASTM C-633-01 standard. Through-thickness residual stresses of selected coatings were measured using the modified layer removal method (MLRM). In addition, mean coating residual stresses were calculated from MLRM results. It was found that adhesion strength increases with increasing substrate surface roughness and decreases with increasing coating thickness. Furthermore, mean coating residual stresses were correlated with adhesion strength and it was suggested that higher adhesion strengths are associated with higher mean compressive stresses and a higher probability for adiabatic shear instability to occur due to the higher particle impact velocities. In general, it was found that under similar cold spray conditions and substrate surface preparation method, adhesion strength was strongest for commercially pure titanium coatings deposited onto Al 6061, followed by Ti, then Steel 1020.

The Development of an Environmentally Compliant, Multi-Functional Aerospace Coating Using Molecular- and Nano-Engineering Methods

DTIC Science & Technology

2006-10-02

Al -TM-RE) alloy which could by spray applied using various deposition routes or deposited as a powder that is...corrosion properties of various spray deposited alloys from their properties as defective coatings on 2024-T3. "* HVOF spray deposited and cold spray ...layer. "* A method has been developed to distinguish the intrinsic corrosion properties of various spray deposited

Kinetics of carbide formation in the molybdenum-tungsten coatings used in the ITER-like Wall

NASA Astrophysics Data System (ADS)

Maier, H.; Rasinski, M.; von Toussaint, U.; Greuner, H.; Böswirth, B.; Balden, M.; Elgeti, S.; Ruset, C.; Matthews, G. F.

2016-02-01

The kinetics of tungsten carbide formation was investigated for tungsten coatings on carbon fibre composite with a molybdenum interlayer as they are used in the ITER-like Wall in JET. The coatings were produced by combined magnetron sputtering and ion implantation. The investigation was performed by preparing focused ion beam cross sections from samples after heat treatment in argon atmosphere. Baking of the samples was done at temperatures of 1100 °C, 1200 °C, and 1350 °C for hold times between 30 min and 20 h. It was found that the data can be well described by a diffusional random walk with a thermally activated diffusion process. The activation energy was determined to be (3.34 ± 0.11) eV. Predictions for the isothermal lifetime of this coating system were computed from this information.

Application of diffusion barriers to the refractory fibers of tungsten, columbium, carbon and aluminum oxide

NASA Technical Reports Server (NTRS)

Douglas, F. C.; Paradis, E. L.; Veltri, R. D.

1973-01-01

A radio frequency powered ion-plating system was used to plate protective layers of refractory oxides and carbide onto high strength fiber substrates. Subsequent overplating of these combinations with nickel and titanium was made to determine the effectiveness of such barrier layers in preventing diffusion of the overcoat metal into the fibers with consequent loss of fiber strength. Four substrates, five coatings, and two metal matrix materials were employed for a total of forty material combinations. The substrates were tungsten, niobium, NASA-Hough carbon, and Tyco sapphire. The diffusion-barrier coatings were aluminum oxide, yttrium oxide, titanium carbide, tungsten carbide with 14% cobalt addition, and zirconium carbide. The metal matrix materials were IN 600 nickel and Ti 6/4 titanium. Adhesion of the coatings to all substrates was good except for the NASA-Hough carbon, where flaking off of the oxide coatings in particular was observed.

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.

Corrosion resistant neutron absorbing coatings

DOEpatents

Choi, Jor-Shan [El Cerrito, CA; Farmer, Joseph C [Tracy, CA; Lee, Chuck K [Hayward, CA; Walker, Jeffrey [Gaithersburg, MD; Russell, Paige [Las Vegas, NV; Kirkwood, Jon [Saint Leonard, MD; Yang, Nancy [Lafayette, CA; Champagne, Victor [Oxford, PA

2012-05-29

A method of forming a corrosion resistant neutron absorbing coating comprising the steps of spray or deposition or sputtering or welding processing to form a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material. Also a corrosion resistant neutron absorbing coating comprising a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material.

Corrosion resistant neutron absorbing coatings

DOEpatents

Choi, Jor-Shan; Farmer, Joseph C; Lee, Chuck K; Walker, Jeffrey; Russell, Paige; Kirkwood, Jon; Yang, Nancy; Champagne, Victor

2013-11-12

A method of forming a corrosion resistant neutron absorbing coating comprising the steps of spray or deposition or sputtering or welding processing to form a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material. Also a corrosion resistant neutron absorbing coating comprising a composite material made of a spray or deposition or sputtering or welding material, and a neutron absorbing material.

Friction surfaced Stellite6 coatings

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rao, K. Prasad; Damodaram, R.; Rafi, H. Khalid, E-mail: khalidrafi@gmail.com

2012-08-15

Solid state Stellite6 coatings were deposited on steel substrate by friction surfacing and compared with Stellite6 cast rod and coatings deposited by gas tungsten arc and plasma transferred arc welding processes. Friction surfaced coatings exhibited finer and uniformly distributed carbides and were characterized by the absence of solidification structure and compositional homogeneity compared to cast rod, gas tungsten arc and plasma transferred coatings. Friction surfaced coating showed relatively higher hardness. X-ray diffraction of samples showed only face centered cubic Co peaks while cold worked coating showed hexagonally close packed Co also. - Highlights: Black-Right-Pointing-Pointer Stellite6 used as coating material formore » friction surfacing. Black-Right-Pointing-Pointer Friction surfaced (FS) coatings compared with casting, GTA and PTA processes. Black-Right-Pointing-Pointer Finer and uniformly distributed carbides in friction surfaced coatings. Black-Right-Pointing-Pointer Absence of melting results compositional homogeneity in FS Stellite6 coatings.« less

Effects of service condition on rolling contact fatigue failure mechanism and lifetime of thermal spray coatings—A review

NASA Astrophysics Data System (ADS)

Cui, Huawei; Cui, Xiufang; Wang, Haidou; Xing, Zhiguo; Jin, Guo

2015-01-01

The service condition determines the Rolling Contact Fatigue(RCF) failure mechanism and lifetime under ascertain material structure integrity parameter of thermal spray coating. The available literature on the RCF testing of thermal spray coatings under various condition services is considerable; it is generally difficult to synthesize all of the result to obtain a comprehensive understanding of the parameters which has a great effect on a thermal spray coating's resistance of RCF. The effects of service conditions(lubrication states, contact stresses, revolve speed, and slip ratio) on the changing of thermal spray coatings' contact fatigue lifetime is introduced systematically. The effects of different service condition on RCF failure mechanism of thermal spray coating from the change of material structure integrity are also summarized. Moreover, In order to enhance the RCF performance, the parameter optimal design formula of service condition and material structure integrity is proposed based on the effect of service condition on thermal spray coatings' contact fatigue lifetime and RCF failure mechanism. The shortage of available literature and the forecast focus in future researches are discussed based on available research. The explicit result of RCF lifetime law and parameter optimal design formula in term of lubrication states, contact stresses, revolve speed, and slip ratio, is significant to improve the RCF performance on the engineering application.

Medical equipment bio-capability processes using the atmospheric plasma-sprayed titanium coating

NASA Astrophysics Data System (ADS)

Rezaei, F.; Saviz, S.; Ghoranneviss, M.

2017-12-01

Antibacterial surfaces such as titanium coatings are able to have capability in the human body environment. In this study, titanium coatings are deposited on the 316 stainless steel substrates by a handmade plasma spray system. Some mechanical, chemical properties and microstructure of the created titanium layer are determined to evaluate the quality of coating. The XRD, SEM, adhesion tests from cross cut and corrosion test by potentiodynamic are used. During the different stages, some of the parameters are changed in different samples to achieve the best quality in the coating. It is shown that by increasing the spray time, the production of nanoparticles begins. On the other hand, the best layers are created when the spray main gas flow rate has a certain amount.

Replacement of corrosion protection chromate primers and paints used in cryogenic applications on the Space Shuttle with wire arc sprayed aluminum coatings

NASA Technical Reports Server (NTRS)

Daniel, R. L.; Sanders, H. L.; Zimmerman, F. R.

1995-01-01

With the advent of new environmental laws restricting volatile organic compounds and hexavalent chrome emissions, 'environmentally safe' thermal spray coatings are being developed to replace the traditional corrosion protection chromate primers. A wire arc sprayed aluminum coating is being developed for corrosion protection of low pressure liquid hydrogen carrying ducts on the Space Shuttle Main Engine. Currently, this hardware utilizes a chromate primer to provide protection against corrosion pitting and stress corrosion cracking induced by the cryogenic operating environment. The wire are sprayed aluminum coating has been found to have good potential to provide corrosion protection for flight hardware in cryogenic applications. The coating development, adhesion test, corrosion test and cryogenic flexibility test results will be presented.

Deuterium diffusion and retention in tungsten coated with barrier layer during ion irradiation

NASA Astrophysics Data System (ADS)

Begrambekov, L. B.; Kaplevsky, A. S.; Dovganyuk, S. S.; Evsin, A. E.; Baryshnikova, I. E.

2017-12-01

The results of the comparative analysis of low-temperature desorption of deuterium from tungsten coated with aluminum and yttrium films under the irradiation by hydrogen plasma with oxygen impurity are presented. The irradiation of aluminum or yttrium coating by H2+1%O2 plasma leads to the desorption of implanted deuterium from the samples. It was shown that the number of atoms desorbed depends on the sign of enthalpy of hydrogen solution in the metal film.

The effect of a simple annealing heat treatment on the mechanical properties of cold-sprayed aluminum

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hall, Aaron Christopher; Roemer, Timothy John; Hirschfeld, Deidre A.

2004-11-01

Cold spray, a new member of the thermal spray process family, can be used to prepare dense, thick metal coatings. It has tremendous potential as a spray-forming process. However, it is well known that significant cold work occurs during the cold spray deposition process. This cold work results in hard coatings but relatively brittle bulk deposits. This work investigates the mechanical properties of cold-sprayed aluminum and the effect of annealing on those properties. Cold spray coatings approximately 1 cm thick were prepared using three different feedstock powders: Valimet H-10; Valimet H-20; and Brodmann Flomaster. ASTM E8 tensile specimens were machinedmore » from these coatings and tested using standard tensile testing procedures. Each material was tested in two conditions: as-sprayed; and after a 300 C, 22 h air anneal. The as-sprayed material showed high ultimate strength and low ductility, with <1% elongation. The annealed samples showed a reduction in ultimate strength but a dramatic increase in ductility, with up to 10% elongation. The annealed samples exhibited mechanical properties that were similar to those of wrought 1100 H14 aluminum. Microstructural examination and fractography clearly showed a change in fracture mechanism between the as-sprayed and annealed materials. These results indicate good potential for cold spray as a bulk-forming process.« less

The effect of a simple annealing heat treatement on the mechanical properties of cold-sprayed aluminium.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hall, Aaron Christopher; Roemer, Timothy John; Hirschfeld, Deidre A.

2005-08-01

Cold spray, a new member of the thermal spray process family, can be used to prepare dense, thick metal coatings. It has tremendous potential as a spray-forming process. However, it is well known that significant cold work occurs during the cold spray deposition process. This cold work results in hard coatings but relatively brittle bulk deposits. This work investigates the mechanical properties of cold-sprayed aluminum and the effect of annealing on those properties. Cold spray coatings approximately 1 cm thick were prepared using three different feedstock powders: Valimet H-10: Valimet H-20: and Brodmann Flomaster. ASTM E8 tensile specimens were machinedmore » from these coatings and tested using standard tensile testing procedures. Each material was tested in two conditions: as-sprayed; and after a 300 C, 22h air anneal. The as-sprayed material showed high ultimate strength and low ductility, with <1% elongation. The annealed samples showed a reduction in ultimate strength but a dramatic increase in ductility, with up to 10% elongation. The annealed samples exhibited mechanical properties that were similar to those of wrought 1100 H14 aluminum. Microstructural examination and fractography clearly showed a change in fracture mechanism between the as-sprayed and annealed materials. These results indicate good potential for cold spray as a bulkforming process.« less

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.

Fast turn-on osmium coated cathode

NASA Astrophysics Data System (ADS)

Marrian, C. R. K.; Haas, G. A.; Shih, A.

1984-03-01

This abstract discloses a fast turn-on refractory coated cathode comprising a porous tungsten metal matrix impregnated with barium calcium aluminate and coated with osmium. The osmium coating has a planned series of interruptions with each interruption being on the order of several microns in width to thereby expose the tungsten. These interruptions permit the barium and oxygen from the impregnant to rise to the cathode surface during activation or reactivation to form a desired near monolayer of barium and oxygen to enhance electron emission. Thus, this cathode design provides a fast turn-on characteristic even after shelf storage.

Surface studies of thermionic cathodes and the mechanism of operation of an impregnated tungsten cathode

NASA Technical Reports Server (NTRS)

Forman, R.

1976-01-01

The surface properties of conventional impregnated cathodes were investigated by the use of Auger spectroscopy and work function measurements, and these were compared with a synthesized barium or barium oxide coated tungsten surface. The barium and barium oxide coated surfaces were prepared by evaporating barium onto a tungsten surface that can be heated to elevated temperatures. Multilayer or monolayer coverages can be investigated using this technique. The results of this study show that the surface of an impregnated tungsten cathode is identical to that observed for a synthesized monolayer or partial monolayer of barium on partially oxidized tungsten, using the criteria of identical Auger patterns and work functions. Desorption measurements of barium from a tungsten surface were also made. These results in conjunction with Auger and work function data were interpreted to show that throughout most of its life an impregnated cathode operating in the range of 1100 C has a partial monolayer rather than a monolayer of barium on its surface.

Cold Spray Deposition of Ni and WC-Reinforced Ni Matrix Composite Coatings

NASA Astrophysics Data System (ADS)

Alidokht, S. A.; Vo, P.; Yue, S.; Chromik, R. R.

2017-12-01

Ni-WC composites are ideal protective coatings against wear and are often fabricated using laser cladding and thermal spray processes, but the high temperatures of these processes result in decarburization, which deteriorates the performance of the coating. Cold spray has the potential to deposit Ni-WC composite coatings and retain the composition of the initial WC feedstock. However, the insignificant plastic deformation of hard WC particles makes it difficult to build up a high WC content coating by cold spray. By using three different WC powder sizes, the effect of feedstock powder size on WC retention was tested. To improve WC retention, a WC/Ni composite powder in mixture with Ni was also sprayed. Microstructural characterization, including the deformed structure of Ni splats, retention, distribution, and fragmentation of WC, was performed by scanning electron microscopy. An improvement in WC retention was achieved using finer WC particles. Significant improvement in WC particles retention was achieved using WC/Ni composite powder, with the WC content in the coating being close to that of the feedstock.

Evaluation of dip and spray coating techniques in corrosion inhibition of AA2024 alloy using a silicon/zirconium sol-gel film as coating

NASA Astrophysics Data System (ADS)

Garcia, R. B. R.; Silva, F. S.; Kawachi, E. Y.

2017-02-01

For corrosion protection of aluminum alloy AA2024 -T3 a silicon/zirconium films were obtained via sol-gel process, prepared from tetraethoxysilane and zirconium acetate, in acid medium with a 5 wt% of nonionic surfactant in order to replace the pre-treatment based on chromium conversion coatings. A homogeneous film was obtained and deposited, at low viscosity condition of the sol (˜10cP), by dip and spray coating techniques. The films morphology was evaluated by Scanning Electron Microscopy (SEM), and to know more about the used deposition methodology, the deposited mass and the film thickness were measured. The corrosion protection efficiency of deposited films was evaluated by potentiodynamic polarization. The film deposition by both dip and spray coatings were effective for the deposition of a homogeneous film layer, and the results showed the thickness is directly related with the deposited mass, and the film deposited by spray technique presented the lower value. Potentiodynamic polarization indicated that the film deposited by spray coating apparently has a better inert ceramic film due the polarization resistance increased around 57% against 27 and 14% of dip coating samples (4 and 1 layer, respectively).

PAINT SPRAY BOOTH DESIGN USING RECIRCULATION/PARTITIONING VENTILATION

EPA Science Inventory

Many spray painting facility operators have been attempting to reduce the discharge of volatile organic compounds (VOCs) from paint spray booths to the atmosphere. Some have been able to convert to lower VOC containing paints and coatings such as powder coating, waterborne coatin...

Simulations of tungsten, tungsten-coated and tungsten-doped targets at low KrF laser intensities

NASA Astrophysics Data System (ADS)

Colombant, D.; Klapisch, M.; Lehecka, T.; Seely, J.; Schmitt, A.; Obenschain, S.

1998-11-01

High-Z coatings can be used to create X-rays to preheat the ablator, thus reducing the laser imprint and the R-T instability. Targets with tungsten coated on the surface or mixed with CH have recently been irradiated using Nike at intensities of a few 10^12W/cm^2, typical of the foot of a laser fusion pulse. The present simulations in 1D have been carried out to provide an interpretation of these experiments and to validate the code for radiation-preheated target designs(S. E. Bodner et al., Phys. Plasmas, 5, 1901 (1998).). All computations were performed in non-LTE(M. Busquet, Phys. Fluids B, 5, 4191 (1993); M. Klapisch, A. Bar-Shalom, J. Oreg and D. Colombant, Phys. Plasmas, 5, 1919 (1998).). Low resolution X-ray spectra obtained from on-line computations are compared to time-integrated experimental spectra between 100 eV and 500 eV. Agreements and differences between computations and experiments will be discussed.

Consolidation of Surface Coatings by Friction Stir Techniques

DTIC Science & Technology

2010-09-01

alloy samples were plasma sprayed with a Titanium-Nickel-Chrome coating or a Titanium coating. Single and multiple pass experiments were performed...based coatings onto the Aluminum alloy surface. Results showed that the most successful results were accomplished using a flat, pinless tool, with...properties. Aluminum alloy samples were plasma sprayed with a Titanium-Nickel-Chrome coating or a Titanium coating. Single and multiple pass experiments

Vapor Phase Deposition Using Plasma Spray-PVD™

NASA Astrophysics Data System (ADS)

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

2010-01-01

Plasma spray—physical vapor deposition (PS-PVD) is a low pressure plasma spray technology to deposit coatings out of the vapor phase. PS-PVD is a part of the family of new hybrid processes recently developed by Sulzer Metco AG (Switzerland) on the basis of the well-established low pressure plasma spraying (LPPS) technology. Included in this new process family are plasma spray—chemical vapor deposition (PS-CVD) and plasma spray—thin film (PS-TF) processes. In comparison to conventional vacuum plasma spraying and LPPS, these new processes use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats, but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional PVD technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and EB-PVD coatings. This paper reports on the progress made at Sulzer Metco to develop functional coatings build up from vapor phase of oxide ceramics and metals.

Low Earth Orbit Environmental Durability of Recently Developed Thermal Control Coatings

NASA Technical Reports Server (NTRS)

Jaworske, Donald A.

2015-01-01

The Materials International Space Station Experiment provided a means to expose materials and devices to the low Earth orbit environment on the exterior of the International Space Station. By returning the specimens to Earth after flight, the specimens could be evaluated by comparison with pre-flight measurements. One area of continuing interest is thermal control paints and coatings that are applied to exterior surfaces of spacecraft. Though traditional radiator coatings have been available for decades, recent work has focused on new coatings that offer custom deposition or custom optical properties. The custom deposition of interest is plasma spraying and one type of coating recently developed as part of a Small Business Innovative Research effort was designed to be plasma sprayed onto radiator surfaces. The custom optical properties of interest are opposite to those of a typical radiator coating, having a combination of high solar absorptance and low infrared emittance for solar absorber applications, and achieved in practice via a cermet coating. Selected specimens of the plasma sprayed coatings and the solar absorber coating were flown on Materials International Space Station Experiment 7, and were recently returned to Earth for post-flight analyses. For the plasma sprayed coatings in the ram direction, one specimen increased in solar absorptance and one specimen decreased in solar absorptance, while the plasma sprayed coatings in the wake direction changed very little in solar absorptance. For the cermet coating deployed in both the ram and wake directions, the solar absorptance increased. Interestingly, all coatings showed little change in infrared emittance.

Advances in the Development of a WCl6 CVD System for Coating UO2 Powders with Tungsten

NASA Technical Reports Server (NTRS)

Mireles, Omar R.; Tieman, Alyssa; Broadway, Jeramie; Hickman, Robert

2013-01-01

Demonstrated viability and utilization of: a) Fluidized powder bed. b) WCl6 CVD process. c) Coated spherical particles with tungsten. The highly corrosive nature of the WCl6 solid reagent limits material of construction. Indications that identifying optimized process variables with require substantial effort and will likely vary with changes in fuel requirements.

Surface Modification of Thermal Barrier Coatings by Single-Shot Defocused Laser Treatments

NASA Astrophysics Data System (ADS)

Akdoğan, Vakur; Dokur, Mehmet M.; Göller, Gültekin; Keleş, Özgül

2013-09-01

Thermal barrier coatings (TBC) consisting of atmospheric plasma-sprayed ZrO2-8 wt.% Y2O3 and a high velocity oxygen fuel-sprayed metallic bond coat were subjected to CO2 continuous wave laser treatments. The effects of laser power on TBCs were investigated as was the thermally grown oxide (TGO) layer development of all as-sprayed and laser-treated coatings after thermal oxidation tests in air environment for 50, 100, and 200 h at 1100 °C. The effects of laser power on TBCs were investigated. TGO layer development was examined on all as-sprayed and laser-treated coatings after thermal oxidation tests in air environment for 50, 100, and 200 h at 1100 °C. Melted and heat-affected zone regions were observed in all the laser-treated samples. Oxidation tests showed a stable alumina layer and mixed spinel oxides in the TGO layers of the as-sprayed and laser-treated TBCs.

Comparative characteristic and erosion behavior of NiCr coatings deposited by various high-velocity oxyfuel spray processes

NASA Astrophysics Data System (ADS)

Sidhu, Hazoor Singh; Sidhu, Buta Singh; Prakash, S.

2006-12-01

The purpose of this study is to analyze and compare the mechanical properties and microstructure details at the interface of high-velocity oxyfuel (HVOF)-sprayed NiCr-coated boiler tube steels, namely ASTM-SA-210 grade A1, ASTM-SA213-T-11, and ASTM-SA213-T-22. Coatings were developed by two different techniques, and in these techniques liquefied petroleum gas was used as the fuel gas. First, the coatings were characterized by metallographic, scanning electron microscopy/energy-dispersive x-ray analysis, x-ray diffraction, surface roughness, and microhardness, and then were subjected to erosion testing. An attempt has been made to describe the transformations taking place during thermal spraying. It is concluded that the HVOF wire spraying process offers a technically viable and cost-effective alternative to HVOF powder spraying process for applications in an energy generation power plant with a point view of life enhancement and to minimize the tube failures because it gives a coating having better resistance to erosion.

Automated Plasma Spray (APS) process feasibility study: Plasma spray process development and evaluation

NASA Technical Reports Server (NTRS)

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

1979-01-01

An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal-barrier coatings to aircraft gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical blade positioner incorporating two interlaced six-degree-of-freedom assemblies; a noncoherent optical metrology subsystem; a microprocessor-based adaptive system controller; and commercial plasma spray equipment. Over fifty JT9D first stage turbine blades specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary specimens achieved an overall coating thickness uniformity of + or - 53 micrometers, much better than is achievable manually. Factors limiting this performance were identified and process modifications were initiated accordingly. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were initiated. One of the preliminary evaluation specimens was subjected to a torch test and metallographic evaluation.

A New Type of Self-lubricated Thermal Spray Coatings: Liquid Lubricants Embedded in a Metal Matrix

NASA Astrophysics Data System (ADS)

Espallargas, N.; Armada, S.

2015-01-01

Oils and greases are commonly used for lubricating, rotating and sliding systems such as bearings, gears, connectors, etc. The maintenance of such lubricated systems in some applications where access is difficult (e.g., offshore wind farms and subsea equipment) increases the operational costs. In some cases, it can be thought that the use of solid lubricants (MoS2, PTFE, graphite, etc.) embedded in coatings could be a solution for such applications; however, the mechanical and dynamic conditions of most of the systems are not appropriate for solid lubricants. Despite this, solid lubricants such as PTFE and MoS2 have been largely employed in different industries, especially in those applications where liquid lubricants cannot be used and when the dynamic conditions allow for it. Self-lubricated coatings have been a major topic of interest in thermal spray in the last decades. Although the use of liquid lubricants is desirable whenever it is possible, limited research has been addressed toward the development of self-lubricated coatings containing liquid lubricants. One of the main reasons for this is due to the complexity of embedding liquid lubricant reservoirs inside the coating matrix. In the present work, a new type of liquid-solid self-lubricated coatings is presented, being the matrix a metal alloy. Three thermal spray techniques used were as follows: arc-spray, plasma spray, and HVOAF. The metal matrices were two stainless steel types and liquid lubricant-filled capsules with different liquid contents were used. No degradation of the capsules during spraying was observed and the coatings containing capsules were able to keep a low coefficient of friction. The optimal performance is found for the coatings obtained at the lowest spraying temperature and velocity.

Development of Cold Spray Coatings for Accident-Tolerant Fuel Cladding in Light Water Reactors

NASA Astrophysics Data System (ADS)

Maier, Benjamin; Yeom, Hwasung; Johnson, Greg; Dabney, Tyler; Walters, Jorie; Romero, Javier; Shah, Hemant; Xu, Peng; Sridharan, Kumar

2018-02-01

The cold spray coating process has been developed at the University of Wisconsin-Madison for the deposition of oxidation-resistant coatings on zirconium alloy light water reactor fuel cladding with the goal of improving accident tolerance during loss of coolant scenarios. Coatings of metallic (Cr), alloy (FeCrAl), and ceramic (Ti2AlC) materials were successfully deposited on zirconium alloy flats and cladding tube sections by optimizing the powder size, gas preheat temperature, pressure and composition, and other process parameters. The coatings were dense and exhibited excellent adhesion to the substrate. Evaluation of the samples after high-temperature oxidation tests at temperatures up to 1300°C showed that the cold spray coatings significantly mitigate oxidation kinetics because of the formation of thin passive oxide layers on the surface. The results of the study indicate that the cold spray coating process is a viable near-term option for developing accident-tolerant zirconium alloy fuel cladding.

Laser induced heating of coated carbon steel sheets: Consideration of melting and Marangoni flow

NASA Astrophysics Data System (ADS)

Shuja, S. Z.; Yilbas, B. S.

2013-04-01

Laser induced melting of coated carbon steel workpiece is simulated. The coating materials include tungsten carbide, alumina, and boron are incorporated in the simulations. The coating thickness is kept constant at 7.5 μm in the analysis. The enthalpy porosity method is used to account for the phase change in the irradiated region. The study is extended to include the influence of laser intensity transverse mode pattern (β) on the resulting melting characteristics. It is found that peak temperature predicted at the surface is higher for alumina and boron coatings than that of tungsten carbide coating. The influence of the laser intensity transverse mode pattern on the melting characteristics is considerable. Surface temperature predicted agrees with the thermocouple data.

Tungsten-nickel-cobalt alloy and method of producing same

DOEpatents

Dickinson, James M.; Riley, Robert E.

1977-03-15

An improved tungsten alloy having a tungsten content of approximately 95 weight percent, a nickel content of about 3 weight percent, and the balance being cobalt of about 2 weight percent is described. A method for producing said tungsten-nickel-cobalt alloy is further described and comprises (a) coating the tungsten particles with a nickel-cobalt alloy, (b) pressing the coated particles into a compact shape, (c) heating said compact in hydrogen to a temperature in the range of 1400.degree. C and holding at this elevated temperature for a period of about 2 hours, (d) increasing this elevated temperature to about 1500.degree. C and holding for 1 hour at this temperature, (e) cooling to about 1200.degree. C and replacing the hydrogen atmosphere with an inert argon atmosphere while maintaining this elevated temperature for a period of about 1/2 hour, and (f) cooling the resulting alloy to room temperature in this argon atmosphere.

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.

Warm spraying—a novel coating process based on high-velocity impact of solid particles

PubMed Central

Kuroda, Seiji; Kawakita, Jin; Watanabe, Makoto; Katanoda, Hiroshi

2008-01-01

In recent years, coating processes based on the impact of high-velocity solid particles such as cold spraying and aerosol deposition have been developed and attracting much industrial attention. A novel coating process called ‘warm spraying’ has been developed, in which coatings are formed by the high-velocity impact of solid powder particles heated to appropriate temperatures below the melting point of the powder material. The advantages of such process are as follows: (1) the critical velocity needed to form a coating can be significantly lowered by heating, (2) the degradation of feedstock powder such as oxidation can be significantly controlled compared with conventional thermal spraying where powder is molten, and (3) various coating structures can be realized from porous to dense ones by controlling the temperature and velocity of the particles. The principles and characteristics of this new process are discussed in light of other existing spray processes such as high-velocity oxy-fuel spraying and cold spraying. The gas dynamics of particle heating and acceleration by the spraying apparatus as well as the high-velocity impact phenomena of powder particles are discussed in detail. Several examples of depositing heat sensitive materials such as titanium, metallic glass, WC–Co cermet and polymers are described with potential industrial applications. PMID:27877996

Warm Spraying of High-Strength Ni-Al-Bronze: Cavitation Characteristics and Property Prediction

NASA Astrophysics Data System (ADS)

Krebs, Sebastian; Kuroda, Seiji; Katanoda, Hiroshi; Gaertner, Frank; Klassen, Thomas; Araki, Hiroshi; Frede, Simon

2017-01-01

Bronze materials such as Ni-Al-bronze show exceptional performances against cavitation erosion, due to their high fatigue strength and high strength. These materials are used for ship propellers, pump systems or for applications with alternating stresses. Usually, the respective parts are cast. With the aim to use resources more efficiently and to reduce costs, this study aimed to evaluate opportunities to apply bronze as a coating to critical areas of respective parts. The coatings should have least amounts of pores and non-bonded areas and any contaminations that might act as crack nuclei and contribute to material damages. Processes with low oxidation and high kinetic impacts fulfill these criteria. Especially warm spraying, a nitrogen-cooled HVOF process, with similar impact velocities as cold gas spraying but enhanced process temperature, allows for depositing high-strength Ni-Al-bronze. This study systematically simulates and evaluates the formation and performance of warm-sprayed Ni-Al-bronze coatings for different combustion pressures and nitrogen flow rates. Substrate preheating was used to improve coating adhesion for lower spray parameter sets. Furthermore, this study introduces an energy-based concept to compare spray parameter sets and to predict coating properties. Coatings with low porosities and high mechanical strengths are obtained, allowing for a cavitation resistance similar to bulk material.

Evaluation of mechanical properties of Aluminum-Copper cold sprayed and alloy 625 wire arc sprayed coatings

NASA Astrophysics Data System (ADS)

Bashirzadeh, Milad

This study examines microstructural-based mechanical properties of Al-Cu composite deposited by cold spraying and wire arc sprayed nickel-based alloy 625 coating using numerical modeling and experimental techniques. The microhardness and elastic modulus of samples were determined using the Knoop hardness technique. Hardness in both transverse and longitudinal directions on the sample cross-sections has been measured. An image-based finite element simulation algorithm was employed to determine the mechanical properties through an inverse analysis. In addition mechanical tests including, tensile, bending, and nano-indentation tests were performed on alloy 625 wire arc sprayed samples. Overall, results from the experimental tests are in relatively good agreement for deposited Al-Cu composites and alloy 625 coating. However, results obtained from numerical simulation are significantly higher in value than experimentally obtained results. Examination and comparison of the results are strong indications of the influence of microstructure characteristics on the mechanical properties of thermally spray deposited coatings.

Towards fully spray coated organic light emitting devices

NASA Astrophysics Data System (ADS)

Gilissen, Koen; Stryckers, Jeroen; Manca, Jean; Deferme, Wim

2014-10-01

Pi-conjugated polymer light emitting devices have the potential to be the next generation of solid state lighting. In order to achieve this goal, a low cost, efficient and large area production process is essential. Polymer based light emitting devices are generally deposited using techniques based on solution processing e.g.: spin coating, ink jet printing. These techniques are not well suited for cost-effective, high throughput, large area mass production of these organic devices. Ultrasonic spray deposition however, is a deposition technique that is fast, efficient and roll to roll compatible which can be easily scaled up for the production of large area polymer light emitting devices (PLEDs). This deposition technique has already successfully been employed to produce organic photovoltaic devices (OPV)1. Recently the electron blocking layer PEDOT:PSS2 and metal top contact3 have been successfully spray coated as part of the organic photovoltaic device stack. In this study, the effects of ultrasonic spray deposition of polymer light emitting devices are investigated. For the first time - to our knowledge -, spray coating of the active layer in PLED is demonstrated. Different solvents are tested to achieve the best possible spray-able dispersion. The active layer morphology is characterized and optimized to produce uniform films with optimal thickness. Furthermore these ultrasonic spray coated films are incorporated in the polymer light emitting device stack to investigate the device characteristics and efficiency. Our results show that after careful optimization of the active layer, ultrasonic spray coating is prime candidate as deposition technique for mass production of PLEDs.

Wear and corrosion behaviour of tungsten carbide based coatings with different metallic binder

NASA Astrophysics Data System (ADS)

Kamdi, Z.; Apandi, M. N. M.; Ibrahim, M. D.

2017-12-01

Tungsten carbide based coating has been well known as wear and corrosion resistance materials. However, less study is done on comparing the coating with different binder. Thus, in this work the wear and corrosion behaviour of high velocity oxy-fuel (HVOF) coatings, namely (i) tungsten carbide cobalt and (ii) tungsten carbide nickel will be evaluated. Both coatings were characterised using X-ray Diffractometer (XRD) and Scanning Electron Microscope (SEM). The wear behaviour has been examined using the modified grinder machine by weight loss measurement. Two types of abrasive have been used that include 3 g by weight alumina and silica. While for the corrosion behaviour, it is monitored by three electrodes of electrochemical test and immersion test for 30 days in an acidic environment. The electrolyte used was 0.5 M sulphuric acids (H2SO4). It was found that the cobalt binder shows higher wear resistance compares to the nickel binder for both slurry types. The harder alumina compared to silica results in higher wear rate with removal of carbide and binder is about the same rate. For silica abrasive, due to slightly lower hardness compared to the carbide, the wear is dominated by binder removal followed by carbide detachment. For corrosion, the nickel binder shows four times higher wear resistance compared to the cobalt binder as expected due to its natural behaviour. These finding demonstrate that the selection of coating to be used in different application in this case, wear and corrosion shall be chosen carefully to maximize the usage of the coating.

Spray-painted human fibronectin coating as an effective strategy to enhance graft ligamentization of a polyethylene terephthalate artificial ligament.

PubMed

Li, Hong; Chen, Chen; Ge, Yunsheng; Chen, Shiyi

2014-05-01

To enhance graft ligamentization after anterior cruciate ligament (ACL) reconstruction, human fibronectin (FN) was coated on polyethylene terephthalate (PET) ligaments by spray painting. The FN-coated PET ligaments were investigated in vitro using rat mesenchymal stromal cells (MSCs). MSCs cultured on FN-coated grafts resulted in similar cell densities and amounts of proliferating cells with control grafts without coating. The FN-coated group not only gave rise to MSC-derived collagen-like tissues but also enhanced the expression of collagen-I gene. Furthermore, rat ACL reconstruction models were used to evaluate the effect of the FN coating in vivo. The FN coating significantly promoted new ligament tissue regeneration into the graft fibers. In conclusion, sprayed FN coating had a positive effect to enhance graft ligamentization of PET artificial ligament.

Thermal Spray Maps: Material Genomics of Processing Technologies

NASA Astrophysics Data System (ADS)

Ang, Andrew Siao Ming; Sanpo, Noppakun; Sesso, Mitchell L.; Kim, Sun Yung; Berndt, Christopher C.

2013-10-01

There is currently no method whereby material properties of thermal spray coatings may be predicted from fundamental processing inputs such as temperature-velocity correlations. The first step in such an important understanding would involve establishing a foundation that consolidates the thermal spray literature so that known relationships could be documented and any trends identified. This paper presents a method to classify and reorder thermal spray data so that relationships and correlations between competing processes and materials can be identified. Extensive data mining of published experimental work was performed to create thermal spray property-performance maps, known as "TS maps" in this work. Six TS maps will be presented. The maps are based on coating characteristics of major importance; i.e., porosity, microhardness, adhesion strength, and the elastic modulus of thermal spray coatings.

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

Mechanical, in vitro antimicrobial, and biological properties of plasma-sprayed silver-doped hydroxyapatite coating.

PubMed

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

2012-03-01

Implant-related infection is one of the key concerns in total joint hip arthroplasties. To reduce bacterial adhesion, we used silver (Ag)/silver oxide (Ag(2)O) doping 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). Our 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. © 2012 American Chemical Society

Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former

NASA Astrophysics Data System (ADS)

Medřický, Jan; Curry, Nicholas; Pala, Zdenek; Vilemova, Monika; Chraska, Tomas; Johansson, Jimmy; Markocsan, Nicolaie

2015-04-01

Yttria-stabilized zirconia thermal barrier coatings are extensively used in turbine industry; however, increasing performance requirements have begun to make conventional air plasma sprayed coatings insufficient for future needs. Since the thermal conductivity of bulk material cannot be lowered easily; the design of highly porous coatings may be the most efficient way to achieve coatings with low thermal conductivity. Thus the approach of fabrication of coatings with a high porosity level based on plasma spraying of ceramic particles of dysprosia-stabilized zirconia mixed with polymer particles, has been tested. Both polymer and ceramic particles melt in plasma and after impact onto a substrate they form a coating. When the coating is subjected to heat treatment, polymer burns out and a complex structure of pores and cracks is formed. In order to obtain desired porosity level and microstructural features in coatings; a design of experiments, based on changes in spray distance, powder feeding rate, and plasma-forming atmosphere, was performed. Acquired coatings were evaluated for thermal conductivity and thermo-cyclic fatigue, and their morphology was assessed using scanning electron microscopy. It was shown that porosity level can be controlled by appropriate changes in spraying parameters.

Preparation of YBa2Cu3O7 High Tc Superconducting Coatings by Plasma Spraying

NASA Astrophysics Data System (ADS)

Danroc, J.; Lacombe, J.

The following sections are included: * INTRODUCTION * THE COMPOUND YBa2Cu3O7-δ * Structure * Critical temperature * Critical current density * Phase equilibria in the YBaCuO system * PREPARATION OF YBa2Cu3O7 COATINGS * General organisation of the preparation process * The powder * Hot plasma spraying of YBa2Cu3O7 * The post-spraying thermal treatment * CHARACTERISTICS OF THE YBa2Cu3O7-δ COATINGS * Chemical composition * Crystalline structure * Morphology of the coatings * Electrical and magnetic characteristics * Conclusion * REFERENCES

Effect of Ceramic Particle Velocity on Cold Spray Deposition of Metal-Ceramic Coatings

NASA Astrophysics Data System (ADS)

Sova, A.; Kosarev, V. F.; Papyrin, A.; Smurov, I.

2011-01-01

In this paper, metal-ceramic coatings are cold sprayed taking into account the spray parameters of both metal and ceramic particles. The effect of the ceramic particle velocity on the process of metal-ceramic coating formation and the coating properties is analyzed. Copper and aluminum powders are used as metal components. Two fractions of aluminum oxide and silicon carbide are sprayed in the tests. The ceramic particle velocity is varied by the particle injection into different zones of the gas flow: the subsonic and supersonic parts of the nozzle and the free jet after the nozzle exit. The experiments demonstrated the importance of the ceramic particle velocity for the stability of the process: Ceramic particles accelerated to a high enough velocity penetrate into the coating, while low-velocity ceramic particles rebound from its surface.

Surface and biological evaluation of hydroxyapatite-based coatings on titanium deposited by different techniques.

PubMed

Massaro, C; Baker, M A; Cosentino, F; Ramires, P A; Klose, S; Milella, E

2001-01-01

Hydroxyapatite coatings have been deposited on titanium cp by plasma spray, sol-gel, and sputtering techniques for dental implant applications. The latter two techniques are of current interest, as they allow coatings of micrometer dimensions to be deposited. Coating morphology, composition, and structure have been investigated by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD). All coatings were homogeneous and exhibited a rough morphology suitable for implant applications. The sputtered (after annealing), plasma spray, and sol-gel coatings all showed diffraction peaks corresponding to hydroxyapatite. The surface contaminants were observed to be different for the different coating types. The sputtered coatings were found to have a composition most similar to hydroxyapatite; the sol-gel deposits also showed a high concentration of hydroxyl ions. A discrepancy in the Ca/P ratio was observed for the plasma spray coatings, and a small concentration of carbonate ions was found in the sputter-deposited coatings. The in vitro cell-culture studies using MG63 osteoblast-like cells demonstrated the ability of cells to proliferate on the materials tested. The sol-gel coating promotes higher cell growth, greater alkaline phosphatase activity, and greater osteocalcin production compared to the sputtered and plasma-sprayed coatings. Copyright 2001 John Wiley & Sons, Inc.

Improved bonding strength of bioactive cermet Cold Gas Spray coatings.

PubMed

Gardon, M; Concustell, A; Dosta, S; Cinca, N; Cano, I G; Guilemany, J M

2014-12-01

The fabrication of cermet biocompatible coatings by means Cold Gas Spray (CGS) provides prosthesis with outstanding mechanical properties and the required composition for enhancing the bioactivity of prosthetic materials. In this study, hydroxyapatite/Titanium coatings were deposited by means of CGS technology onto titanium alloy substrates with the aim of building-up well-bonded homogeneous coatings. Powders were blended in different percentages and sprayed; as long as the amount of hydroxyapatite in the feedstock increased, the quality of the coating was reduced. Besides, the relation between the particle size distribution of ceramic and metallic particles is of significant consideration. Plastic deformation of titanium particles at the impact eased the anchoring of hard hydroxyapatite particles present at the top surface of the coating, which assures the looked-for interaction with the cells. Coatings were immersed in Hank's solution for 1, 4 and 7 days; bonding strength value was above 60 MPa even after 7 days, which enhances common results of HAp coatings obtained by conventional thermal spray technologies. Copyright © 2014 Elsevier B.V. All rights reserved.

Alternate Spray-coating for the Direct Fabrication of Hydroxyapatite Films without Crystal Growth Step in Solution.

PubMed

Watanabe, Satoshi; Kashiwagi, Rei; Matsumoto, Mutsuyoshi

2017-03-01

We discuss an alternate spray-coating technique for the direct fabrication of hydroxyapatite films using metal masks, suction-type spray nozzles and two calcification solutions of calcium hydroxide and phosphoric acid aqueous solutions. Hydroxyapatite films were formed only on the hydrophobic surface of the substrates. Scanning electron microscopy and energy dispersive X-ray spectroscopy showed that the spray-coated films consisted of hydroxyapatite nanoparticles. The Ca/P ratio was estimated to be about 1.26. X-ray diffraction patterns of the spray-coated films almost coincided with those of the hydroxyapatite powders, showing that the spray-coated films consisted of hydroxyapatite nanoparticles. Dot arrays of hydroxyapatite films at a diameter of 100 μm were formed by tuning the concentrations of calcium hydroxide and phosphoric acid aqueous solutions. This technique allows for the direct fabrication of the hydroxyapatite films without crystal growth process in hydroxyapatite precursors, the scaffolds of crystal growth such as biocompatibility SiO 2 -CaO glasses, or electrophoresis processes. By using this technique, large-area ceramic films with biocompatibility will be micropatterned with minimized material consumption, short fabrication time, and reduced equipment investments.

Microstructures of plasma-sprayed hydroxyapatite-coated Ti-6Al-4V dental implants.

PubMed

Tufekci, E; Brantley, W A; Mitchell, J C; McGlumphy, E A

1997-01-01

The purpose of this study was to investigate the microstructure of plasma-sprayed hydroxyapatite coatings and the elemental composition near the coating-substrate interface for two commercial implants, using the scanning electron microscope. Both coating surfaces and cross-sectioned specimens were examined. The results indicated that while the surface microstructures of both implants were consistent with the plasma-spraying process, the scale of the constituents was much finer for one product. In cross-section, both coatings exhibited minimal porosity and intimate contact with the titanium alloy substrate. It was found that limited interdiffusion of titanium and calcium occurred near the interface.

Structure of Biocompatible Coatings Produced from Hydroxyapatite Nanoparticles by Detonation Spraying

NASA Astrophysics Data System (ADS)

Nosenko, Valentyna; Strutynska, Nataliia; Vorona, Igor; Zatovsky, Igor; Dzhagan, Volodymyr; Lemishko, Sergiy; Epple, Matthias; Prymak, Oleg; Baran, Nikolai; Ishchenko, Stanislav; Slobodyanik, Nikolai; Prylutskyy, Yuriy; Klyui, Nickolai; Temchenko, Volodymyr

2015-12-01

Detonation-produced hydroxyapatite coatings were studied by scanning electron microscopy (SEM), X-ray powder diffraction (XRD), Raman spectroscopy, and electron paramagnetic resonance (EPR) spectroscopy. The source material for detonation spraying was a B-type carbonated hydroxyapatite powder. The coatings consisted of tetracalcium phosphate and apatite. The ratio depended slightly on the degree of crystallinity of the initial powder and processing parameters of the coating preparation. The tetracalcium phosphate phase was homogeneous; the apatite phase contained defects localized on the sixfold axis and consisted of hydroxyapatite and oxyapatite. Technological factors contributing to the transformation of hydroxyapatite powder structure during coating formation by detonation spraying are discussed.

Structure of Biocompatible Coatings Produced from Hydroxyapatite Nanoparticles by Detonation Spraying.

PubMed

Nosenko, Valentyna; Strutynska, Nataliia; Vorona, Igor; Zatovsky, Igor; Dzhagan, Volodymyr; Lemishko, Sergiy; Epple, Matthias; Prymak, Oleg; Baran, Nikolai; Ishchenko, Stanislav; Slobodyanik, Nikolai; Prylutskyy, Yuriy; Klyui, Nickolai; Temchenko, Volodymyr

2015-12-01

Detonation-produced hydroxyapatite coatings were studied by scanning electron microscopy (SEM), X-ray powder diffraction (XRD), Raman spectroscopy, and electron paramagnetic resonance (EPR) spectroscopy. The source material for detonation spraying was a B-type carbonated hydroxyapatite powder. The coatings consisted of tetracalcium phosphate and apatite. The ratio depended slightly on the degree of crystallinity of the initial powder and processing parameters of the coating preparation. The tetracalcium phosphate phase was homogeneous; the apatite phase contained defects localized on the sixfold axis and consisted of hydroxyapatite and oxyapatite. Technological factors contributing to the transformation of hydroxyapatite powder structure during coating formation by detonation spraying are discussed.

Plasma spraying of Wc-Co part II: Experimental study of particle deposition and coating microstructure

NASA Astrophysics Data System (ADS)

Joshiand, S. V.; Srivastava, M. P.

1993-06-01

WC-Co base wear-resistant coatings deposited by plasma spraying are widely used to enhance component longevity in a variety of wear environments. During spraying of WC-Co, ideally only the cobalt phase should melt and act as a binder for the WC particles. Although it is undesirable to fully melt WC because it can cause decarburization, complete melting of the cobalt phase and its satisfactory flattening on impacting the substrate is necessary to minimize porosity and achieve good substrate/coating adhesion. In this article, the influence of the primary plasma spray variables on the melting characteristics of WC-Co powders is investigated with respect to the microstructure of these coatings. This experimental work complements an analytical study on plasma spraying of WC-Co, and thus, observations are presented to support the predictions of the modeling effort.

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

NASA Astrophysics Data System (ADS)

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

2000-03-01

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

Technology Insertion for Recapitalization of Legacy Systems

DTIC Science & Technology

2015-09-30

peened, and 4) an Abcite coating will be flame sprayed on the component. The ALCM program (B) has 1) evaluated data provided, 2) gathered questions...Report Technology Insertion for the Recapitalization of Legacy Systems Laser sintering, thermal spray and cold spray are additive manufacturing methods... coatings Need an experienced operator Requires a special spray booth to limit overspray and protect operator Requires primer or surface treatment

Fracture Behaviour of Plasma Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Malzbender, Jürgen; Wakui, Takashi; Wessel, Egbert; Steinbrech, Rolf W.

Thermal barrier coatings (TBCs) of plasma sprayed yttria stabilised zirconia (YSZ) are increasingly utilised for heat exposed components of advanced gas turbines1,2. An important reason for the application of zirconia coatings is the low thermal conductivity of this ceramic material which is further diminished in a TBC by the high concentration of spraying induced microstructural defects, e.g. crack-shaped defects between and within the spraying splats. Thus with TBCs on gas cooled turbine components stiff temperature gradients can be realised as an important prerequisite for an increased thermal efficiency of the energy conversion process.

The effect of high-power plasma flows on tungsten plates with multilayer films of tungsten nanoparticles

NASA Astrophysics Data System (ADS)

Gorokhov, M. V.; Kozhevin, V. M.; Yavsin, D. A.; Voronin, A. V.; Gurevich, S. A.

2017-04-01

We have experimentally studied the action of high-power plasma flows on pure tungsten plates covered with multilayer films of tungsten nanoparticles formed by the method of laser electrodeposition. The samples were irradiated using a plasma gun producing hydrogen (helium) plasma flows with power density up to 35 GW/cm2. The resulting surface morphology was studied by scanning electron microscopy (SEM). SEM data showed that tungsten plates coated by nanoparticles are more resistant to the formation of microcracks than are pure tungsten plates.

Corrosion And Thermal Processing In Cold Gas Dynamic Spray Deposited Austenitic Stainless Steel Coatings

DTIC Science & Technology

2016-06-01

Novosibirsk during the 1980s [14]. In this process, particles of the coating material are accelerated by entrainment in a supersonic jet of gas ...THERMAL PROCESSING IN COLD GAS DYNAMIC SPRAY DEPOSITED AUSTENITIC STAINLESS STEEL COATINGS by John A Luhn June 2016 Thesis Advisor: Sarath...REPORT TYPE AND DATES COVERED Master’s thesis 4. TITLE AND SUBTITLE CORROSION AND THERMAL PROCESSING IN COLD GAS DYNAMIC SPRAY DEPOSITED AUSTENITIC

Optimization of laser cladding of cold spray coatings with B4C and Ni powders

NASA Astrophysics Data System (ADS)

Fomin, V. M.; Golyshev, A. A.; Malikov, A. G.; Orishich, A. M.; Filippov, A. A.; Ryashin, N. S.

2017-12-01

In the present work, a combined method is considered for the production of a metal-matrix composite coating based on Ni and B4C. The coating is created by consistently applied methods: cold spray and laser cladding. The conditions of obtaining cermet layers are investigated depending on the parameters of laser cladding and cold spray. It is shown that the laser track structure significantly changes in accordance to the size of ceramic particles ranging 3-75 µm and its concentration. It is shown that the most perspective layers for additive manufacturing could be obtain from cold spray coatings with ceramic concentrations more than 50% by weight treated in the heat-conductivity laser mode.

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.

A comparative physico-chemical study of chlorapatite and hydroxyapatite: from powders to plasma sprayed thin coatings.

PubMed

Demnati, I; Grossin, D; Combes, C; Parco, M; Braceras, I; Rey, C

2012-10-01

Due to their bioactivity and osteoconductivity, hydroxyapatite (HA) plasma sprayed coatings have been widely developed for orthopedic uses. However, the thermodynamic instability of HA leads frequently to a mixture of phases which limit the functional durability of the coating. This study investigates the plasma spraying of chlorapatite (ClA) powder, known to melt without decomposition, onto pure titanium substrates using a low energy plasma spray system (LEPS). Pure ClA powder was prepared by a solid gas reaction at 950 °C and thermogravimetric analysis showed the good thermal stability of ClA powder in the range 30-1400 °C compared to that of the HA powder. Characterization of ClA coating showed that ClA had a very high crystalline ratio and no other crystalline phase was detected in the coating. HA and ClA coatings composition, microstructure and in vitro bioactivity potential were studied, compared and discussed. In vitro SBF test on HA and ClA coatings revealed the formation of a poorly crystalline apatite on the coating surface suggesting that we could expect a good osteoconductivity especially for the ClA coating prepared by the LEPS system.

Plasma-sprayed titanium coating to polyetheretherketone improves the bone-implant interface.

PubMed

Walsh, William R; Bertollo, Nicky; Christou, Chrisopher; Schaffner, Dominik; Mobbs, Ralph J

2015-05-01

Rapid and stable fixation at the bone-implant interface would be regarded as one of the primary goals to achieve clinical efficacy, regardless of the surgical site. Although mechanical and physical properties of polyetheretherketone (PEEK) provide advantages for implant devices, the hydrophobic nature and the lack of direct bone contact remains a limitation. To examine the effects of a plasma-sprayed titanium coated PEEK on the mechanical and histologic properties at the bone-implant interface. A preclinical laboratory study. Polyetheretherketone and plasma-sprayed titanium coated PEEK implants (Ti-bond; Spinal Elements, Carlsbad, CA, USA) were placed in a line-to-line manner in cortical bone and in a press-fit manner in cancellous bone of adult sheep using an established ovine model. Shear strength was assessed in the cortical sites at 4 and 12 weeks, whereas histology was performed in cortical and cancellous sites at both time points. The titanium coating dramatically improved the shear strength at the bone-implant interface at 4 weeks and continued to improve with time compared with PEEK. Direct bone ongrowth in cancellous and cortical sites can be achieved using a plasma-sprayed titanium coating on PEEK. Direct bone to implant bonding can be achieved on PEEK in spite of its hydrophobic nature using a plasma-sprayed titanium coating. The plasma-sprayed titanium coating improved mechanical properties in the cortical sites and the histology in cortical and cancellous sites. Copyright © 2015 Elsevier Inc. All rights reserved.

Antibacterial Property of Cold-Sprayed HA-Ag/PEEK Coating

NASA Astrophysics Data System (ADS)

Sanpo, Noppakun; Tan, Meng Lu; Cheang, Philip; Khor, K. A.

2009-03-01

The antibacterial behavior of HA-Ag (silver-doped hydroxyapatite) nanopowder and their composite coatings were investigated against Escherichia coli (DH5α). HA-Ag nanopowder and PEEK (poly-ether-ether-ketone)-based HA-Ag composite powders were synthesized using in-house powder processing techniques. Bacteria culture assay of HA-Ag nanopowder and their composite powders displayed excellent bacteriostatic activity against E. coli. The antibacterial activity increased with increasing concentration of HA-Ag nanoparticle in these composite powders. These nanocomposite powders were subsequently used as feedstock to generate antibacterial coatings via cold spray technology. The ratios of HA-Ag to PEEK in their composite powders were 80:20, 60:40, 40:60, and 20:80 (wt.%). Microstructural characterization and phase analysis of feedstock powders and as-deposited coatings were carried out using FESEM/EDX and XRD. Antibacterial nanocomposite HA-Ag/PEEK coatings were successfully deposited using cold spraying parameters of 11-12 bars at preheated air temperature between 150 and 160 °C. These as-sprayed coatings of HA-Ag/PEEK composite powders comprising varying HA-Ag and PEEK ratios retained their inherent antibacterial property as verified from bacterial assay. The results indicated that the antibacterial activity increased with increasing HA-Ag nanopowder concentration in the composite powder feedstock and cold-sprayed coating.

Optimization of In-Situ Shot-Peening-Assisted Cold Spraying Parameters for Full Corrosion Protection of Mg Alloy by Fully Dense Al-Based Alloy Coating

NASA Astrophysics Data System (ADS)

Wei, Ying-Kang; Luo, Xiao-Tao; Li, Cheng-Xin; Li, Chang-Jiu

2017-01-01

Magnesium-based alloys have excellent physical and mechanical properties for a lot of applications. However, due to high chemical reactivity, magnesium and its alloys are highly susceptible to corrosion. In this study, Al6061 coating was deposited on AZ31B magnesium by cold spray with a commercial Al6061 powder blended with large-sized stainless steel particles (in-situ shot-peening particles) using nitrogen gas. Microstructure and corrosion behavior of the sprayed coating was investigated as a function of shot-peening particle content in the feedstock. It is found that by introducing the in-situ tamping effect using shot-peening (SP) particles, the plastic deformation of deposited particles is significantly enhanced, thereby resulting in a fully dense Al6061 coating. SEM observations reveal that no SP particle is deposited into Al6061 coating at the optimization spraying parameters. Porosity of the coating significantly decreases from 10.7 to 0.4% as the SP particle content increases from 20 to 60 vol.%. The electrochemical corrosion experiments reveal that this novel in-situ SP-assisted cold spraying is effective to deposit fully dense Al6061 coating through which aqueous solution is not permeable and thus can provide exceptional protection of the magnesium-based materials from corrosion.

Fabrication of Water Jet Resistant and Thermally Stable Superhydrophobic Surfaces by Spray Coating of Candle Soot Dispersion.

PubMed

Qahtan, Talal F; Gondal, Mohammed A; Alade, Ibrahim O; Dastageer, Mohammed A

2017-08-08

A facile synthesis method for highly stable carbon nanoparticle (CNP) dispersion in acetone by incomplete combustion of paraffin candle flame is presented. The synthesized CNP dispersion is the mixture of graphitic and amorphous carbon nanoparticles of the size range of 20-50 nm and manifested the mesoporosity with an average pore size of 7 nm and a BET surface area of 366 m 2 g -1 . As an application of this material, the carbon nanoparticle dispersion was spray coated (spray-based coating) on a glass surface to fabricate superhydrophobic (water contact angle > 150° and sliding angle < 10 °) surfaces. The spray coated surfaces were found to exhibit much improved water jet resistance and thermal stability up to 400 °C compared to the surfaces fabricated from direct candle flame soot deposition (candle-based coating). This study proved that water jet resistant and thermally stable superhydrophobic surfaces can be easily fabricated by simple spray coating of CNP dispersion gathered from incomplete combustion of paraffin candle flame and this technique can be used for different applications with the potential for the large scale fabrication.

Aircraft surface coatings study: Energy efficient transport program. [sprayed and adhesive bonded coatings for drag reduction

NASA Technical Reports Server (NTRS)

1979-01-01

Surface coating materials for application on transport type aircraft to reduce drag, were investigated. The investigation included two basic types of materials: spray on coatings and adhesively bonded films. A cost/benefits analysis was performed, and recommendations were made for future work toward the application of this technology.

Evaluation of glass resin coatings for solar cell applications

NASA Technical Reports Server (NTRS)

Field, M. B.

1978-01-01

Using a variety of non-vacuum deposition techniques coatings were implemented on silicon solar cells and arrays of cells interconnected on Kapton substrates. The coatings provide both antireflection optical matching and environmental protection. Reflectance minima near 2% was achieved at a single wavelength in the visible. Reflectance averaging below 5% across the useful collection range was demonstrated. The coatings and methods of deposition were: (1) Ta2O5 spun, dipped or sprayed; (2) Ta2O5.SiO2 spun, dipped or sprayed; (3) GR908 (SiO2) spun, dipped, or sprayed. Total coating thickness were in the range of 18 microns to 25 microns. The coatings and processes are compatible with single cells or cells mounted on Kapton substrates.

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

NASA Astrophysics Data System (ADS)

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

2016-07-01

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

Suspension thermal spraying of hydroxyapatite: microstructure and in vitro behaviour.

PubMed

Bolelli, Giovanni; Bellucci, Devis; Cannillo, Valeria; Lusvarghi, Luca; Sola, Antonella; Stiegler, Nico; Müller, Philipp; Killinger, Andreas; Gadow, Rainer; Altomare, Lina; De Nardo, Luigi

2014-01-01

In cementless fixation of metallic prostheses, bony ingrowth onto the implant surface is often promoted by osteoconductive plasma-sprayed hydroxyapatite coatings. The present work explores the use of the innovative High Velocity Suspension Flame Spraying (HVSFS) process to coat Ti substrates with thin homogeneous hydroxyapatite coatings. The HVSFS hydroxyapatite coatings studied were dense, 27-37μm thick, with some transverse microcracks. Lamellae were sintered together and nearly unidentifiable, unlike conventional plasma-sprayed hydroxyapatite. Crystallinities of 10%-70% were obtained, depending on the deposition parameters and the use of a TiO2 bond coat. The average hardness of layers with low (<24%) and high (70%) crystallinity was ≈3.5GPa and ≈4.5GPa respectively. The distributions of hardness values, all characterised by Weibull modulus in the 5-7 range, were narrower than that of conventional plasma-sprayed hydroxyapatite, with a Weibull modulus of ≈3.3. During soaking in simulated body fluid, glassy coatings were progressively resorbed and replaced by a new, precipitated hydroxyapatite layer, whereas coatings with 70% crystallinity were stable up to 14days of immersion. The interpretation of the precipitation behaviour was also assisted by surface charge assessments, performed through Z-potential measurements. During in vitro tests, HA coatings showed no cytotoxicity towards the SAOS-2 osteoblast cell line, and surface cell proliferation was comparable with proliferation on reference polystyrene culture plates. © 2013.

Anti-icing Behavior of Thermally Sprayed Polymer Coatings

NASA Astrophysics Data System (ADS)

Koivuluoto, Heli; Stenroos, Christian; Kylmälahti, Mikko; Apostol, Marian; Kiilakoski, Jarkko; Vuoristo, Petri

2017-01-01

Surface engineering shows an increasing potential to provide a sustainable approach to icing problems. Currently, several passive anti-ice properties adoptable to coatings are known, but further research is required to proceed for practical applications. This is due to the fact that icing reduces safety, operational tempo, productivity and reliability of logistics, industry and infrastructure. An icing wind tunnel and a centrifugal ice adhesion test equipment can be used to evaluate and develop anti-icing and icephobic coatings for a potential use in various arctic environments, e.g., in wind power generation, oil drilling, mining and logistic industries. The present study deals with evaluation of icing properties of flame-sprayed polyethylene (PE)-based polymer coatings. In the laboratory-scale icing tests, thermally sprayed polymer coatings showed low ice adhesion compared with metals such as aluminum and stainless steel. The ice adhesion strength of the flame-sprayed PE coating was found to have approximately seven times lower ice adhesion values compared with metallic aluminum, indicating a very promising anti-icing behavior.

Enhanced bonding property of cold-sprayed Zn-Al coating on interstitial-free steel substrate with a nanostructured surface layer

NASA Astrophysics Data System (ADS)

Liang, Y. L.; Wang, Z. B.; Zhang, J.; Zhang, J. B.; Lu, K.

2016-11-01

By means of surface mechanical attrition treatment (SMAT), a gradient nanostructured surface layer was fabricated on a hot-rolled interstitial-free steel plate. A Zn-Al coating was subsequently deposited on the SMAT sample by using cold spray process. The bonding property of the coating on the SMAT substrate was compared with that on the coarse-grained (CG) sample. Stud-pull tests showed that the bonding strength in the as-sprayed SMAT sample is ∼30% higher than that in the as-sprayed CG sample. No further improvement in bonding strength was achieved in the coated SMAT sample after annealing at 400 °C, mostly due to the formation of cracks and intermetallic compounds at the coating/substrate interface in an earlier stage (<30 min) and in a final stage (>90 min), respectively. The enhanced bonding property of the Zn-Al coating on the SMAT sample might be related with the promoted atomic diffusion and hardness in the nanostructured surface layer.

Process optimization of ultrasonic spray coating of polymer films.

PubMed

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

2013-06-11

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

Joint Test Plan for Gas Dynamic Spray Technology Demonstration

NASA Technical Reports Server (NTRS)

Lewis, Pattie

2008-01-01

Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.

Anomalous Epitaxial Growth in Thermally Sprayed YSZ and LZ Splats

NASA Astrophysics Data System (ADS)

Chen, Lin; Yang, Guan-Jun

2017-08-01

Thermally sprayed coatings are essentially layered materials, and lamellar interfaces are of great importance to coatings' performances. In the present study, to investigate the microstructures and defect features at thermally sprayed coating interfaces, homoepitaxial 8 mol.% yttria-stabilized zirconia (YSZ) and heteroepitaxial lanthanum zirconia (LZ) films were fabricated. The epitaxial interfaces were examined by high-resolution transmission electron microscope (HR-TEM) in detail. As a result, we report, for the first time, an anomalous incommensurate homoepitaxial growth with mismatch-induced dislocations in thermally sprayed YSZ splats to create a homointerface. We also find the anomalous heteroepitaxial growth in thermally sprayed LZ splats. The mechanism of the anomalous incommensurate growth was analyzed in detail. Essentially, it is a pseudo-heteroepitaxy because of the lattice mismatch between the film and the locally heated substrate, as the locally heated substrate is significantly strained by its cold surroundings. Moreover, the super-high-density dislocations were found in the interfacial region, which resulted from sufficient thermal fluctuations and extremely rapid cooling rates. Both the anomalous lattice mismatch and super-high-density dislocations lead to weak interfaces and violent cracking in thermally sprayed coatings. These were also the essential differences between the conventional and the present epitaxy by thermal spray technique.

Down-selection and optimization of thermal-sprayed coatings for aluminum mould tool protection and upgrade

NASA Astrophysics Data System (ADS)

Gibbons, Gregory John; Hansell, Robert George

2006-09-01

This article details the down-selection procedure for thermally sprayed coatings for aluminum injection mould tooling. A down-selection metric was used to rank a wide range of coatings. A range of high-velocity oxyfuel (HVOF) and atmospheric plasma spray (APS) systems was used to identify the optimal coating-process-system combinations. Three coatings were identified as suitable for further study; two CrC NiCr materials and one Fe Ni Cr alloy. No APS-deposited coatings were suitable for the intended application due to poor substrate adhesion (SA) and very high surface roughness (SR). The DJ2700 deposited coating properties were inferior to the coatings deposited using other HVOF systems and thus a Taguchi L18 five parameter, three-level optimization was used to optimize SA of CRC-1 and FE-1. Significant mean increases in bond strength were achieved (147±30% for FE-1 [58±4 MPa] and 12±1% for CRC-1 [67±5 MPa]). An analysis of variance (ANOVA) indicated that the coating bond strengths were primarily dependent on powder flow rate and propane gas flow rate, and also secondarily dependent on spray distance. The optimal deposition parameters identified were: (CRC-1/FE-1) O2 264/264 standard liters per minute (SLPM); C3H8 62/73 SLPM; air 332/311 SLPM; feed rate 30/28 g/min; and spray distance 150/206 mm.

Characterization, shaping, and joining of SiC/superalloy sheet for exhaust system components

NASA Technical Reports Server (NTRS)

Cornie, J. A.

1977-01-01

Hafnium carbide was shown to be virtually inert when in contact with silicon carbide and Waspaloy for at least 200 hr at 1093 C (2000 F). Extensive interaction was noted with other superalloys such as HA-188. A continuous CVD HfC deposition process was developed for deposition of up to 8 microns on .14 mm (.0056 in.) SiC tungsten core filament at rates as high as .6 m/min. The rate can be increased by increasing the length of the reactor and the output of the power supply used in resistive heating of the filament substrate. The strength of HfC coated filament varies with thickness in a Griffith-like manner. This strength reduction was greater for HfC coatings than for tungsten coatings, presumably because of the greater ductility of tungsten.

Development of a new low cost antireflective coating technique for solar cells

NASA Technical Reports Server (NTRS)

Wohlgemuth, J. H.; Warfield, D. B.; Johnson, G. A.

1982-01-01

The goal of this study was the development of an antireflective (AR) coating technique that has the potential for high throughput and low cost yet is capable of producing films of good optical quality. Previous efforts to develop sprayed AR coatings had utilized titanium isopropoxide mixed with volatile solvents. These films worked well on smooth surfaces but when applied to etched semi-crystalline silicon surfaces yielded inconsistent results with more than 20 percent of the AM1 incident light being reflected. In this program titanium isopropoxide was sprayed directly onto heater wafers (410 C) to produce a uniform AR coating even on highly textured surfaces. Tests on various types of solar cells yielded performance improvements for the hot sprayed AR cells that are equivalent to that observed for evaporated TiOx AR coated cells. As an extension of this effort a new double layer AR consisting of a bottom layer of hot sprayed titanium isopropoxide and a top layer of hot sprayed aluminum isopropoxide in methylene chloride has resulted in more than 10 percent improvement in cell output as compared to a single layer AR cell.

Method of fabricating thin-walled articles of tungsten-nickel-iron alloy

DOEpatents

Hovis, Jr., Victor M.; Northcutt, Jr., Walter G.

1982-01-01

The present invention relates to a method for fabricating thin-walled high-density structures oftungsten-nickel-iron alloys. A powdered blend of the selected alloy constituents is plasma sprayed onto a mandrel having the desired article configuration. The sprayed deposit is removed from the mandrel and subjected to liquid phase sintering to provide the alloyed structure. The formation of the thin-walled structure by plasma spraying significantly reduces shrinkage, and cracking while increasing physical properties of the structure over that obtainable by employing previously known powder metallurgical procedures.

Influence of Bond Coat on HVOF-Sprayed Gradient Cermet Coating on Copper Alloy

NASA Astrophysics Data System (ADS)

Ke, Peng; Cai, Fei; Chen, Wanglin; Wang, Shuoyu; Ni, Zhenhang; Hu, Xiaohong; Li, Mingxi; Zhu, Guanghong; Zhang, Shihong

2017-06-01

Coatings are required on mold copper plates to prolong their service life through enhanced hardness, wear resistance, and oxidation resistance. In the present study, NiCr-30 wt.%Cr3C2 ceramic-metallic (cermet) layers were deposited by high velocity oxy-fuel (HVOF) spraying on different designed bond layers, including electroplated Ni, HVOF-sprayed NiCr, and double-decker Ni-NiCr. Annealing was also conducted on the gradient coating (GC) with NiCr bond layer to improve the wear resistance and adhesion strength. Coating microstructure was investigated by scanning electron microscopy and x-ray diffraction analysis. Mechanical properties including microhardness, wear resistance, and adhesion strength of the different coatings were evaluated systematically. The results show that the types of metallic bond layer and annealing process had a significant impact on the mechanical properties of the GCs. The GCs with electroplated Ni bond layer exhibited the highest adhesion strength (about 70 MPa). However, the GC with HVOF-sprayed NiCr bond layer exhibited better wear resistance. The wear resistance and adhesion strength of the coating with NiCr metallic bond layer were enhanced after annealing.

Oxidation Behavior of Titanium Carbonitride Coating Deposited by Atmospheric Plasma Spray Synthesis

NASA Astrophysics Data System (ADS)

Zhu, Lin; He, Jining; Yan, Dianran; Liao, Hanlin; Zhang, Nannan

2017-10-01

As a high-hardness and anti-frictional material, titanium carbonitride (TiCN) thick coatings or thin films are increasingly being used in many industrial fields. In the present study, TiCN coatings were obtained by atmospheric plasma spray synthesis or reactive plasma spray. In order to promote the reaction between the Ti particles and reactive gases, a home-made gas tunnel was mounted on a conventional plasma gun to perform the spray process. The oxidation behavior of the TiCN coatings under different temperatures in static air was carefully investigated. As a result, when the temperature was over 700 °C, the coatings suffered from serious oxidation, and finally they were entirely oxidized to the TiO2 phase at 1100 °C. The principal oxidation mechanism was clarified, indicating that the oxygen can permeate into the defects and react with TiCN at high temperatures. In addition, concerning the use of a TiCN coating in high-temperature conditions, the microhardness of the oxidized coatings at different treatment temperatures was also evaluated.

Effect of Feedstock Size and its Distribution on the Properties of Detonation Sprayed Coatings

NASA Astrophysics Data System (ADS)

Suresh Babu, P.; Rao, D. S.; Rao, G. V. N.; Sundararajan, G.

2007-06-01

The detonation spraying is one of the most promising thermal spray variants for depositing wear and corrosion resistant coatings. The ceramic (Al2O3), metallic (Ni-20 wt%Cr) , and cermets (WC-12 wt%Co) powders that are commercially available were separated into coarser and finer size ranges with relatively narrow size distribution by employing centrifugal air classifier. The coatings were deposited using detonation spray technique. The effect of particle size and its distribution on the coating properties were examined. The surface roughness and porosity increased with increasing powder particle size for all the coatings consistently. The feedstock size was also found to influence the phase composition of Al2O3 and WC-Co coatings; however does not influence the phase composition of Ni-Cr coatings. The associated phase change and %porosity of the coatings imparted considerable variation in the coating hardness, fracture toughness, and wear properties. The fine and narrow size range WC-Co coating exhibited superior wear resistance. The coarse and narrow size distribution Al2O3 coating exhibited better performance under abrasion and sliding wear modes however under erosion wear mode the as-received Al2O3 coating exhibited better performance. In the case of metallic (Ni-Cr) coatings, the coatings deposited using coarser powder exhibited marginally lower-wear rate under abrasion and sliding wear modes. However, under erosion wear mode, the coating deposited using finer particle size exhibited considerably lower-wear rate.

Characterization of plasma sprayed and explosively consolidated simulated lunar soil

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 exhibitedmore » good adhesion. Simultaneously, an explosively consolidated sample was similarly characterized to afford a comparison of structural features associated with each mode of proposed use.« less

Fabrication process development of SiC/superalloy composite sheet for exhaust system components

NASA Technical Reports Server (NTRS)

Cornie, J. A.; Cook, C. S.; Anderson, C. A.

1976-01-01

A chemical compatibility study was conducted between SiC filament and the following P/M matrix alloys: Waspaloy, Hastelloy-X, NiCrAlY, Ha-188, S-57, FeCrAlY, and Incoloy 800. None of the couples demonstrated sufficient chemical compatibility to withstand the minimum HIP consolidation temperatures (996 C) or intended application temperature of the composite (982 C). However, Waspaloy, Haynes 188, and Hastelloy-X were the least reactive with SiC of the candidate alloys. Chemical vapor deposited tungsten was shown to be an effective diffusion barrier between the superalloy matrix and SiC filament providing a defect-free coating of sufficient thickness. However, the coating breaks down when the tungsten is converted into intermetallic compounds by interdiffusion with matrix constituents. Waspaloy was demonstrated to be the most effective matrix alloy candidate in contact with the CVD tungsten barrier because of its relatively low growth rate constant of the intermediate compound and the lack of formation of Kirkendall voids at the matrix-barrier interface. Fabrication methods were developed for producing panels of uniaxial and angle ply composites utilizing CVD tungsten coated filament.

Sol-gel-Derived nano-sized double layer anti-reflection coatings (SiO2/TiO2) for low-cost solar cell fabrication.

PubMed

Lee, Seung Jun; Hur, Man Gyu; Yoon, Dae Ho

2013-11-01

We investigate nano-sized double layer anti-reflection coatings (ARCs) using a TiO2 and SiO2 sol-gel solution process for mono-crystalline silicon solar cells. The process can be easily adapted for spraying sol-gel coatings to reduce manufacturing cost. The spray-coated SiO2/TiO2 nano-sized double layer ARCs were deposited on mono-crystalline silicon solar cells, and they showed good optical properties. The spray coating process is a lower-cost fabrication process for large-scale coating than vacuum deposition processes such as PECVD. The measured average optical reflectance (300-1200 nm) was about approximately 8% for SiO2/TiO2 nano-sized double layer ARCs. The electrical parameters of a mono-crystalline silicon solar cell and reflection losses show that the SiO2/TiO2 stacks can improve cell efficiency by 0.2% compared to a non-coated mono-crystalline silicon solar cell. In the results, good correlation between theoretical and experimental data was obtained. We expect that the sol-gel spray-coated mono-crystalline silicon solar cells have high potential for low-cost solar cell fabrication.

Synthesis and Phase Stability of Scandia, Gadolinia, and Ytterbia Co-doped Zirconia for Thermal Barrier Coating Application

NASA Astrophysics Data System (ADS)

Li, Qi-Lian; Cui, Xiang-Zhong; Li, Shu-Qing; Yang, Wei-Hua; Wang, Chun; Cao, Qian

2015-01-01

Scandia, gadolinia, and ytterbia co-doped zirconia (SGYZ) ceramic powder was synthesized by chemical co-precipitation and calcination processes for application in thermal barrier coatings to promote the durability of gas turbines. The ceramic powder was agglomerated and sintered at 1150 °C for 2 h, and the powder exhibited good flowability and apparent density to be suitable for plasma spraying process. The microstructure, morphology and phase stability of the powder and plasma-sprayed SGYZ coatings were analyzed by means of scanning electron microscope and x-ray diffraction. Thermal conductivity of plasma-sprayed SGYZ coatings was measured. The results indicated that the SGYZ ceramic powder and the coating exhibit excellent stability to retain single non-transformable tetragonal zirconia even after high temperature (1400 °C) exposure for 500 h and do not undergo a tetragonal-to-monoclinic phase transition upon cooling. Furthermore, the plasma-sprayed SGYZ coating also exhibits lower thermal conductivity than yttria stabilized zirconia coating currently used in gas turbine engine industry. SGYZ can be explored as a candidate material of ultra-high temperature thermal barrier coating for advanced gas turbine engines.

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.

Mitigation of Corrosion in 5 Series Al-Mg Alloys in Marine Environments: Grain Boundary Engineering and Cold Spray Coating Approaches

DTIC Science & Technology

2014-03-26

powders for cold spray are nominally ductile materials such as Cu and Al or Al alloys with particles in the 5-45|am size range. It is for...wavelength) as the x-ray source. Since cold spray is a solid state deposition process , the composition and microstructure of the feedstock powder ...surface of the recently deposited coating build up and a thick coating with theoretical bulk properties can be achieved [27]. The cold

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.

Essential Factors Influencing the Bonding Strength of Cold-Sprayed Aluminum Coatings on Ceramic Substrates

NASA Astrophysics Data System (ADS)

Drehmann, R.; Grund, T.; Lampke, T.; Wielage, B.; Wüstefeld, C.; Motylenko, M.; Rafaja, D.

2018-02-01

The present work summarizes the most important results of a research project dealing with the comprehensive investigation of the bonding mechanisms between cold-sprayed Al coatings and various poly- and monocrystalline ceramic substrates (Al2O3, AlN, Si3N4, SiC, MgF2). Due to their exceptional combination of properties, metallized ceramics are gaining more and more importance for a wide variety of applications, especially in electronic engineering. Cold spray provides a quick, flexible, and cost-effective one-step process to apply metallic coatings on ceramic surfaces. However, since most of the existing cold-spray-related publications focus on metallic substrates, only very little is known about the bonding mechanisms acting between cold-sprayed metals and ceramic substrates. In this paper, the essential factors influencing the bonding strength in such composites are identified. Besides mechanical tensile strength testing, a thorough analysis of the coatings and especially the metal/ceramic interfaces was conducted by means of HRTEM, FFT, STEM, EDX, EELS, GAXRD, and EBSD. The influence of substrate material, substrate temperature, and particle size is evaluated. The results suggest that, apart from mechanical interlocking, the adhesion of cold-sprayed metallic coatings on ceramics is based on a complex interplay of different mechanisms such as quasiadiabatic shearing, static recrystallization, and heteroepitaxial growth.

A Method to Predict the Thickness of Poorly-Bonded Material Along Spray and Spray-Layer Boundaries in Cold Spray Deposition

NASA Astrophysics Data System (ADS)

Li, Yangfan; Hamada, Yukitaka; Otobe, Katsunori; Ando, Teiichi

2017-02-01

Multi-traverse CS provides a unique means for the production of thick coatings and bulk materials from powders. However, the material along spray and spray-layer boundaries is often poorly bonded as it is laid by the leading and trailing peripheries of the spray that carry powder particles with insufficient kinetic energy. For the same reason, the splats in the very first layer deposited on the substrate may not be bonded well either. A mathematical spray model was developed based on an axisymmetric Gaussian mass flow rate distribution and a stepped deposition yield to predict the thickness of such poorly-bonded layers in multi-traverse CS deposition. The predicted thickness of poorly-bonded layers in a multi-traverse Cu coating falls in the range of experimental values. The model also predicts that the material that contains poorly bonded splats could exceed 20% of the total volume of the coating.

Metal flame spray coating protects electrical cables in extreme environment

NASA Technical Reports Server (NTRS)

Brady, R. D.; Fox, H. A.

1967-01-01

Metal flame spray coating prevents EMF measurement error in sheathed instrumentation cables which are externally attached to cylinders which were cooled on the inside, but exposed to gamma radiation on the outside. The coating provides a thermoconductive path for radiation induced high temperatures within the cables.

40 CFR 60.391 - Definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... truck including hoods, fenders, cargo boxes, doors, and grill opening panels. Bake oven means a device...-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven. Guide coat operation means the guide coat spray booth, flash-off area and bake oven(s) which are...

40 CFR 60.391 - Definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... truck including hoods, fenders, cargo boxes, doors, and grill opening panels. Bake oven means a device...-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven. Guide coat operation means the guide coat spray booth, flash-off area and bake oven(s) which are...

40 CFR 60.391 - Definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... truck including hoods, fenders, cargo boxes, doors, and grill opening panels. Bake oven means a device...-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven. Guide coat operation means the guide coat spray booth, flash-off area and bake oven(s) which are...

40 CFR 60.391 - Definitions.

Code of Federal Regulations, 2010 CFR

2010-07-01

... truck including hoods, fenders, cargo boxes, doors, and grill opening panels. Bake oven means a device...-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven. Guide coat operation means the guide coat spray booth, flash-off area and bake oven(s) which are...

40 CFR 60.391 - Definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... truck including hoods, fenders, cargo boxes, doors, and grill opening panels. Bake oven means a device...-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven. Guide coat operation means the guide coat spray booth, flash-off area and bake oven(s) which are...

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.

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.

Measuring the dynamic polarizability of tungsten atom via electrical wire explosion in vacuum

NASA Astrophysics Data System (ADS)

Shi, Huantong; Zou, Xiaobing; Wang, Xinxin

2018-02-01

Electrical explosion of wire provides a practical approach to the experimental measurement of dynamic polarizability of metal atoms with high melting and boiling temperatures. With the help of insulation coating, a section of tungsten wire was transformed to the plasma state while the near electrode region was partially vaporized, which enabled us to locate the "neutral-region" (consisting of gaseous atoms) in the Mach-Zehnder interferogram. In this paper, the polarizability of the tungsten atom at 532 nm was reconstructed based on a technique previously used for the same purpose, and the basic preconditions of the measurement were verified in detail, including the existence of the neutral region, conservation of linear density of tungsten during wire expansion, and neglect of the vaporized insulation coating. The typical imaging time varied from 80 ns to as late as 200 ns and the reconstructed polarizability of the tungsten atom was 16 ± 1 Å3, which showed good statistical consistency and was also in good agreement with the previous results.

Structure, phases, and mechanical response of Ti-alloy bioactive glass composite coatings.

PubMed

Nelson, G M; Nychka, J A; McDonald, A G

2014-03-01

Porous titanium alloy-bioactive glass composite coatings were manufactured via the flame spray deposition process. The porous coatings, targeted for orthodontic and bone-fixation applications, were made from bioactive glass (45S5) powder blended with either commercially pure titanium (Cp-Ti) or Ti-6Al-4V alloy powder. Two sets of spray conditions, two metallic particle size distributions, and two glass particle size distributions were used for this study. Negative control coatings consisting of pure Ti-6Al-4V alloy or Cp-Ti were sprayed under both conditions. The as-sprayed coatings were characterized through quantitative optical cross-sectional metallography, X-ray diffraction (XRD), and ASTM Standard C633 tensile adhesion testing. Determination of the porosity and glassy phase distribution was achieved by using image analysis in accordance with ASTM Standard E2109. Theoretical thermodynamic and heat transfer modeling was conducted to explain experimental observations. Thermodynamic modeling was performed to estimate the flame temperature and chemical environment for each spray condition and a lumped capacitance heat transfer model was developed to estimate the temperatures attained by each particle. These models were used to establish trends among the choice of alloy, spray condition, and particle size distribution. The deposition parameters, alloy composition, and alteration of the feedstock powder size distribution had a significant effect on the coating microstructure, porosity, phases present, mechanical response, and theoretical particle temperatures that were attained. The most promising coatings were the Ti-6Al-4V-based composite coatings, which had bond strength of 20±2MPa (n=5) and received reinforcement and strengthening from the inclusion of a glassy phase. It was shown that the use of the Ti-6Al-4V-bioactive glass composite coatings may be a superior choice due to the possible osteoproductivity from the bioactive glass, the potential ability to support tissue ingrowth and vascular tissue, and the comparable strength to similar coatings. Copyright © 2013 Elsevier B.V. All rights reserved.

Development and evaluation of suspension plasma sprayed yttria stabilized zirconia coatings as thermal barriers

NASA Astrophysics Data System (ADS)

van Every, Kent J.

The insulating effects from thermal barrier coatings (TBCs) in gas turbine engines allow for increased operational efficiencies and longer service lifetimes. Consequently, improving TBCs can lead to enhanced gas turbine engine performance. This study was conducted to investigate if yttria-stabilized zirconia (YSZ) coatings, the standard industrial choice for TBCs, produced from nano-sized powder could provide better thermal insulation than current commericial YSZ coatings generated using micron-sized powders. The coatings for this research were made via the recently developed suspension plasma spraying (SPS) process. With SPS, powders are suspended in a solvent containing dispersing agents; the suspension is then injected directly into a plasma flow that evaporates the solvent and melts the powder while transporting it to the substrate. Although related to the industrial TBC production method of air plasma spraying (APS), SPS has two important differences---the ability to spray sub-micron diameter ceramic particles, and the ability to alloy the particles with chemicals dissolved in the solvent. These aspects of SPS were employed to generate a series of coatings from suspensions containing ˜100 nm diameter YSZ powder particles, some of which were alloyed with neodymium and ytterbium ions from the solvent. The SPS coatings contained columnar structures not observed in APS TBCs; thus, a theory was developed to explain the formation of these features. The thermal conductivity of the coatings was tested to evaluate the effects of these unique microstructures and the effects of the alloying process. The results for samples in the as-sprayed and heat-treated conditions were compared to conventional YSZ TBCs. This comparison showed that, relative to APS YSZ coatings, the unalloyed SPS samples typically exhibited higher as-sprayed and lower heat-treated thermal conductivities. All thermal conductivity values for the alloyed samples were lower than conventional YSZ TBCs. The different thermal conduction behaviors were linked to the porosity and compositional properties of the coatings using immersion density, SEM, and synchrotron radiation characterization techniques.

Effect of thickness of insulation coating on temperature of electrically exploded tungsten wires in vacuum

NASA Astrophysics Data System (ADS)

Shi, Huantong; Zou, Xiaobing; Wang, Xinxin

2017-07-01

This paper reports an interesting observation of great differences in the temperature of exploded wires with insulation coating of different thicknesses. Two kinds of polyimide-coated tungsten wires were used with the same conductive diameter 12.5 μm but a different thickness of coating, 0.75-2.25 μm and 2.25-4.25 μm, respectively. The specific energy reconstructed from the current and voltage signals was quite close for the tested wires. However, the exploding scenario, obtained from Mach-Zehnder interferograms, showed great differences: a neutral outer-layer was observed around the thick-coated wire, which was absent for the thin-coated wire; and the calculated electron density and local thermal equilibrium temperature were much higher for thick-coated wires. The heat-preserving neutral layer formed by the decomposition of the insulation was supposed to be the cause of this phenomenon.

Controlling Microstructure of Yttria-Stabilized Zirconia Prepared from Suspensions and Solutions by Plasma Spraying with High Feed Rates

NASA Astrophysics Data System (ADS)

Musalek, Radek; Medricky, Jan; Tesar, Tomas; Kotlan, Jiri; Pala, Zdenek; Lukac, Frantisek; Illkova, Ksenia; Hlina, Michal; Chraska, Tomas; Sokolowski, Pawel; Curry, Nicholas

2017-12-01

Introduction of suspension and solution plasma spraying led to a breakthrough in the deposition of yttria-stabilized zirconia (YSZ) coatings and enabled preparation of new types of layers. However, their deposition with high feed rates needed, for example, for the deposition of thermal barrier coatings (TBCs) on large-scale components, is still challenging. In this study, possibility of high-throughput plasma spraying of YSZ coatings is demonstrated for the latest generation of high-enthalpy hybrid water-stabilized plasma (WSP-H) torch technology. The results show that microstructure of the coatings prepared by WSP-H may be tailored for specific applications by the choice of deposition conditions, in particular formulation of the liquid feedstock. Porous and columnar coatings with low thermal conductivity (0.5-0.6 W/mK) were prepared from commercial ethanol-based suspension. Dense vertically cracked coatings with higher thermal conductivity but also higher internal cohesion were deposited from suspension containing ethanol/water mixture and coarser YSZ particles. Spraying of solution formulated from diluted zirconium acetate and yttrium nitrate hexahydrate led also to the successful deposition of YSZ coating combining regions of porous and denser microstructure and providing both low thermal conductivity and improved cohesion of the coating. Enthalpy content, liquid-plasma interaction and coating buildup mechanisms are also discussed.

Cold Spraying of Cu-Al-Bronze for Cavitation Protection in Marine Environments

NASA Astrophysics Data System (ADS)

Krebs, S.; Gärtner, F.; Klassen, T.

2015-01-01

Traveling at high speeds, ships have to face the problem of rudder cavitation-erosion. At present, the problem is countered by fluid dynamically optimized rudders, synthetic, and weld-cladded coatings on steel basis. Nevertheless, docking and repair is required after certain intervals. Bulk Cu-Al-bronzes are in use at ships propellers to withstand corrosion and cavitation. Deposited as coatings with bulk-like properties, such bronzes could also enhance rudder life times. The present study investigates the coating formation by cold spraying CuAl10Fe5Ni5 bronze powders. By calculations of the impact conditions, the range of optimum spray parameters was preselected in terms of the coating quality parameter η on steel substrates with different temperatures. As-atomized and annealed powders were compared to optimize cavitation resistance of the coatings. Results provide insights about the interplay between the mechanical properties of powder and substrate for coating formation. Single particle impact morphologies visualize the deformation behavior. Coating performance was assessed by analyzing microstructures, bond strength, and cavitation resistance. These first results demonstrate that cold-sprayed bronze coatings have a high potential for ensuring a good performances in rudder protection. With further optimization, such coatings could evolve towards a competitive alternative to existing anti-cavitation procedures.

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.

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).

The role of nano-particles in the field of thermal spray coating technology

NASA Astrophysics Data System (ADS)

Siegmann, Stephan; Leparoux, Marc; Rohr, Lukas

2005-06-01

Nano-particles play not only a key role in recent research fields, but also in the public discussions about health and safety in nanotechnology. Nevertheless, the worldwide activities in nano-particles research increased dramatically during the last 5 to 10 years. There are different potential routes for the future production of nano-particles at large scale. The main directions envisaged are mechanical milling, wet chemical reactions or gas phase processes. Each of the processes has its specific advantages and limitations. Mechanical milling and wet chemical reactions are typically time intensive and batch processes, whereas gas phase productions by flames or plasma can be carried out continuously. Materials of interest are mainly oxide ceramics, carbides, nitrides, and pure metals. Nano-ceramics are interesting candidates for coating technologies due to expected higher coating toughness, better thermal shock and wear resistance. Especially embedded nano-carbides and-nitrides offer homogenously distributed hard phases, which enhance coatings hardness. Thermal spraying, a nearly 100 years old and world wide established coating technology, gets new possibilities thanks to optimized, nano-sized and/or nano-structured powders. Latest coating system developments like high velocity flame spraying (HVOF), cold gas deposition or liquid suspension spraying in combination with new powder qualities may open new applications and markets. This article gives an overview on the latest activities in nano-particle research and production in special relation to thermal spray coating technology.

Effect of Carbide Dissolution on Chlorine Induced High Temperature Corrosion of HVOF and HVAF Sprayed Cr3C2-NiCrMoNb Coatings

NASA Astrophysics Data System (ADS)

Fantozzi, D.; Matikainen, V.; Uusitalo, M.; Koivuluoto, H.; Vuoristo, P.

2018-01-01

Highly corrosion- and wear-resistant thermally sprayed chromium carbide (Cr3C2)-based cermet coatings are nowadays a potential highly durable solution to allow traditional fluidized bed combustors (FBC) to be operated with ecological waste and biomass fuels. However, the heat input of thermal spray causes carbide dissolution in the metal binder. This results in the formation of carbon saturated metastable phases, which can affect the behavior of the materials during exposure. This study analyses the effect of carbide dissolution in the metal matrix of Cr3C2-50NiCrMoNb coatings and its effect on chlorine-induced high-temperature corrosion. Four coatings were thermally sprayed with HVAF and HVOF techniques in order to obtain microstructures with increasing amount of carbide dissolution in the metal matrix. The coatings were heat-treated in an inert argon atmosphere to induce secondary carbide precipitation. As-sprayed and heat-treated self-standing coatings were covered with KCl, and their corrosion resistance was investigated with thermogravimetric analysis (TGA) and ordinary high-temperature corrosion test at 550 °C for 4 and 72 h, respectively. High carbon dissolution in the metal matrix appeared to be detrimental against chlorine-induced high-temperature corrosion. The microstructural changes induced by the heat treatment hindered the corrosion onset in the coatings.

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.

Correlation between Hierarchical Structure and Processing Control of Large-area Spray-coated Polymer Solar Cells toward High Performance

PubMed Central

Huang, Yu-Ching; Tsao, Cheng-Si; Cha, Hou-Chin; Chuang, Chih-Min; Su, Chun-Jen; Jeng, U-Ser; Chen, Charn-Ying

2016-01-01

The formation mechanism of a spray-coated film is different from that of a spin-coated film. This study employs grazing incidence small- and wide-angle X-ray Scattering (GISAXS and GIWAXS, respectively) quantitatively and systematically to investigate the hierarchical structure and phase-separated behavior of a spray-deposited blend film. The formation of PCBM clusters involves mutual interactions with both the P3HT crystal domains and droplet boundary. The processing control and the formed hierarchical structure of the active layer in the spray-coated polymer/fullerene blend film are compared to those in the spin-coated film. How the different post-treatments, such as thermal and solvent vapor annealing, tailor the hierarchical structure of the spray-coated films is quantitatively studied. Finally, the relationship between the processing control and tailored BHJ structures and the performance of polymer solar cell devices is established here, taking into account the evolution of the device area from 1 × 0.3 and 1 × 1 cm2. The formation and control of the special networks formed by the PCBM cluster and P3HT crystallites, respectively, are related to the droplet boundary. These structures are favorable for the transverse transport of electrons and holes. PMID:26817585

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.

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

Presence of electrostatically adsorbed polysaccharides improves spray drying of liposomes.

PubMed

Karadag, Ayse; Özçelik, Beraat; Sramek, Martin; Gibis, Monika; Kohlus, Reinhard; Weiss, Jochen

2013-02-01

Spray drying of liposomes with conventional wall materials such as maltodextrins often yields nonfunctional powders, that is, liposomes break down during drying and rehydration. Electrostatically coating the surface of liposomes with a charged polymer prior to spray drying may help solve this problem. Anionic lecithin liposomes (approximately 400 nm) were coated with lower (approximately 500 kDa, LMW-C) or higher (approximately 900 kDa, HMW-C) molecular weight cationic chitosan using the layer-by-layer depositing method. Low (DE20, LMW-MD) or high molecular weight (DE2, HMW-MD) maltodextrin was added as wall material to facilitate spray drying. If surfaces of liposomes (1%) were completely covered with chitosan (0.4%), no bridging or depletion flocculation would occur, and mean particle diameters would be approximately 500 nm. If maltodextrins (20%) were added to uncoated liposomes, extensive liposomal breakdown would occur making the system unsuitable for spray drying. No such aggregation or breakdown was observed when maltodextrin was added to chitosan-coated liposomes. Size changed little or even decreased slightly depending on the molecular weight of maltodextrin added. Scanning electron microscopy images of powders containing chitosan-coated liposomes revealed that their morphologies depended on the type of maltodextrin added. Powders prepared with LMW-MD contained mostly spherical particles while HMW-MD powders contained particles with concavities and dents. Upon redispersion, coated liposomes yielded back dispersions with particle size distributions similar to the original ones, except for LMW-C coated samples that had been spray dried with HMW-MD which yielded aggregates (approximately 30 μm). Results show that coating of liposomes with an absorbing polymer allows them to be spray dried with conventional maltodextrin wall materials. Liposomes have attracted considerable attention in the food and agricultural, biomedical industries for the delivery of functional components. However, maintaining their stability in aqueous dispersion represents a challenge for their commercialization. Spray drying may promise a solution to that problem. However, prior to this study spray drying of liposomes often led to the loss of structural integrity. Results of this study suggest that spray drying might be used to produce commercially feasible liposomal powders if proper combinations of adsorbing and nonadsorbing polymers are used in the liquid precursor system. © 2013 Institute of Food Technologists®

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.

Projection par plasma de depots de dioxyde de titane: Contribution a l'etude de leurs microstructures et proprietes electriques

NASA Astrophysics Data System (ADS)

Branland, Nadege

2002-04-01

The aim of this PhD work is, thanks to particle parameters (velocity and temperature) characterization, to try to understand the influence of plasma spray parameters on titania coating microstructures and the influence of the latter one on their electrical resistivity, for the same substrate conditions. The experimental approach has consisted in using two plasma spraying processes (Arc plasma spraying and Inductive plasma spraying) which have permitted to obtain a broad range of particle velocities and temperatures leading to coatings with specific microstructures. Despite the stoichiometry of the starting powder, all coatings obtained were grey, the oxygen loss increasing with the particle temperature. Isolating the stoichiometry influence has permitted to show that the decrease of the coatings electrical resistivity is especially due to the decrease of the number of bad interlamellar contacts.

Supplementary Microstructural Features Induced During Laser Surface Melting of Thermally Sprayed Inconel 625 Coatings

NASA Astrophysics Data System (ADS)

Ahmed, Nauman; Voisey, K. T.; McCartney, D. G.

2014-02-01

Laser surface melting of thermally sprayed coatings has the potential to enhance their corrosion properties by incorporating favorable microstructural changes. Besides homogenizing the as-sprayed structure, laser melting may induce certain microstructural modifications (i.e., supplementary features) in addition to those that directly improve the corrosion performance. Such features, being a direct result of the laser treatment process, are described in this paper which is part of a broader study in which high velocity oxy-fuel sprayed Inconel 625 coatings on mild-steel substrates were treated with a diode laser and the modified microstructure characterized using optical and scanning electron microscopy and x-ray diffraction. The laser treated coating features several different zones, including a region with a microstructure in which there is a continuous columnar dendritic structure through a network of retained oxide stringers.

Vacuum plasma coatings for turbine blades

NASA Technical Reports Server (NTRS)

Holmes, R. R.

1985-01-01

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

Next Generation Thermal Barrier Coatings for the Gas Turbine Industry

NASA Astrophysics Data System (ADS)

Curry, Nicholas; Markocsan, Nicolaie; Li, Xin-Hai; Tricoire, Aurélien; Dorfman, Mitch

2011-01-01

The aim of this study is to develop the next generation of production ready air plasma sprayed thermal barrier coating with a low conductivity and long lifetime. A number of coating architectures were produced using commercially available plasma spray guns. Modifications were made to powder chemistry, including high purity powders, dysprosia stabilized zirconia powders, and powders containing porosity formers. Agglomerated & sintered and homogenized oven spheroidized powder morphologies were used to attain beneficial microstructures. Dual layer coatings were produced using the two powders. Laser flash technique was used to evaluate the thermal conductivity of the coating systems from room temperature to 1200 °C. Tests were performed on as-sprayed samples and samples were heat treated for 100 h at 1150 °C. Thermal conductivity results were correlated to the coating microstructure using image analysis of porosity and cracks. The results show the influence of beneficial porosity on reducing the thermal conductivity of the produced coatings.

Preparation and characterization of hydroxyapatite-coated iron oxide particles by spray-drying technique.

PubMed

Donadel, Karina; Felisberto, Marcos D V; Laranjeira, Mauro C M

2009-06-01

Magnetic particles of iron oxide have been increasingly used in medical diagnosis by magnetic resonance imaging and in cancer therapies involving targeted drug delivery and magnetic hyperthermia. In this study we report the preparation and characterization of iron oxide particles coated with bioceramic hydroxyapatite by spray-drying. The iron oxide magnetic particles (IOMP) were coated with hydroxyapatite (HAp) by spray-drying using two IOMP/HAp ratios (0.7 and 3.2). The magnetic particles were characterized by way of scanning electronic microscopy, energy dispersive X-ray, X-ray diffraction, Fourier transformed infrared spectroscopy, flame atomic absorption spectrometry,vibrating sample magnetometry and particle size distribution (laser diffraction). The surface morphology of the coated samples is different from that of the iron oxide due to formation of hydroxyapatite coating. From an EDX analysis, it was verified that the surface of the coated magnetic particles is composed only of HAp, while the interior containsiron oxide and a few layers of HAp as expected. The results showed that spray-drying technique is an efficient and relatively inexpensive method for forming spherical particles with a core/shell structure.

Development of Ultra-High Molecular Weight Polyethylene (UHMWPE) Coating by Cold Spray Technique

NASA Astrophysics Data System (ADS)

Ravi, Kesavan; Ichikawa, Yuji; Deplancke, Tiana; Ogawa, Kazuhiro; Lame, Olivier; Cavaille, Jean-Yves

2015-08-01

Ultra-high molecular weight polyethylene or UHMWPE is an extremely difficult material to coat with, as it is rubbery and chemically very inert. The Cold Spray process appears to be a promising alternative processing technique but polymers are in general difficult to deposit using this method. So, attempts to develop UHMWPE coatings were made using a downstream injection cold spray technique incorporating a few modifications. A conventional cold spray machine yielded only a few deposited particles of UHMWPE on the substrate surface, but with some modifications in the nozzle geometry (especially the length and inner geometry) a thin coating of 45 μm on Al substrate was obtained. Moreover, experiments with the addition of fumed nano-alumina to the feedstock yielded a coating of 1-4 mm thickness on Al and polypropylene substrates. UHMWPE was seen to be melt crystallized during the coating formation, as can be seen from the differential calorimetry curves. Influence of nano-ceramic particles was explained by observing the creation of a bridge bond between UHMWPE particles.

Thermo-mechanical modeling of laser treatment on titanium cold-spray coatings

NASA Astrophysics Data System (ADS)

Paradiso, V.; Rubino, F.; Tucci, F.; Astarita, A.; Carlone, P.

2018-05-01

Titanium coatings are very attractive to several industrial fields, especially aeronautics, due to the enhanced corrosion resistance and wear properties as well as improved compatibility with carbon fiber reinforced plastic (CFRP) materials. Cold sprayed titanium coatings, among the others deposition processes, are finding a widespread use in high performance applications, whereas post-deposition treatments are often used to modify the microstructure of the cold-sprayed layer. Laser treatments allow one to noticeably increase the superficial properties of titanium coatings when the process parameters are properly set. On the other hand, the high heat input required to melt titanium particles may result in excessive temperature increase even in the substrate. This paper introduces a thermo-mechanical model to simulate the laser treatment effects on a cold sprayed titanium coating as well as the aluminium substrate. The proposed thermo-mechanical finite element model considers the transient temperature field due to the laser source and applied boundary conditions using them as input loads for the subsequent stress-strain analysis. Numerical outcomes highlighted the relevance of thermal gradients and thermally induced stresses and strains in promoting the damage of the coating.

Effects of MgO and SiO2 on Plasma-Sprayed Hydroxyapatite Coating: An in Vivo Study in Rat Distal Femoral Defects.

PubMed

Ke, Dongxu; Robertson, Samuel F; Dernell, William S; Bandyopadhyay, Amit; Bose, Susmita

2017-08-09

Plasma-sprayed hydroxyapatite (HA)-coated titanium implants have been widely used in orthopedic applications due to their inheritance of an excellent mechanical property from titanium and great osteoconductivity from HA. However, the lack of osteoinductivity limits their further applications. In this study, 1 wt % MgO and 0.5 wt % SiO 2 were mixed with HA for making plasma-sprayed coatings on titanium implants. Plasma-sprayed HA- and MgO/SiO 2 -HA-coated titanium implants showed adhesive bond strengths of 25.73 ± 1.92 and 23.44 ± 2.89 MPa, respectively. The presence of MgO and SiO 2 significantly increased the osteogenesis, osseointegration, and bone mineralization of HA-coated titanium implants by the evaluation of their histomorphology after 6, 10, and 14 weeks of implantation in rat distal femoral defects. Implant pushout tests also showed a shear modulus of 149.83 ± 3.69 MPa for MgO/SiO 2 -HA-coated implants after 14 weeks of implantation, compared to 52.68 ± 10.41 MPa for uncoated implants and 83.92 ± 3.68 MPa for pure HA-coated implants; These are differences in the shear modulus of 96% and 56.4%, respectively. This study assesses for the first time the quality of the bone-implant interface of induction plasma-sprayed MgO and SiO 2 binary-doped HA coatings on load-bearing implants compared to bare titanium and pure HA coatings in a quantitative manner. Relating the osseointegration and interface shear modulus to the quality of implant fixation is critical to the advancement and implementation of HA-coated orthopedic implants.

A novel method to predict the highest hardness of plasma sprayed coating without micro-defects

NASA Astrophysics Data System (ADS)

Zhuo, Yukun; Ye, Fuxing; Wang, Feng

2018-04-01

The plasma sprayed coatings are stacked by splats, which are regarded generally as the elementary units of coating. Many researchers have focused on the morphology and formation mechanism of splat. However, a novel method to predict the highest hardness of plasma sprayed coating without micro-defects is proposed according to the nanohardness of splat in this paper. The effectiveness of this novel method was examined by experiments. Firstly, the microstructure of splats and coating, meanwhile the 3D topography of the splats were observed by SEM (SU1510) and video microscope (VHX-2000). Secondly, the nanohardness of splats was evaluated by nanoindentation (NHT) in order to be compared with microhardness of coating measured by microhardness tester (HV-1000A). The results show that the nanohardness of splats with diameter of 70 μm, 100 μm and 140 μm were in the scope of 11∼12 GPa while the microhardness of coating were in the range of 8∼9 GPa. Because the splats had not micro-defects such as pores and cracks in the nanohardness evaluated nano-zone, the nanohardness of the splats can be utilized to predict the highest hardness of coating without micro-defects. This method indicates the maximum of sprayed coating hardness and will reduce the test number to get high hardness coating for better wear resistance.

Atmospheric Plasma Spraying Low-Temperature Cathode Materials for Solid Oxide Fuel Cells

NASA Astrophysics Data System (ADS)

Harris, J.; Kesler, O.

2010-01-01

Atmospheric plasma spraying (APS) is attractive for manufacturing solid oxide fuel cells (SOFCs) because it allows functional layers to be built rapidly with controlled microstructures. The technique allows SOFCs that operate at low temperatures (500-700 °C) to be fabricated by spraying directly onto robust and inexpensive metallic supports. However, standard cathode materials used in commercial SOFCs exhibit high polarization resistances at low operating temperatures. Therefore, alternative cathode materials with high performance at low temperatures are essential to facilitate the use of metallic supports. Coatings of lanthanum strontium cobalt ferrite (LSCF) were fabricated on steel substrates using axial-injection APS. The thickness and microstructure of the coating layers were evaluated, and x-ray diffraction analysis was performed on the coatings to detect material decomposition and the formation of undesired phases in the plasma. These results determined the envelope of plasma spray parameters in which coatings of LSCF can be manufactured, and the range of conditions in which composite cathode coatings could potentially be manufactured.

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.

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.

Thermophysical Properties of Cold and Vacuum Plasma Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings. Part 1; Electrical and Thermal Conductivity, Thermal Diffusivity, and Total Hemispherical Emissivity

NASA Technical Reports Server (NTRS)

Raj, S. V.

2017-01-01

This two-part paper reports the thermophysical properties of several cold and vacuum plasma sprayed monolithic Cu and Ni-based alloy coatings. Part I presents the electrical and thermal conductivity, thermal diffusivity, and total hemispherical emissivity data while Part II reports the specific heat capacity data for these coatings. Metallic copper alloys, stoichiometric NiAl and NiCrAlY coatings were fabricated by either the cold sprayed or the vacuum plasma spray deposition processes for thermal property measurements between 77 and 1223 K. The temperature dependencies of the thermal conductivities, thermal diffusivities, electrical conductivities and total hemispherical emissivities of these cold and vacuum sprayed monolithic coatings are reported in this paper. The electrical and thermal conductivity data correlate reasonably well for Cu-8%Cr-1%Al, Cu-23%Cr-5%Al and NiAl in accordance with the Wiedemann-Franz (WF) law although a better fit is obtained using the Smith-Palmer relationship. The Lorentz numbers determined from the WF law are close to the theoretical value.

Mueller matrix polarimetry on plasma sprayed thermal barrier coatings for porosity measurement.

PubMed

Luo, David A; Barraza, Enrique T; Kudenov, Michael W

2017-12-10

Yttria-stabilized zirconia (YSZ) is the most widely used material for thermal plasma sprayed thermal barrier coatings (TBCs) used to protect gas turbine engine parts in demanding operation environments. The superior material properties of YSZ coatings are related to their internal porosity level. By quantifying the porosity level, tighter control on the spraying process can be achieved to produce reliable coatings. Currently, destructive measurement methods are widely used to measure the porosity level. In this paper, we describe a novel nondestructive approach that is applicable to classify the porosity level of plasma sprayed YSZ TBCs via Mueller matrix polarimetry. A rotating retarder Mueller matrix polarimeter was used to measure the polarization properties of the plasma sprayed YSZ coatings with different porosity levels. From these measurements, it was determined that a sample's measured depolarization ratio is dependent on the sample's surface roughness and porosity level. To this end, we correlate the depolarization ratio with the samples' surface roughness, as measured by a contact profilometer, as well as the total porosity level, in percentage measured using a micrograph and stereological analysis. With the use of this technique, a full-field and rapid measurement of porosity level can be achieved.

Thermal Spray Deposition, Phase Stability and Mechanical Properties of La2Zr2O7/LaAlO3 Coatings

NASA Astrophysics Data System (ADS)

Lozano-Mandujano, D.; Poblano-Salas, C. A.; Ruiz-Luna, H.; Esparza-Esparza, B.; Giraldo-Betancur, A. L.; Alvarado-Orozco, J. M.; Trápaga-Martínez, L. G.; Muñoz-Saldaña, J.

2017-08-01

This paper deals with the deposition of La2Zr2O7 (LZO) and LaAlO3 (LAO) mixtures by air plasma spray (APS). The raw material for thermal spray, single phase LZO and LAO in a 70:30 mol.% ratio mixture was prepared from commercial metallic oxides by high-energy ball milling (HEBM) and high-temperature solid-state reaction. The HEBM synthesis route, followed by a spray-drying process, successfully produced spherical agglomerates with adequate size distribution and powder-flow properties for feeding an APS system. The as-sprayed coating consisted mainly of a crystalline LZO matrix and partially crystalline LAO, which resulted from the high cooling rate experienced by the molten particles as they impact the substrate. The coatings were annealed at 1100 °C to promote recrystallization of the LAO phase. The reduced elastic modulus and hardness, measured by nanoindentation, increased from 124.1 to 174.7 GPa and from 11.3 to 14.4 GPa, respectively, after the annealing treatment. These values are higher than those reported for YSZ coatings; however, the fracture toughness ( K IC) of the annealed coating was only 1.04 MPa m0.5.

Thermophysical Properties of Cold- and Vacuum Plasma-Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings I: Electrical and Thermal Conductivity, Thermal Diffusivity, and Total Hemispherical Emissivity

NASA Astrophysics Data System (ADS)

Raj, S. V.

2017-11-01

This two-part paper reports the thermophysical properties of several cold- and vacuum plasma-sprayed monolithic Cu- and Ni-based alloy coatings. Part I presents the electrical and thermal conductivity, thermal diffusivity, and total hemispherical emissivity data, while Part II reports the specific heat capacity data for these coatings. Metallic copper alloys and stoichiometric NiAl and NiCrAlY coatings were fabricated by either the cold spray or the vacuum plasma spray deposition processes for thermal property measurements between 77 and 1223 K. The temperature dependencies of the thermal conductivities, thermal diffusivities, electrical conductivities, and total hemispherical emissivities of these cold- and vacuum-sprayed monolithic coatings are reported in this paper. The electrical and thermal conductivity data correlate reasonably well for Cu-8%Cr-1%Al, Cu-23%Cr-5%Al, and NiAl in accordance with the Wiedemann-Franz (WF) law although a better fit is obtained using the Smith-Palmer relationship. The Lorentz numbers determined from the WF law are close to the theoretical value.

Effect of the Cold-Sprayed Aluminum Coating-Substrate Interface Morphology on Bond Strength for Aircraft Repair Application

NASA Astrophysics Data System (ADS)

Blochet, Quentin; Delloro, Francesco; N'Guyen, Franck; Jeulin, Dominique; Borit, François; Jeandin, Michel

2017-04-01

This article is dealing with the effects of surface preparation of the substrate on aluminum cold-sprayed coating bond strength. Different sets of AA2024-T3 specimens have been coated with pure Al 1050 feedstock powder, using a conventional cold spray coating technique. The sets were grit-blasted (GB) before coating. The study focuses on substrate surface topography evolution before coating and coating-substrate interface morphology after coating. To study coating adhesion by LASAT® technique for each set, specimens with and without preceding GB treatment were tested in load-controlled conditions. Then, several techniques were used to evaluate the effects of substrate surface treatment on the final coating mechanical properties. Irregularities induced by the GB treatment modify significantly the interface morphology. Results showed that particle anchoring was improved dramatically by the presence of craters. The substrate surface was characterized by numerous anchors. Numerical simulation results exhibited the increasing deformation of particle onto the grit-blasted surface. In addition, results showed a strong relationship between the coating-substrate bond strength on the deposited material and surface preparation.

Microstructure and Sliding Wear Performance of Cr7C3-(Ni,Cr)3(Al,Cr) Coating Deposited from Cr7C3 In Situ Formed Atomized Powder

NASA Astrophysics Data System (ADS)

Zhu, Hong-Bin; Shen, Jie; Gao, Feng; Yu, Yueguang; Li, Changhai

2017-01-01

This work is aimed at developing a new type of Cr7C3-(Ni,Cr)3(Al,Cr) coating for parts used in heavy-duty diesel engines. The feedstock, in which the stripe-shaped Cr7C3 was in situ formed, was firstly prepared by vacuum melting and gas atomization and then subjected by high-velocity oxy-fuel spraying to form the coatings. The carbon content, microstructure and phase constitution of the powders, as well as the sprayed coatings, were analyzed by chemical analysis, SEM and XRD. The hardness and sliding wear performance of the sprayed coatings were also tested and compared to a commercial Cr3C2-NiCr coating used on piston rings. The results showed that the content of carbon in feedstock was almost the same as designed, and that the volume content of in situ formed Cr7C3 was increased with carbon and chromium added. The major phases of the powders and sprayed coatings are Cr7C3 and Cr-alloyed Ni3Al. Only a small amount of carbon lost during the spraying process. As Cr7C3 content increased in the coatings, the microhardness at room temperature was firstly increased to about 1000Hv0.3. The microhardness of the coatings stayed almost constant, while the testing temperature was raised up to 700 °C for 0.5 h, which illustrates the potential application of the investigated coatings under high temperature conditions. The coatings containing 70 and 77 vol.% Cr7C3 showed the most promising wear resistance, lower friction coefficient and better tribological compatibility to gray cast iron counterpart than other tested Cr7C3-(Ni,Cr)3(Al,Cr) coatings and the reference Cr3C2-NiCr coating.

Laser surface modification of Yttria Stabilized Zirconia (YSZ) thermal barrier coating on AISI H13 tool steel substrate

NASA Astrophysics Data System (ADS)

Reza, M. S.; Aqida, S. N.; Ismail, I.

2018-03-01

This paper presents laser surface modification of plasma sprayed yttria stabilized zirconia (YSZ) coating to seal porosity defect. Laser surface modification on plasma sprayed YSZ was conducted using 300W JK300HPS Nd: YAG laser at different operating parameters. Parameters varied were laser power and pulse frequency with constant residence time. The coating thickness was measured using IM7000 inverted optical microscope and surface roughness was analysed using two-dimensional Mitutoyo Surface Roughness Tester. Surface roughness of laser surface modification of YSZ H-13 tool steel decreased significantly with increasing laser power and decreasing pulse frequency. The re-melted YSZ coating showed higher hardness properties compared to as-sprayed coating surface. These findings were significant to enhance thermal barrier coating surface integrity for dies in semi-solid processing.

Structure and Corrosion Behavior of Arc-Sprayed Zn-Al Coatings on Ductile Iron Substrate

NASA Astrophysics Data System (ADS)

Bonabi, Salar Fatoureh; Ashrafizadeh, Fakhreddin; Sanati, Alireza; Nahvi, Saied Mehran

2018-02-01

In this research, four coatings including pure zinc, pure aluminum, a double-layered coating of zinc and aluminum, and a coating produced by simultaneous deposition of zinc and aluminum were deposited on a cast iron substrate using electric arc-spraying technique. The coatings were characterized by XRD, SEM and EDS map and spot analyses. Adhesion strength of the coatings was evaluated by three-point bending tests, where double-layered coating indicated the lowest bending angle among the specimens, with detection of cracks at the coating-substrate interface. Coatings produced by simultaneous deposition of zinc and aluminum possessed a relatively uniform distribution of both metals. In order to evaluate the corrosion behavior of the coatings, cyclic polarization and salt spray tests were conducted. Accordingly, pure aluminum coating showed susceptibility to pitting corrosion and other coatings underwent uniform corrosion. For double-layered coating, SEM micrographs revealed zinc corrosion products as flaky particles in the pores formed by pitting on the surface, an indication of penetration of corrosion products from the lower layer (zinc) to the top layer (aluminum). All coatings experienced higher negative corrosion potentials than the iron substrate, indicative of their sacrificial behavior.

40 CFR 63.5743 - What standards must I meet for aluminum recreational boat surface coating operations?

Code of Federal Regulations, 2013 CFR

2013-07-01

... in paragraph (b)(1), (2), (3), or (4) of this section when cleaning aluminum coating spray guns with solvents containing more than 5 percent organic HAP by weight. (1) Clean spray guns in an enclosed device. Keep the device closed except when you place spray guns in or remove them from the device. (2...

40 CFR 63.5743 - What standards must I meet for aluminum recreational boat surface coating operations?

Code of Federal Regulations, 2011 CFR

2011-07-01

... paragraph (b)(1), (2), (3), or (4) of this section when cleaning aluminum coating spray guns with solvents containing more than 5 percent organic HAP by weight. (1) Clean spray guns in an enclosed device. Keep the device closed except when you place spray guns in or remove them from the device. (2) Disassemble the...

40 CFR 63.5743 - What standards must I meet for aluminum recreational boat surface coating operations?

Code of Federal Regulations, 2010 CFR

2010-07-01

... paragraph (b)(1), (2), (3), or (4) of this section when cleaning aluminum coating spray guns with solvents containing more than 5 percent organic HAP by weight. (1) Clean spray guns in an enclosed device. Keep the device closed except when you place spray guns in or remove them from the device. (2) Disassemble the...

Photon calorimeter

DOEpatents

Chow, Tze-Show

1988-04-22

A photon calorimeter is provided that comprises a laminar substrate that is uniform in density and homogeneous in atomic composition. A plasma-sprayed coating, that is generally uniform in density and homogeneous in atomic composition within the proximity of planes that are parallel to the surfaces of the substrate, is applied to either one or both sides of the laminar substrate. The plasma-sprayed coatings may be very efficiently spectrally tailored in atomic number. Thermocouple measuring junctions, are positioned within the plasma-sprayed coatings. The calorimeter is rugged, inexpensive, and equilibrates in temperature very rapidly. 4 figs.

A Novel Nonelectrolytic Process for Chromium and Nickel Coating

DTIC Science & Technology

2015-06-01

thermal spraying and involves similar protocols for coating an object. The process proceeds after powder is injected into a plasma jet then superheated...HVOF) High velocity oxygen fuel coating is characteristic of a thermal spray coating process , enhancing anti-corrosion and anti-wear properties of...observations due to limited metal deposition on the surface during treatment. No powder particles were produced during this RES process . a. Optical

Tribological Behavior of Plasma-Sprayed Al2O3-20 wt.%TiO2 Coating

NASA Astrophysics Data System (ADS)

Cui, Shiyu; Miao, Qiang; Liang, Wenping; Zhang, Zhigang; Xu, Yi; Ren, Beilei

2017-05-01

Al2O3-20 wt.% TiO2 ceramic coatings were deposited on the surface of Grade D steel by plasma spraying of commercially available powders. The phases and the microstructures of the coatings were investigated by x-ray diffraction and scanning electron microscopy, respectively. The Al2O3-20 wt.% TiO2 composite coating exhibited a typical inter-lamellar structure consisting of the γ-Al2O3 and the Al2TiO5 phases. The dry sliding wear behavior of the coating was examined at 20 °C using a ball-on-disk wear tester. The plasma-sprayed coating showed a low wear rate ( 4.5 × 10-6 mm3 N-1 m-1), which was <2% of that of the matrix ( 283.3 × 10-6 mm3 N-1 m-1), under a load of 15 N. In addition, the tribological behavior of the plasma-sprayed coating was analyzed by examining the microstructure after the wear tests. It was found that delamination of the Al2TiO5 phase was the main cause of the wear during the sliding wear tests. A suitable model was used to simulate the wear mechanism of the coating.

The Wear Behavior of HVOF Sprayed Near-Nanostructured WC-17%Ni(80/20)Cr Coatings in Dry and Slurry Wear Conditions

NASA Astrophysics Data System (ADS)

Ben Mahmud, Tarek A.; Atieh, Anas M.; Khan, Tahir I.

2017-07-01

The ability to deposit nanostructured feedstock by using high-velocity oxygen-fuel (HVOF) spray offers potential improvements in coating hardness, wear resistance and toughness for applications in the oil sands industry. In this study, the wear behavior of a near-nanostructured coating was compared under dry and slurry abrasive wear test using an uncoated AISI-1018 low-carbon steel substrate as a reference. The coating microstructures were analyzed in the as-sprayed, dry and slurry test conditions using scanning electron microscopy, x-ray diffraction and microhardness measurements. Wear behavior of the steel and coating surfaces were assessed using a pin-on-plate wear test under various loads. The results showed that a coating could be successfully deposited using the HVOF spraying technique and with retention of the near-nanosized WC dispersion within the coating structure. The wear rate under dry test conditions was greater for the steel and coating compared to tests performed under slurry conditions. Examination of the wear tracks revealed that the wear mechanism was different for the two test conditions. Wear in the dry test condition resulted from 2-body abrasion, while 3-body abrasion dominated wear in slurry conditions. The latter showed lower wear rates due to a lubricating effect of the oil.

Chemical Stability and Biological Properties of Plasma-Sprayed CaO-SiO2-ZrO2 Coatings

NASA Astrophysics Data System (ADS)

Liang, Ying; Xie, Youtao; Ji, Heng; Huang, Liping; Zheng, Xuebin

2010-12-01

In this work, calcia-stabilized zirconia powders were coated by silica derived from tetraethoxysilane (TEOS) hydrolysis. After calcining at 1400 °C, decalcification of calcia-stabilized zirconia by silica occurred and powders composed of Ca2SiO4, ZrO2, and CaZrO3 were prepared. We produced three kinds of powders with different Ca2SiO4 contents [20 wt.% (denoted as CZS2), 40 wt.% (denoted as CZS4), and 60 wt.% (denoted as CZS6)]. The obtained powders were sprayed onto Ti-6Al-4V substrates using atmospheric plasma spraying. The microstructure of the powders and coatings were analyzed. The dissolution rates of the coatings were assessed by monitoring the ions release and mass losses after immersion in Tris-HCl buffer solution. Results showed that the chemical stability of the coatings were significantly improved compared with pure calcium silicate coatings, and increased with the increase of Zr contents. The CZS4 coating showed not only good apatite-formation ability in simulated body fluid, but also well attachment and proliferation capability for the canine bone marrow stem cells. Results presented here indicate that plasma-sprayed CZS4 coating has medium dissolution rate and good biological properties, suggesting its potential use as bone implants.

Plasma-Sprayed High Entropy Alloys: Microstructure and Properties of AlCoCrFeNi and MnCoCrFeNi

NASA Astrophysics Data System (ADS)

Ang, Andrew Siao Ming; Berndt, Christopher C.; Sesso, Mitchell L.; Anupam, Ameey; S, Praveen; Kottada, Ravi Sankar; Murty, B. S.

2015-02-01

High entropy alloys (HEAs) represent a new class of materials that present novel phase structures and properties. Apart from bulk material consolidation methods such as casting and sintering, HEAs can also be deposited as a surface coating. In this work, thermal sprayed HEA coatings are investigated that may be used as an alternative bond coat material for a thermal barrier coating system. Nanostructured HEAs that were based on AlCoCrFeNi and MnCoCrFeNi were prepared by ball milling and then plasma sprayed. Splat studies were assessed to optimise the appropriate thermal spray parameters and spray deposits were prepared. After mechanical alloying, aluminum-based and manganese-based HEA powders revealed contrary prominences of BCC and FCC phases in their X-ray diffraction patterns. However, FCC phase was observed as the major phase present in both of the plasma-sprayed AlCoCrFeNi and MnCoCrFeNi coatings. There were also minor oxide peaks detected, which can be attributed to the high temperature processing. The measured porosity levels for AlCoCrFeNi and MnCoCrFeNi coatings were 9.5 ± 2.3 and 7.4 ± 1.3 pct, respectively. Three distinct phase contrasts, dark gray, light gray and white, were observed in the SEM images, with the white regions corresponding to retained multicomponent HEAs. The Vickers hardness (HV0.3kgf) was 4.13 ± 0.43 and 4.42 ± 0.60 GPa for AlCoCrFeNi and MnCoCrFeNi, respectively. Both type of HEAs coatings exhibited anisotropic mechanical behavior due to their lamellar, composite-type microstructure.

Influence of microstructure on hardness of plasma sprayed Al2O3-TiO2-MgO coatings with interface diffusion by heat treatment

NASA Astrophysics Data System (ADS)

Chen, Kunlun; Song, Peng; Li, Chao; Lu, Jiansheng

2017-12-01

The effect of heat treatment on the microstructure and mechanical properties of Al2O3-TiO2 coatings doped with 5 wt% MgO was investigated in this paper. The composite coatings were prepared by atmospheric plasma spraying (APS) and heat treated at 1000 °C for 24 h in Ar. The coatings were analyzed using scanning electron microscopy with electron probe x-ray microanalysis and x-ray diffraction. The hardness was determined using a Vickers hardness test on the as-sprayed coatings and after heat treatment. The results showed that the interface diffusion between the Al-rich and Ti-rich layers resulted in mutual pinning within the coating during the heat treatment. The newly formed MgAl2O4 phase promoted cracking-healing behavior within the coating. We conclude that increase of the hardness of the coatings was mainly caused by the mutual pinning interface and crack healing.

Synthesis and characterization of in situ TiC-TiB2 composite coatings by reactive plasma spraying on a magnesium alloy

NASA Astrophysics Data System (ADS)

Zou, Binglin; Tao, Shunyan; Huang, Wenzhi; Khan, Zuhair S.; Fan, Xizhi; Gu, Lijian; Wang, Ying; Xu, Jiaying; Cai, Xiaolong; Ma, Hongmei; Cao, Xueqiang

2013-01-01

TiC-TiB2 composite coatings were successfully synthesized using the technique of reactive plasma spraying (RPS) on a magnesium alloy. Phase composition, microstructure and wear resistance of the coatings were characterized by using X-ray diffraction, scanning electron microscopy and pin-on-disk wear test, respectively. The results showed that the resultant product in the RPS coatings was composed of TiC and TiB2. Depending on the ignition of self-propagating high-temperature synthesis reaction in the agglomerate particles, the RPS coatings displayed porous and dense microstructures. The porosity of the RPS coatings, to some extent, decreased when the feed powders were plasma sprayed with Ni powders. The RPS coatings provided good wear resistance for the substrate under various loads. For high loads (e.g., ≥15 N), the wear resistance could be significantly improved by the proper addition of Ni into the RPS coatings.

Characterization of Cold Sprayed CuCrAl-Coated and Uncoated GRCop-84 Substrates for Space Launch Vehicles

NASA Technical Reports Server (NTRS)

Raj, S. V.; Karthikeyan, J.; Lerch, B. A.; Barrett, C.; Garlich, R.

2007-01-01

A newly developed Cu-23(wt.%)Cr-5%Al (CuCrAl) alloy is currently being considered as a protective coating for GRCop-84 (Cu-8(at.%)Cr-4%Nb). The coating was deposited on GRCop-84 substrates by the cold spray deposition technique. Cyclic oxidation tests conducted in air on both coated and uncoated substrates between 773 and 1073 K revealed that the coating remained intact and protected the substrate up to 1073 K. No significant weight loss of the coated specimens were observed at 773 and 873 K even after a cumulative cyclic time of 500 h. In contrast, the uncoated substrate lost as much as 80% of its original weight under similar test conditions. Low cycle fatigue tests revealed that the fatigue lives of thinly coated GRCop-84 specimens were similar to the uncoated specimens within the limits of experimental scatter. It is concluded that the cold sprayed CuCrAl coating is suitable for protecting GRCop-84 substrates.

Inorganic fullerene-like tungsten disulfide nanocoating for friction reduction of nickel-titanium alloys.

PubMed

Samorodnitzky-Naveh, Gili R; Redlich, Meir; Rapoport, Lev; Feldman, Yishay; Tenne, Reshef

2009-12-01

To fabricate a friction-reducing coating onto different nickel-titanium (NiTi) substrates using inorganic fullerene-like tungsten disulfide (IF-WS(2)) nanoparticles and to estimate in vitro friction reducing extent of the coating. Different NiTi substrates were coated with cobalt and IF-WS(2) nanoparticles film by the electrodeposition procedure. Coating composition analyses was made by scanning-electron microscopy, energy dispersive x-ray spectroscopy, x-ray powder diffractometry and x-ray photoelectron spectroscopy. Friction evaluation was carried out using standard tribological tests and an Instron system. Stable and well-adhered cobalt + IF-WS(2) coating of the NiTi substrates was obtained. Friction tests presented up to 66% reduction of the friction coefficient. NiTi alloy is widely used for many medical appliances; hence, this unique friction-reducing coating could be implemented to provide better manipulation and lower piercing rates.

INTERIOR VIEW, LOOKING WEST, WITH PIPE BEING SPRAYED WITH ZINC ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

INTERIOR VIEW, LOOKING WEST, WITH PIPE BEING SPRAYED WITH ZINC COATING. - United States Pipe & Foundry Company Plant, Coating, Painting, Lining & Packaging Building, 2023 St. Louis Avenue at I-20/59, Bessemer, Jefferson County, AL

Zinc-rich coatings: A market survey

NASA Technical Reports Server (NTRS)

Lizak, R.

1975-01-01

Zinc-rich coatings with both organic and inorganic binders were considered for coastal bridges which require more corrosion protection than inland bridges because of exposure to salt spray and fog. Inorganics give longer protection and may be applied without a finish coat; those currently available are harder to apply than organics. The NASA potassium silicate/zinc - dust coating appears to provide longer protection, resist thermal shock, and overcome the application problem. Panels coated with the formulation withstood 5308 hours in a salt spray chamber with no rusting or blistering.

Influence of Surface Finishing on the Oxidation Behaviour of VPS MCrAlY Coatings

NASA Astrophysics Data System (ADS)

Fossati, Alessio; di Ferdinando, Martina; Bardi, Ugo; Scrivani, Andrea; Giolli, Carlo

2012-03-01

CoNiCrAlY coatings were produced by means of the vacuum plasma spraying (VPS) process onto CMSX-4 single crystal nickel superalloy disk substrates. As-sprayed samples were annealed at high temperatures in low vacuum. Three kinds of finishing processes were carried out, producing three types of samples: as-sprayed, mechanically smoothed by grinding, ground and PVD coated by using aluminum targets in an oxygen atmosphere. Samples were tested under isothermal conditions, in air, at 1000 °C, and up to 5000 h. Morphological, microstructural and compositional analyses were performed on the coated samples in order to assess the high temperature oxidation behavior provided by the three different surface finishing processes. Several differences were observed: grinding operations decrease the oxidation resistance, whereas the PVD process can increase the performances over longer time with respect of the as-sprayed samples.

Wear Behavior of Plasma Spray Deposited and Post Heat-Treated Hydroxyapatite (HA)-Based Composite Coating on Titanium Alloy (Ti-6Al-4V) Substrate

NASA Astrophysics Data System (ADS)

Kumari, Renu; Majumdar, Jyotsna Dutta

2018-04-01

The present study concerns a detailed evaluation of wear resistance property of plasma spray deposited composite hydroxyapatite (HA)-based (HA-50 wt pct TiO2 and HA-10 wt pct ZrO2) bioactive coatings developed on Ti-6Al-4V substrate and studying the effect of heat treatment on it. Heat treatment of plasma spray deposited samples has been carried out at 650 °C for 2 hours (for HA-50 wt pct TiO2 coating) and at 750 °C for 2 hours (for HA-10 wt pct ZrO2 coating). There is significant deterioration in wear resistance for HA-50 wt pctTiO2 coating and a marginal deterioration in wear resistance for HA-10 wt pct ZrO2 coating in as-sprayed state (as compared to as-received Ti-6Al-4V) which is, however, improved after heat treatment. The coefficient of friction is marginally increased for both HA-50 wt pct TiO2 and HA-10 wt pct ZrO2 coatings in as-sprayed condition as compared to Ti-6Al-4V substrate. However, coefficient of friction is decreased for both HA-50 wt pct TiO2 and HA-10 wt pct ZrO2 coatings after heat-treated condition as compared to Ti-6Al-4V substrate. The maximum improvement in wear resistance property is, however, observed for HA-10 wt pct ZrO2 sample after heat treatment. The mechanism of wear has been investigated.

Comparative Study of Microstructure and Properties of Thermal Sprayed MCrAlY Bond Coatings

NASA Astrophysics Data System (ADS)

Inglima, Michael William

A series of experiments were performed in order to observe certain process-property trends in thermally sprayed MCrAlY bond coatings for thermal barrier coating (TBC) applications in gas-turbine engines. Firstly, the basis of gas-turbine operation and design is discussed with a focus on the Brayton cycle and basic thermodynamic properties with respect to both the thermal and fuel efficiency of the turbine. The high-temperature environment inside the gas-turbine engine creates an extremely corrosive medium in which the engineering components must operate with sufficient operating life times. These engineering constraints, both thermal/fuel efficiency and operating life, pose a serious problem during long operation as well as thermal cycling of a civil aerospace engine. The concept of a thermal barrier coating is introduced along with how these coatings protect the internal engineering components, mostly in the hot-section of the turbine, and increase both the efficiency as well as the operating life of the components. The method used to create TBC's is then introduced being thermal spray processing along with standard operating procedures (SOP) used during coating deposition. The main focus of the experiments was to quantify the process-property trends seen during thermal spray processing of TBC's with respect to the adhesion and thermally grown oxide (TGO) layer, as well as how sensitive these properties are to changing variables during coating deposition. The design of experiment (DOE) method was used in order to have sufficient statistical process control over the output as well as a standard method for quantifying the results. A total of three DOE's were performed using two main types of thermal spray processes being high-velocity oxygen fuel (HVOF) and atmospheric plasma spray (APS), with a total of five different types of torches which are categorized by liquid-fuel, gas-fuel, and single cathode plasma. The variables used in the proceeding experiments were mainly spray distance, air/fuel ratio, raster speed, powder feed rate, combustion pressure, current, primary and secondary gas flow, as well as three different powder chemistries. The results of the experiments showed very clear process-property trends with respect to mean bond strength of the coatings as well as TGO growth on the as-sprayed coating surface. The effect of either increasing/decreasing the melting index of the powder as well as increasing/decreasing the kinetic energy of the particles is shown with corresponding cross-sectional microstructures of the coating interfaces. The temperature and velocity of the particles were measured with spray diagnostic sensors as well as using an in-situ curvature property sensor (ICP) to monitor the stress-states of the coatings both during deposition as well as residual stresses, and how these might affect the bond strength. An SOP referred to as furnace cycling was used to quantify the TGO growth of the bond coatings by measuring the thickness via a scanning electron microscope (SEM) as well as performing energy dispersive x-ray spectroscopy (EDX) on the coatings to measure chemical changes.

Investigation of the microstructure of Ni and B4C ceramic-metal mixtures obtained by cold spray coating and followed by laser cladding

NASA Astrophysics Data System (ADS)

Filippov, A. A.; Fomin, V. M.; Orishich, A. M.; Malikov, A. G.; Ryashin, N. S.; Golyshev, A. A.

2017-10-01

In the present work, a combined method is considered for the production of a metal-matrix composite coating based on Ni and B4C. The coating is created by consistently applied methods: cold spray and laser cladding. Main focus of this work aimed to microstructure of coatings, element content and morphology of laser tracks. At this stage, the authors focused on the interaction of the laser unit with the substance without affecting the layer-growing technology products. It is shown that coating has deformed particles of nickel and the significantly decreased content of ceramic particles B4C after cold spray. After laser cladding there are no boundaries between nickel and dramatically changes in ceramic particles.

Microscopic Examination of Cold Spray Cermet Sn+In2O3 Coatings for Sputtering Target Materials

PubMed Central

Baszczuk, A.; Rutkowska-Gorczyca, M.; Jasiorski, M.; Małachowska, A.; Posadowski, W.; Znamirowski, Z.

2017-01-01

Low-pressure cold spraying is a newly developed technology with high application potential. The aim of this study was to investigate potential application of this technique for producing a new type of transparent conductive oxide films target. Cold spraying technique allows the manufacture of target directly on the backing plate; therefore the proposed sputtering target has a form of Sn+In2O3 coating sprayed onto copper substrate. The microstructure and properties of the feedstock powder prepared using three various methods as well as the deposited ones by low-pressure cold spraying coatings were evaluated, compared, and analysed. Produced cermet Sn+In2O3 targets were employed in first magnetron sputtering process to deposit preliminary, thin, transparent conducting oxide films onto the glass substrates. The resistivity of obtained preliminary films was measured and allows believing that fabrication of TCO (transparent conducting oxide) films using targets produced by cold spraying is possible in the future, after optimization of the deposition conditions. PMID:29109810

Microscopic Examination of Cold Spray Cermet Sn+In2O3 Coatings for Sputtering Target Materials.

PubMed

Winnicki, M; Baszczuk, A; Rutkowska-Gorczyca, M; Jasiorski, M; Małachowska, A; Posadowski, W; Znamirowski, Z; Ambroziak, A

2017-01-01

Low-pressure cold spraying is a newly developed technology with high application potential. The aim of this study was to investigate potential application of this technique for producing a new type of transparent conductive oxide films target. Cold spraying technique allows the manufacture of target directly on the backing plate; therefore the proposed sputtering target has a form of Sn+In 2 O 3 coating sprayed onto copper substrate. The microstructure and properties of the feedstock powder prepared using three various methods as well as the deposited ones by low-pressure cold spraying coatings were evaluated, compared, and analysed. Produced cermet Sn+In 2 O 3 targets were employed in first magnetron sputtering process to deposit preliminary, thin, transparent conducting oxide films onto the glass substrates. The resistivity of obtained preliminary films was measured and allows believing that fabrication of TCO (transparent conducting oxide) films using targets produced by cold spraying is possible in the future, after optimization of the deposition conditions.

Effect of Impact Angle on Ceramic Deposition Behavior in Composite Cold Spray: A Finite-Element Study

NASA Astrophysics Data System (ADS)

Chakrabarty, Rohan; Song, Jun

2017-10-01

During the cold spraying of particle-reinforced metal matrix composite coatings (ceramic and metal particles mixture) on metal substrates, ceramic particles may either get embedded in the substrate/deposited coating or may rebound from the substrate surface. In this study, the dependence of the ceramic rebounding phenomenon on the spray angle and its effect on substrate erosion have been analyzed using finite-element analysis. From the numerical simulations, it was found that the ceramic particle density and substrate material strength played the major roles in determining the embedding and ceramic retention behavior. Substrate material erosion also influenced the ceramic retention, and the material loss increased as the impact angles decreased from normal. In general, the results concluded that decreasing the impact angle promoted the retention possibility of ceramics in the substrate. This study provides new theoretical insights into the effect of spray angles on the ceramic retention and suggests a new route toward optimizing the spraying process to increase the ceramic retention in composite coatings cold spray.

Effect of Thermal Treatment on High-Temperature Mechanical Properties Enhancement in LPPS, HVOF, and APS CoNiCrAlY Coatings

NASA Astrophysics Data System (ADS)

Waki, Hiroyuki; Kitamura, Takeshi; Kobayashi, Akira

2009-12-01

The mechanical properties of a MCrAlY coating significantly influence the initiation of cracks in the superalloy substrate under thermomechanical-fatigue conditions. Previous studies have developed a convenient method for evaluating the mechanical properties of sprayed coatings by lateral compression of a circular tube coating. This method does not need chucking, and manufacturing the free-standing coating is quite straightforward. In this study, the mechanical properties of the free-standing CoNiCrAlY coatings prepared using low-pressure plasma spraying (LPPS), high-velocity oxyfuel (HVOF) spraying, and atmospheric plasma spraying (APS) were systematically measured with the lateral compression method at room temperature through to 920 °C. The effect of postspray thermal treatments, in vacuum and in air, on the mechanical properties was investigated in the 400 to 1100 °C temperature range. It was found that high-temperature thermal treatment in air was effective in increasing the bending strength and Young’s modulus. It was especially effective on the APS coatings, which were produced using powders with average size 60 μm, and on HVOF coating, whose bending strengths increased by approximately three times. On the contrary, the enhancement in the LPPS and APS coatings produced with powders 21 μm in size was found to be approximately 1.6 times.

Effect of Particle and Carbide Grain Sizes on a HVOAF WC-Co-Cr Coating for the Future Application on Internal Surfaces: Microstructure and Wear

NASA Astrophysics Data System (ADS)

Pulsford, J.; Kamnis, S.; Murray, J.; Bai, M.; Hussain, T.

2018-01-01

The use of nanoscale WC grain or finer feedstock particles is a possible method of improving the performance of WC-Co-Cr coatings. Finer powders are being pursued for the development of coating internal surfaces, as less thermal energy is required to melt the finer powder compared to coarse powders, permitting spraying at smaller standoff distances. Three WC-10Co-4Cr coatings, with two different powder particle sizes and two different carbide grain sizes, were sprayed using a high velocity oxy-air fuel (HVOAF) thermal spray system developed by Castolin Eutectic-Monitor Coatings Ltd., UK. Powder and coating microstructures were characterized using XRD and SEM. Fracture toughness and dry sliding wear performance at three loads were investigated using a ball-on-disk tribometer with a WC-Co counterbody. It was found that the finer powder produced the coating with the highest microhardness, but its fracture toughness was reduced due to increased decarburization compared to the other powders. The sprayed nanostructured powder had the lowest microhardness and fracture toughness of all materials tested. Unlubricated sliding wear testing at the lowest load showed the nanostructured coating performed best; however, at the highest load this coating showed the highest specific wear rates with the other two powders performing to a similar, better standard.

Bioactive calcium silicate ceramics and coatings.

PubMed

Liu, Xuanyong; Morra, Marco; Carpi, Angelo; Li, Baoe

2008-10-01

CaO-SiO2 based ceramics have been regarded as potential candidates for artificial bone due to their excellent bone bioactivity and biocompatibility. However, they cannot be used as implants under a heavy load because of their poor mechanical properties, in particular low fracture toughness. Plasma spraying CaO-SiO2 based ceramic coatings onto titanium alloys can expand their application to the hard tissue replacement under a heavy load. Plasma sprayed wollastonite, dicalcium silicate and diopside coatings have excellent bone bioactivity and high bonding strength to titanium alloys. It is possible that these plasma sprayed CaO-SiO2 based ceramic coatings will be applied in clinic after they are widely and systematically researched.

Amorphous metal formulations and structured coatings for corrosion and wear resistance

DOEpatents

Farmer, Joseph C.

2014-07-15

A system for coating a surface comprising providing a source of amorphous metal that contains more than 11 elements and applying the amorphous metal that contains more than 11 elements to the surface by a spray. Also a coating comprising a composite material made of amorphous metal that contains more than 11 elements. An apparatus for producing a corrosion-resistant amorphous-metal coating on a structure comprises a deposition chamber, a deposition source in the deposition chamber that produces a deposition spray, the deposition source containing a composite material made of amorphous metal that contains more than 11 elements, and a system that directs the deposition spray onto the structure.

Amorphous metal formulations and structured coatings for corrosion and wear resistance

DOEpatents

Farmer, Joseph C [Tracy, CA

2011-12-13

A system for coating a surface comprising providing a source of amorphous metal that contains more than 11 elements and applying the amorphous metal that contains more than 11 elements to the surface by a spray. Also a coating comprising a composite material made of amorphous metal that contains more than 11 elements. An apparatus for producing a corrosion-resistant amorphous-metal coating on a structure comprises a deposition chamber, a deposition source in the deposition chamber that produces a deposition spray, the deposition source containing a composite material made of amorphous metal that contains more than 11 elements, and a system that directs the deposition spray onto the structure.

Information extraction from FN plots of tungsten microemitters.

PubMed

Mussa, Khalil O; Mousa, Marwan S; Fischer, Andreas

2013-09-01

Tungsten based microemitter tips have been prepared both clean and coated with dielectric materials. For clean tungsten tips, apex radii have been varied ranging from 25 to 500 nm. These tips were manufactured by electrochemical etching a 0.1 mm diameter high purity (99.95%) tungsten wire at the meniscus of two molar NaOH solution. Composite micro-emitters considered here are consisting of a tungsten core coated with different dielectric materials-such as magnesium oxide (MgO), sodium hydroxide (NaOH), tetracyanoethylene (TCNE), and zinc oxide (ZnO). It is worthwhile noting here, that the rather unconventional NaOH coating has shown several interesting properties. Various properties of these emitters were measured including current-voltage (IV) characteristics and the physical shape of the tips. A conventional field emission microscope (FEM) with a tip (cathode)-screen (anode) separation standardized at 10 mm was used to electrically characterize the electron emitters. The system was evacuated down to a base pressure of ∼10(-8) mbar when baked at up to ∼180 °C overnight. This allowed measurements of typical field electron emission (FE) characteristics, namely the IV characteristics and the emission images on a conductive phosphorus screen (the anode). Mechanical characterization has been performed through a FEI scanning electron microscope (SEM). Within this work, the mentioned experimental results are connected to the theory for analyzing Fowler-Nordheim (FN) plots. We compared and evaluated the data extracted from clean tungsten tips of different radii and determined deviations between the results of different extraction methods applied. In particular, we derived the apex radii of several clean and coated tungsten tips by both SEM imaging and analyzing FN plots. The aim of this analysis is to support the ongoing discussion on recently developed improvements of the theory for analyzing FN plots related to metal field electron emitters, which in particular introduces a new form of intercept correction factors. The results derived demonstrate the applicability of the applied method on needle shaped - i.e. non planar - emitters as well as its limits. Copyright © 2013 Elsevier B.V. All rights reserved.

Antibacterial characteristics of thermal plasma spray system.

PubMed

Goudarzi, M; Saviz, Sh; Ghoranneviss, M; Salar Elahi, A

2018-03-15

The objective of this study is to investigate antibacterial characteristics of a thermal plasma spray system. For this purpose, copper powder was coated on a handmade atmospheric plasma spraying system made by the stainless steel 316 substrate, which is preheated at different temperatures before spraying. A number of deposition characteristics such as antibacterial characteristics, adhesion strength and hardness of coating, was investigated. All of the spray parameters are fixed except the substrate temperature. The chemical composition was analyzed by X-ray diffraction (XRD). A scanning electron microscopy (SEM) and back scattering electron microscopy (BSE) were used to show the coating microstructure, its thickness and also the powder micrograph. The energy dispersive X-ray spectroscopy (EDX) was used to analyze the coating particles. Hardness of the deposition was examined by Vickers tester (HV0.1). Its adhesion strength was declared by cross cut tester (TQC). In addition, the percentage of bactericidal coating was evidenced with Staphylococcus aurous and Escherichia coli bacteria. Study results show that as the substrates temperature increases, the number of splats in the shape of pancake increases, the greatness and percentage of the deposition porosity both decrease. The increment of the substrate temperature leads to more oxidation and makes thicker dendrites on the splat. The enhancement of the substrate temperature also enlarges thickness and efficiency of coating. The interesting results are that antibacterial properties of coatings against the Escherichia coli are more than Staphylococcus aurous bacteria. However the bactericidal percentage of the coatings against Staphylococcus aurous and Escherichia coli bacteria roughly does not change with increasing the substrate temperature. Furthermore, by increment of the substrate temperature, coatings with both high adhesion and hardness are obtained. Accordingly, the temperature of substrate can be an important parameter for progressing mechanical properties of the antiseptic deposition.

Development and Application of Binary Suspensions in the Ternary System Cr2O3-TiO2-Al2O3 for S-HVOF Spraying

NASA Astrophysics Data System (ADS)

Potthoff, Annegret; Kratzsch, Robert; Barbosa, Maria; Kulissa, Nick; Kunze, Oliver; Toma, Filofteia-Laura

2018-04-01

Compositions in the system Cr2O3-TiO2-Al2O3 are among the most used ceramic materials for thermally sprayed coating solutions. Cr2O3 coatings present good sliding wear resistance; Al2O3 coatings show excellent insulation behavior and TiO2 striking corrosion properties. In order to combine these properties, coatings containing more than one oxide are highly interesting. The conventional spraying process is limited to the availability of binary feedstock powders with defined compositions. The use of suspensions offers the opportunity for tailor-made chemical compositions: within the triangle of Cr2O3-TiO2-Al2O3, each mixture of oxides can be created. Criteria for the selection of raw materials as well as the relevant aspects for the development of binary suspensions in the Cr2O3-TiO2-Al2O3 system to be used as feedstock for thermal spraying are presented. This formulation of binary suspensions required the development of water-based single-oxide suspensions with suitable behavior; otherwise, the interaction between the particles while mixing could lead up to a formation of agglomerates, which affect both the stability of the spray process and the coating properties. For the validation of this formulation procedure, binary Cr2O3-TiO2 and Al2O3-TiO2 suspensions were developed and sprayed using the S-HVOF process. The binary coatings were characterized and discussed in terms of microstructure and microhardness.

A deep look into the spray coating process in real-time—the crucial role of x-rays

NASA Astrophysics Data System (ADS)

Roth, Stephan V.

2016-10-01

Tailoring functional thin films and coating by rapid solvent-based processes is the basis for the fabrication of large scale high-end applications in nanotechnology. Due to solvent loss of the solution or dispersion inherent in the installation of functional thin films and multilayers the spraying and drying processes are strongly governed by non-equilibrium kinetics, often passing through transient states, until the final structure is installed. Therefore, the challenge is to observe the structural build-up during these coating processes in a spatially and time-resolved manner on multiple time and length scales, from the nanostructure to macroscopic length scales. During installation, the interaction of solid-fluid interfaces and between the different layers, the flow and evaporation themselves determine the structure of the coating. Advanced x-ray scattering methods open a powerful pathway for observing the involved processes in situ, from the spray to the coating, and allow for gaining deep insight in the nanostructuring processes. This review first provides an overview over these rapidly evolving methods, with main focus on functional coatings, organic photovoltaics and organic electronics. Secondly the role and decisive advantage of x-rays is outlined. Thirdly, focusing on spray deposition as a rapidly emerging method, recent advances in investigations of spray deposition of functional materials and devices via advanced x-ray scattering methods are presented.

Cold spraying of aluminum bronze on profiled submillimeter cermet structures formed by laser cladding

NASA Astrophysics Data System (ADS)

Ryashin, N. S.; Malikov, A. G.; Shikalov, V. S.; Gulyaev, I. P.; Kuchumov, B. M.; Klinkov, S. V.; Kosarev, V. F.; Orishich, A. M.

2017-10-01

The paper presents results of the cold spraying of aluminum bronze coatings on substrates profiled with WC/Ni tracks obtained by laser cladding. Reinforcing cermet frames shaped as grids with varied mesh sizes were clad on stainless steel substrates using a CO2 laser machine "Siberia" (ITAM SB RAS, Russia). As a result, surfaces/substrates with heterogeneous shape, composition, and mechanical properties were obtained. Aluminum bronze coatings were deposited from 5lF-NS powder (Oerlikon Metco, Switzerland) on those substrates using cold spraying equipment (ITAM SB RAS). Data of profiling, microstructure diagnostics, EDS analysis, and mechanical tests of obtained composites is reported. Surface relief of the sprayed coatings dependence on substrate structure has been demonstrated.

Investigating Tribological Characteristics of HVOF Sprayed AISI 316 Stainless Steel Coating by Pulsed Plasma Nitriding

NASA Astrophysics Data System (ADS)

Mindivan, H.

2018-01-01

In this study, surface modification of aluminum alloy using High-Velocity Oxygen Fuel (HVOF) thermal spray and pulsed plasma nitriding processes was investigated. AISI 316 stainless steel coating on 1050 aluminum alloy substrate by HVOF process was pulsed plasma nitrided at 793 K under 0.00025 MPa pressure for 43200 s in a gas mixture of 75 % N2 and 25 % H2. The results showed that the pulse plasma nitriding process produced a surface layer with CrN, iron nitrides (Fe3N, Fe4N) and expanded austenite (γN). The pulsed plasma nitrided HVOF-sprayed coating showed higher surface hardness, lower wear rate and coefficient of friction than the untreated HVOF-sprayed one.

Superhydrophobic hybrid inorganic-organic thiol-ene surfaces fabricated via spray-deposition and photopolymerization.

PubMed

Sparks, Bradley J; Hoff, Ethan F T; Xiong, Li; Goetz, James T; Patton, Derek L

2013-03-13

We report a simple and versatile method for the fabrication of superhydrophobic inorganic-organic thiol-ene coatings via sequential spray-deposition and photopolymerization under ambient conditions. The coatings are obtained by spray-deposition of UV-curable hybrid inorganic-organic thiol-ene resins consisting of pentaerythritol tetra(3-mercaptopropionate) (PETMP), triallyl isocyanurate (TTT), 2,4,6,8-tetramethyl-2,4,6,8-tetravinylcyclotetrasiloxane (TMTVSi), and hydrophobic fumed silica nanoparticles. The spray-deposition process and nanoparticle agglomeration/dispersion provide surfaces with hierarchical morphologies exhibiting both micro- and nanoscale roughness. The wetting behavior, dependent on the concentration of TMTVSi and hydrophobic silica nanoparticles, can be varied over a broad range to ultimately provide coatings with high static water contact angles (>150°), low contact angle hysteresis, and low roll off angles (<5°). The cross-linked thiol-ene coatings are solvent resistant, stable at low and high pH, and maintain superhydrophobic wetting behavior after extended exposure to elevated temperatures. We demonstrate the versatility of the spray-deposition and UV-cure process on a variety of substrate surfaces including glass, paper, stone, and cotton fabric.

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.

W-containing oxide layers obtained on aluminum and titanium by PEO as catalysts in thiophene oxidation

NASA Astrophysics Data System (ADS)

Rudnev, V. S.; Lukiyanchuk, I. V.; Vasilyeva, M. S.; Morozova, V. P.; Zelikman, V. M.; Tarkhanova, I. G.

2017-11-01

W-containing oxide layers fabricated on titanium and aluminum alloys by Plasma electrolytic oxidation (PEO) have been tested in the reaction of the peroxide oxidation of thiophene. Samples with two types of coatings have been investigated. Coatings I contained tungsten oxide in the matrix and on the surface of amorphous silica-titania or silica-alumina layers, while coatings II comprised crystalline WO3 and/or Al2(WO4)3. Aluminum-supported catalyst containing a smallest amount of transition metals in the form of tungsten oxides and manganese oxides in low oxidation levels showed high activity and stability.

Investigation about the Chrome Steel Wire Arc Spray Process and the Resulting Coating Properties

NASA Astrophysics Data System (ADS)

Wilden, J.; Bergmann, J. P.; Jahn, S.; Knapp, S.; van Rodijnen, F.; Fischer, G.

2007-12-01

Nowadays, wire-arc spraying of chromium steel has gained an important market share for corrosion and wear protection applications. However, detailed studies are the basis for further process optimization. In order to optimize the process parameters and to evaluate the effects of the spray parameters DoE-based experiments had been carried out with high-speed camera shoots. In this article, the effects of spray current, voltage, and atomizing gas pressure on the particle jet properties, mean particle velocity and mean particle temperature and plume width on X46Cr13 wire are presented using an online process monitoring device. Moreover, the properties of the coatings concerning the morphology, composition and phase formation were subject of the investigations using SEM, EDX, and XRD-analysis. These deep investigations allow a defined verification of the influence of process parameters on spray plume and coating properties and are the basis for further process optimization.

Laser cladding of tungsten carbides (Spherotene ®) hardfacing alloys for the mining and mineral industry

NASA Astrophysics Data System (ADS)

Amado, J. M.; Tobar, M. J.; Alvarez, J. C.; Lamas, J.; Yáñez, A.

2009-03-01

The abrasive nature of the mechanical processes involved in mining and mineral industry often causes significant wear to the associated equipment and derives non-negligible economic costs. One of the possible strategies to improve the wear resistance of the various components is the deposition of hardfacing layers on the bulk parts. The use of high power lasers for hardfacing (laser cladding) has attracted a great attention in the last decade as an alternative to other more standard methods (arc welding, oxy-fuel gas welding, thermal spraying). In laser cladding the hardfacing material is used in powder form. For high hardness applications Ni-, Co- or Fe-based alloys containing hard phase carbides at different ratios are commonly used. Tungsten carbides (WC) can provide coating hardness well above 1000 HV (Vickers). In this respect, commercially available WC powders normally contain spherical micro-particles consisting of crushed WC agglomerates. Some years ago, Spherotene ® powders consisting of spherical-fused monocrystaline WC particles, being extremely hard, between 1800 and 3000 HV, were patented. Very recently, mixtures of Ni-based alloy with Spherotene powders optimized for laser processing were presented (Technolase ®). These mixtures have been used in our study. Laser cladding tests with these powders were performed on low carbon steel (C25) substrates, and results in terms of microstructure and hardness will be discussed.

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.

Plasma sprayed hydroxyapatite coatings on titanium substrates. Part 2: optimisation of coating properties.

PubMed

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

1998-11-01

Heat treatment and the introduction of a Ti bond coat have been applied to hydroxyapatite (HA) coatings sprayed using different plasma powers and gas mixtures. Attempts were made in this way to achieve optimal coating properties for orthopaedic implants. In particular, the effects on the degree of crystallinity, the adhesion, the OH ion content and the purity were evaluated. Heat treatment at 700 C for 1 h in air proved to be effective in increasing the crystallinity, regaining the OH- ion and removing other non-HA compounds, although it caused a significant decrease in the degree of adhesion (interfacial fracture toughness) for those specimens sprayed at high powers. This heat treatment was found to induce significant transformation of amorphous HA to the crystalline form, while not detrimentally changing the properties of the underlying Ti-6Al-4V substrates. Precoating with a 100 microm Ti layer increased the adhesion of the HA coatings on Ti-6Al-4V substrates, primarily by providing a rougher surface and promoting better mechanical interlocking. Changes in coating properties during immersion in biological fluids were also studied and were found to depend critically on the chemical composition of the fluids. Small precipitates formed on the coating surfaces when immersed in Ringers solution. These might account for the apparent drop in the degree of crystallinity when measured using X-ray diffraction. A significant drop in the interfacial adhesion was found for those coatings sprayed at high powers. This could be offset by prior precoating with a titanium bond coat and suitable heat treatment. In summary, the following processing sequence is suggested in order to achieve optimum coating properties: precoating the substrate with a layer of Ti (approximately 100 microm), spraying HA at a sufficiently high-power level (depending on particle size and gas mixture) and heat treatment at 700 degrees C for 1 h in air.

The Substitution of Ion Vapor Deposited (IVD) Aluminum for Cadmium

DTIC Science & Technology

1990-05-25

Coating Spray 1 0.0030 15 nin a 250TF Epoxy Powder Coating Spray 1 0.0030 15 nln @ 250OF Zinc Phosphate Tank Immersion 1 0.0002 Not Required Whitford: P...1candidate protection systems. MCAIR includ ed barrier-type coatings in the corrosion inhibitors ý;iich wMY be controlled by a~r-to-ic regulations that are

Cold Gas-Sprayed Deposition of Metallic Coatings onto Ceramic Substrates Using Laser Surface Texturing Pre-treatment

NASA Astrophysics Data System (ADS)

Kromer, R.; Danlos, Y.; Costil, S.

2018-04-01

Cold spraying enables a variety of metals dense coatings onto metal surfaces. Supersonic gas jet accelerates particles which undergo with the substrate plastic deformation. Different bonding mechanisms can be created depending on the materials. The particle-substrate contact time, contact temperature and contact area upon impact are the parameters influencing physicochemical and mechanical bonds. The resultant bonding arose from plastic deformation of the particle and substrate and temperature increasing at the interface. The objective was to create specific topography to enable metallic particle adhesion onto ceramic substrates. Ceramic did not demonstrate deformation during the impact which minimized the intimate bonds. Laser surface texturing was hence used as prior surface treatment to create specific topography and to enable mechanical anchoring. Particle compressive states were necessary to build up coating. The coating deposition efficiency and adhesion strength were evaluated. Textured surface is required to obtain strong adhesion of metallic coatings onto ceramic substrates. Consequently, cold spray coating parameters depend on the target material and a methodology was established with particle parameters (diameters, velocities, temperatures) and particle/substrate properties to adapt the surface topography. Laser surface texturing is a promising tool to increase the cold spraying applications.

Effect of Particle Morphology on Cold Spray Deposition of Chromium Carbide-Nickel Chromium Cermet Powders

NASA Astrophysics Data System (ADS)

Fernandez, Ruben; Jodoin, Bertrand

2017-08-01

Nickel chromium-chromium carbide coatings provide good corrosion and wear resistance at high temperatures, making them ideal for applications where a harsh environment and high temperatures are expected. Thermal spray processes are preferred as deposition technique of cermets, but the high process temperatures can lead to decarburization and reduction of the coatings properties. Cold spray uses lower temperatures preventing decarburization. Since the metallic phase remains solid, the feedstock powder morphology becomes crucial on the deposition behavior. Six commercially available powders were studied, varying in morphology and metal/ceramic ratios. The powders were categorized into 4 groups depending on their morphology. Spherical powders lead to substrate erosion due to their limited overall ductility. Porous agglomerated and sintered powders lead to severely cracked coatings. For dense agglomerated and sintered powders, the outcome depended on the initial metal/ceramic ratio: powders with 25 wt.% NiCr led to substrate erosion while 35 wt.% NiCr powders led to dense coatings. Finally, blended ceramic-metal mixtures also lead to dense coatings. All coatings obtained had lower ceramic content than the initial feedstock powders. Interrupted spray tests, combined with FEA, helped drawing conclusions on the deposition behavior to explain the obtained results.

Experimental and Numerical Study of the Effect of Gas-Shrouded Plasma Spraying on Cathode Coating of Alkaline Electrolysis Cells

NASA Astrophysics Data System (ADS)

Liu, T.; Reißner, R.; Schiller, G.; Ansar, A.

2018-01-01

The aim of this work is to improve the performance of electrodes prepared via atmospheric plasma spray by means of gas shrouding which is expected to apparently reduce the oxygen content of the plasma plume and subsequently improve the coating quality. Electrodes with dual-layer coating for alkaline water electrolysis were deposited on Ni-coated perforated substrates. Microstructure and morphology were studied by SEM. Element content was measured by EDS. Enthalpy probe was employed for measuring plasma temperature and velocity as well as the gas composition. For verifying and better understanding the shrouding effect numerical calculation was carried out according to the experimental settings. Electrochemical test was carried out to validate the shrouding effect. The results showed slight protecting effect of gas shrouding on plasma plume and the final coating. Over the dual-layer section, the measured oxygen fraction was 3.46 and 3.15% for the case without gas shrouding and with gas shrouding, respectively. With gas shrouding the coating exhibited similar element contents as the coating sprayed by VPS, while no obvious improvement was observed in the microstructure or the morphology. Evident electrochemical improvement was nevertheless achieved that with gas shrouding the electrode exhibited similar performance as that of the VPS-sprayed electrode.

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.

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.

Photon Calorimeter

DOEpatents

Chow, Tze-Show

1989-01-01

A photon calorimeter (20, 40) is provided that comprises a laminar substrate (10, 22, 42) that is uniform in density and homogeneous in atomic composition. A plasma-sprayed coating (28, 48, 52), that is generally uniform in density and homogeneous in atomic composition within the proximity of planes that are parallel to the surfaces of the substrate, is applied to either one or both sides of the laminar substrate. The plasma-sprayed coatings may be very efficiently spectrally tailored in atomic number. Thermocouple measuring junctions (30, 50, 54) are positioned within the plasma-sprayed coatings. The calorimeter is rugged, inexpensive, and equilibrates in temperature very rapidly.

Planar measurements of spray-induced wall cooling using phosphor thermometry

NASA Astrophysics Data System (ADS)

Dragomirov, Plamen; Mendieta, Aldo; Abram, Christopher; Fond, Benoît; Beyrau, Frank

2018-03-01

The wall cooling induced by spray impingement is investigated using phosphor thermometry. Thin coatings of zinc oxide (ZnO) phosphor were applied with a transparent chemical binder onto a steel surface. Instantaneous spatially resolved temperatures were determined using the spectral intensity ratio method directly after the injection of UV-grade hexane onto the surface using a commercial gasoline injector. The investigations showed that 2D temperature measurements with high spatial and shot-to-shot precision of, respectively, 0.5 and 0.6 K can be achieved, allowing the accurate resolution of the cooling induced by the spray. The presence of a liquid film over the phosphor coating during measurements showed no noticeable influence on the measured temperatures. However, in some cases a change in the intensity ratio at the spray impingement area, in the form of a permanent "stain", could be observed after multiple injections. The formation of this stain was less likely with increasing annealing time of the coating as well as lower plate operating temperatures during the injection experiments. Finally, the experimental results indicate a noticeable influence of the thickness of the phosphor coating on the measured spray-induced wall cooling history. Hence, for quantitative analysis, a compromise between coating thickness and measurement accuracy needs to be considered for similar applications where the heat transfer rates are very high.

Spray-coating of superhydrophobic aluminum alloys with enhanced mechanical robustness.

PubMed

Zhang, Youfa; Ge, Dengteng; Yang, Shu

2014-06-01

A superhydrophobic aluminum alloy was prepared by one-step spray coating of an alcohol solution consisting of hydrophobic silica nanoparticles (15-40 nm) and methyl silicate precursor on etched aluminum alloy with pitted morphology. The as-sprayed metal surface showed a water contact angle of 155° and a roll-off angle of 4°. The coating was subjected to repeated mechanical tests, including high-pressure water jetting, sand particles impacting, and sandpaper shear abrasion. It remained superhydrophobic with a roll-off angle <10° up to three cycles of water jetting (25 kPa for 10 min) and sand particle impinging. After five cycles, the roll-off angle increased, but no more than 19° while the water contact angle remained greater than 150°. The superhydrophobic state was also maintained after three cycles of sandpaper abrasion. It was found that the micro-protrusion structures on the etched aluminum alloy played an important role to enhance the coating mechanical robustness, where the nanoparticles could grab on the rough surface, specifically in the groove structures, in comparison with the smooth glass substrates spray coated with the same materials. Further, we showed that the superhydrophobicity could be restored by spray a new cycle of the nanocomposite solution on the damaged surface. Copyright © 2014 Elsevier Inc. All rights reserved.

Recent Trends in Newly Developed Plasma-Sprayed and Sintered Coatings for Implant Applications

NASA Astrophysics Data System (ADS)

Bsat, Suzan; Speirs, Andrew; Huang, Xiao

2016-08-01

The current paper aims to review recent trends (2011 to 2015) in newly developed plasma-sprayed and sintered coatings for implant applications. Recent developments in plasma-sprayed and sintered coatings have focused on improving biological performance, bacterial growth resistance, and mechanical properties, predominantly of HA and glass ceramics. The majority of these improvements are attributed to the addition of dopants. To improve biological performance, trace elements, such as Zn and Mg, both of which are found in bone, were added to replicate the functions they provide for the skeletal system. Though bacterial growth resistance is traditionally improved by Ag dopant, the addition of new dopants such as CeO2 and Zn were explored as well. Great effort has also been made to improve coating adherence and reduce stresses by minimizing coefficient of thermal expansion mismatch between the coating and substrate through the addition of elements such as Zn and Mg or the inclusion of a buffer layer. For sintering process in particular, there was an emphasis on reducing sintering temperature through modification of 45S5 Bioglass. New plasma spray and sintering technologies aimed at reducing high-temperature exposure are briefly introduced as well. These include microplasma spray and spark plasma sintering.

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

PubMed

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

2015-08-01

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

Formation of interfacial compounds and the effects on stripping behaviors of a cold-sprayed Zn-Al coating on interstitial-free steel

NASA Astrophysics Data System (ADS)

Liang, Y. L.; Wang, Z. B.; Zhang, J. B.; Lu, K.

2015-06-01

By means of cold spray, a Zn-Al coating was successfully deposited on an interstitial-free (IF) steel sheet. The formation of interfacial compounds between the coating and the IF steel was studied during diffusion annealing at 400 °C. And its correlations with the stripping behaviors of the coating were investigated by using a three-point bending method. The results showed that Fe-Zn and Fe-Al-Zn compounds begin to form at the coating/substrate interface after an annealing duration of 60 min, and the stripping resistance increases slightly before that duration and then decreases significantly by further increasing annealing duration. The enhanced stripping resistance at the earlier stage might be due to the modifications of microstructure and deformation compatibility of the sprayed coating, while the decreased stripping resistance at the later stage is related to the high stress concentration at the interface of the formed brittle Fe-Al-Zn phase and the Zn-Al coating.

Development of Ceramic Coating on Metal Substrate using Industrial Waste and Ore Minerals

NASA Astrophysics Data System (ADS)

Bhuyan, S. K.; Thiyagarajan, T. K.; Mishra, S. C.

2017-02-01

The technological advancement in modern era has a boon for enlightening human life; but also is a bane to produce a huge amount of (industrial) wastes, which is of great concern for utilization and not to create environmental threats viz. polution etc. In the present piece of research work, attempts have been made to utilize fly ash (wastes of thermal power plants) and along with alumina bearing ore i.e. bauxite, for developing plasma spray ceramic coatings on metals. Fly ash and with 10 and 20% bauxite addition is used to deposit plasma spray coatings on a metal substrate. The surface morphology of the coatings deposited at different power levels of plasma spraying investigated through SEM and EDS analysis. The coating thickness is measured. The porosity levels of the coatings are evaluated. The coating hardness isalso measured. This piece of research work will be beneficial for future development and use of industrial waste and ore minerals for high-valued applications.

Optical Property Enhancement and Durability Evaluation of Heat Receiver Aperture Shield Materials

NASA Technical Reports Server (NTRS)

deGroh, Kim K.; Jaworske, Donald A.; Smith, Daniela C.

1998-01-01

Under the Solar Dynamic Flight Demonstration (SDFD) program, NASA Lewis Research Center worked with AlliedSignal Aerospace, the heat receiver contractor, on the development, characterization and durability testing of refractory metals to obtain appropriate optical and thermal properties for the SDFD heat receiver aperture shield. Molybdenum and tungsten foils were grit-blasted using silicon carbide or alumina grit under various grit-blasting conditions for optical property enhancement. Black rhenium coated tungsten foil was also evaluated. Tungsten, black rhenium-coated tungsten, and grit-blasted tungsten screens of various mesh sizes were placed over the pristine and grit-blasted foils for optical property characterization. Grit-blasting was found to be effective in decreasing the specular reflectance and the absorptance/emittance ratio of the refractory foils. The placement of a screen further enhanced these optical properties, with a grit-blasted screen over a grit-blasted foil producing the best results. Based on the optical property enhancement results, samples were tested for atomic oxygen and vacuum heat treatment durability. Grit-blasted (Al2O3 grit) 2 mil tungsten foil was chosen for the exterior layer of the SDFD heat receiver aperture shield. A 0.007 in. wire diameter, 20 x 20 mesh tungsten screen was chosen to cover the tungsten foil. Based on these test results, a heat receiver aperture shield test unit has been built with the screen covered grit-blast tungsten foil exterior layers. The aperture shield was tested and verified the thermal and structural durability of the outer foil layers during an off-pointing period.

Bactericidal Effects of HVOF-Sprayed Nanostructured TiO2 on Pseudomonas aeruginosa

NASA Astrophysics Data System (ADS)

Jeffery, B.; Peppler, M.; Lima, R. S.; McDonald, A.

2010-01-01

Titanium dioxide (TiO2) has been shown to exhibit photocatalytic bactericidal activity. This preliminary study focused on examining the photocatalytic activity of high-velocity oxy-fuel (HVOF) sprayed nanostructured TiO2 coatings to kill Pseudomonas aeruginosa. The surfaces of the nanostructured TiO2 coatings were lightly polished before addition of the bacterial solution. Plates of P. aeruginosa were grown, and then suspended in a phosphate buffer saline (PBS) solution. The concentration of bacteria used was determined by a photo-spectrometer, which measured the amount of light absorbed by the bacteria-filled solution. This solution was diluted and pipetted onto the coating, which was exposed to white light in 30-min intervals, up to 120 min. It was found that on polished HVOF-sprayed coatings exposed to white light, 24% of the bacteria were killed after exposure for 120 min. On stainless steel controls, approximately 6% of the bacteria were not recovered. These preliminary results show that thermal-sprayed nanostructured TiO2 coatings exhibited photocatalytic bactericidal activity with P. aeruginosa.

Advanced Environmental Barrier Coating Development for SiC-SiC Ceramic Matrix Composite Components

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Harder, Bryan; Hurst, Janet B.; Halbig, Michael Charles; Puleo, Bernadette J.; Costa, Gustavo; Mccue, Terry R.

2017-01-01

This presentation reviews the NASA advanced environmental barrier coating (EBC) system development for SiC-SiC Ceramic Matrix Composite (CMC) combustors particularly under the NASA Environmentally Responsible Aviation, Fundamental Aeronautics and Transformative Aeronautics Concepts Programs. The emphases have been placed on the current design challenges of the 2700-3000F capable environmental barrier coatings for low NOX emission combustors for next generation turbine engines by using advanced plasma spray based processes, and the coating processing and integration with SiC-SiC CMCs and component systems. The developments also have included candidate coating composition system designs, degradation mechanisms, performance evaluation and down-selects; the processing optimizations using TriplexPro Air Plasma Spray Low Pressure Plasma Spray (LPPS), Plasma Spray Physical Vapor Deposition and demonstration of EBC-CMC systems. This presentation also highlights the EBC-CMC system temperature capability and durability improvements under the NASA development programs, as demonstrated in the simulated engine high heat flux, combustion environments, in conjunction with high heat flux, mechanical creep and fatigue loading testing conditions.

Self-Lubricating Coatings for Elevated Temperature Applications Using A High-Velocity-Particle-Consolidation (HVPC) Process

DTIC Science & Technology

2008-12-01

Deposition of copper by cold gas dynamic spraying : An investigation of dependence of microstructure and properties of the deposits on the...the deposition of metals, alloys , polymers, and composite powder -materials onto various substrates without significant heating of the spray powders or... Spray method is a relatively new coating method for deposition of metal, alloy , polymer, and/or composite powder material onto

Influence of Laser Glazing on the Characterization of Plasma-Sprayed YSZ Coatings

NASA Astrophysics Data System (ADS)

Wang, Yan; Liu, Jiangwei; Liao, Hanlin; Darut, Geoffrey; Stella, Jorge; Poirier, Thierry; Planche, Marie-Pierre

2017-01-01

In this study, 8 wt.% yttria-stabilized zirconia powder was deposited on the substrates by atmospheric plasma spray. The coatings were post-treated by laser glazing under different parameters in order to densify them. The characterization of the laser molten pools under different laser treatment conditions was studied. Preheating processes were also employed. Scanning electron microscopy observations of the surface and cross section of as-sprayed and laser-glazed coatings were carried out to investigate the influence of laser glazing on the microstructure on laser-glazed coatings. The results show that preheating processes improve the coating in terms of deepening the laser-glazed layer, reducing the number of vertical cracks and surface density of cracks and widening the molten pool. Finally, the influences of linear energy density on the characterization of the glazed layer are discussed.

Performance of Plasma Sprayed Al2O3 Coating in Bio-Simulated Environment

NASA Astrophysics Data System (ADS)

Yıldız, F.; Yetim, A. F.; Alsaran, A.; Çelik, A.

2014-01-01

Alumina coatings deposited on the surface of stainless steel 316L by the method of plasma spraying are studied. Tests for wear and corrosion are preformed in Ringer's solution simulating a human body environment. The structure, microhardness, wear resistance and corrosion resistance of the steel are determined with and without a coating. Deposition of a coating onto the stainless steel is shown to be an effective means for protecting implants from corrosion and wear.

Characterization of High-Velocity Solution Precursor Flame-Sprayed Manganese Cobalt Oxide Spinel Coatings for Metallic SOFC Interconnectors

NASA Astrophysics Data System (ADS)

Puranen, Jouni; Laakso, Jarmo; Kylmälahti, Mikko; Vuoristo, Petri

2013-06-01

A modified high-velocity oxy-fuel spray (HVOF) thermal spray torch equipped with liquid feeding hardware was used to spray manganese-cobalt solutions on ferritic stainless steel grade Crofer 22 APU substrates. The HVOF torch was modified in such a way that the solution could be fed axially into the combustion chamber through 250- and 300-μm-diameter liquid injector nozzles. The solution used in this study was prepared by diluting nitrates of manganese and cobalt, i.e., Mn(NO3)2·4H2O and Co(NO3)2·6H2O, respectively, in deionized water. The as-sprayed coatings were characterized by X-ray diffraction and field-emission scanning electron microscopy operating in secondary electron mode. Chemical analyses were performed on an energy dispersive spectrometer. Coatings with remarkable density could be prepared by the novel high-velocity solution precursor flame spray (HVSPFS) process. Due to finely sized droplet formation in the HVSPFS process and the use of as delivered Crofer 22 APU substrate material having very low substrate roughness ( R a < 0.5 μm), thin and homogeneous coatings, with thicknesses lower than 10 μm could be prepared. The coatings were found to have a crystalline structure equivalent to MnCo2O4 spinel with addition of Co-oxide phases. Crystallographic structure was restored back to single-phase spinel structure by heat treatment.

Thermal conductivity of zirconia thermal barrier coatings

NASA Technical Reports Server (NTRS)

Dinwiddie, R. B.; Beecher, S. C.; Nagaraj, B. A.; Moore, C. S.

1995-01-01

Thermal barrier coatings (TBC's) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBC's is of primary importance. Physical vapor description (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard power or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increase upon being exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicates that if these coatings reach a temperature above 1100 C during operation, they will begin to lose their effectiveness as a thermal barrier.

Thermal conductivity of zirconia thermal barrier coatings

NASA Technical Reports Server (NTRS)

Dinwiddie, R. B.; Beecher, S. C.; Nagaraj, B. A.; Moore, C. S.

1995-01-01

Thermal barrier coatings (TBC's) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBC's is of primary importance. Physical vapor deposition (PVD) and plasma spraying (PS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The PS coatings were applied with either standard powder or hollow sphere particles. The hollow sphere particles yielded a lower density and lower thermal conductivity coating. The thermal conductivity of both fully and partially stabilized zirconia, before and after thermal aging, will be compared. The thermal conductivity of the coatings permanently increases upon exposed to high temperatures. These increases are attributed to microstructural changes within the coatings. Sintering of the as-fabricated plasma sprayed lamellar structure is observed by scanning electron microscopy of coatings isothermally heat treated at temperatures greater than 1100 C. During this sintering process the planar porosity between lamella is converted to a series of small spherical pores. The change in pore morphology is the primary reason for the observed increase in thermal conductivity. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the PVD coatings are less susceptible to thermal aging effects, preliminary results suggest that they have a higher thermal conductivity than PS coatings, both before and after thermal aging. The increases in thermal conductivity due to thermal aging for partially stabilized plasma sprayed zirconia have been found to be less than for fully stabilized plasma sprayed zirconia coatings. The high temperature thermal diffusivity data indicate that if these coatings reach a temperature above 1100 C during operation, they will begin to lose their effectiveness as a thermal barrier.

Comprehensive process maps for synthesizing high density aluminum oxide-carbon nanotube coatings by plasma spraying for improved mechanical and wear properties

NASA Astrophysics Data System (ADS)

Keshri, Anup Kumar

Plasma sprayed aluminum oxide ceramic coating is widely used due to its outstanding wear, corrosion, and thermal shock resistance. But porosity is the integral feature in the plasma sprayed coating which exponentially degrades its properties. In this study, process maps were developed to obtain Al2O3-CNT composite coatings with the highest density (i.e. lowest porosity) and improved mechanical and wear properties. Process map is defined as a set of relationships that correlates large number of plasma processing parameters to the coating properties. Carbon nanotubes (CNTs) were added as reinforcement to Al2O 3 coating to improve the fracture toughness and wear resistance. Two novel powder processing approaches viz spray drying and chemical vapor growth were adopted to disperse CNTs in Al2O3 powder. The degree of CNT dispersion via chemical vapor deposition (CVD) was superior to spray drying but CVD could not synthesize powder in large amount. Hence optimization of plasma processing parameters and process map development was limited to spray dried Al2O3 powder containing 0, 4 and 8 wt. % CNTs. An empirical model using Pareto diagram was developed to link plasma processing parameters with the porosity of coating. Splat morphology as a function of plasma processing parameter was also studied to understand its effect on mechanical properties. Addition of a mere 1.5 wt. % CNTs via CVD technique showed ˜27% and ˜24% increase in the elastic modulus and fracture toughness respectively. Improved toughness was attributed to combined effect of lower porosity and uniform dispersion of CNTs which promoted the toughening by CNT bridging, crack deflection and strong CNT/Al2O3 interface. Al2O 3-8 wt. % CNT coating synthesized using spray dried powder showed 73% improvement in the fracture toughness when porosity reduced from 4.7% to 3.0%. Wear resistance of all coatings at room and elevated temperatures (573 K, 873 K) showed improvement with CNT addition and decreased porosity. Such behavior was due to improved mechanical properties, protective film formation due to tribochemical reaction, and CNT bridging between the splats. Finally, process maps correlating porosity content, CNT content, mechanical properties, and wear properties were developed.

Field repair of coated columbium Thermal Protection System (TPS)

NASA Technical Reports Server (NTRS)

Culp, J. D.

1972-01-01

The requirements for field repair of coated columbian panels were studied, and the probable cause of damage were identified. The following types of repair methods were developed, and are ready for use on an operational system: replacement of fused slurrey silicide coating by a short processing cycle using a focused radiant spot heater; repair of the coating by a glassy matrix ceramic composition which is painted or sprayed over the defective area; and repair of the protective coating by plasma spraying molybdenum disilicide over the damaged area employing portable equipment.

Ceramic electrolyte coating and methods

DOEpatents

Seabaugh, Matthew M [Columbus, OH; Swartz, Scott L [Columbus, OH; Dawson, William J [Dublin, OH; McCormick, Buddy E [Dublin, OH

2007-08-28

Aqueous coating slurries useful in depositing a dense coating of a ceramic electrolyte material (e.g., yttrium-stabilized zirconia) onto a porous substrate of a ceramic electrode material (e.g., lanthanum strontium manganite or nickel/zirconia) and processes for preparing an aqueous suspension of a ceramic electrolyte material and an aqueous spray coating slurry including a ceramic electrolyte material. The invention also includes processes for depositing an aqueous spray coating slurry including a ceramic electrolyte material onto pre-sintered, partially sintered, and unsintered ceramic substrates and products made by this process.

High temperature solar energy absorbing surfaces

DOEpatents

Schreyer, J.M.; Schmitt, C.R.; Abbatiello, L.A.

A solar collector having an improved coating is provided. The coating is a plasma-sprayed coating comprising a material having a melting point above 500/sup 0/C at which it is stable and selected from the group of boron carbide, boron nitride, metals and metal oxides, nitrides, carbides, borides, and silicates. The coatings preferably have a porosity of about 15 to 25% and a thickness of less than 200 micrometers. The coatings can be provided by plasma-spraying particles having a mean diameter of about 10 to 200 micrometers.

Ceramic thermal barrier coatings for commercial gas turbine engines

NASA Technical Reports Server (NTRS)

Meier, Susan Manning; Gupta, Dinesh K.; Sheffler, Keith D.

1991-01-01

The paper provides an overview of the short history, current status, and future prospects of ceramic thermal barrier coatings for gas turbine engines. Particular attention is given to plasma-sprayed and electron beam-physical vapor deposited yttria-stabilized (7 wt pct Y2O3) zirconia systems. Recent advances include improvements in the spallation life of thermal barrier coatings, improved bond coat composition and spraying techniques, and improved component design. The discussion also covers field experience, life prediction modeling, and future directions in ceramic coatings in relation to gas turbine engine design.

Titanium Dioxide Coatings Sprayed by a Water-Stabilized Plasma Gun (WSP) with Argon and Nitrogen as the Powder Feeding Gas: Differences in Structural, Mechanical and Photocatalytic Behavior

NASA Astrophysics Data System (ADS)

Ctibor, P.; Pala, Z.; Sedláček, J.; Štengl, V.; Píš, I.; Zahoranová, T.; Nehasil, V.

2012-06-01

Titanium dioxide coatings were sprayed by a water-stabilized plasma gun to form robust self-supporting bodies with a photocatalytically active surface. Agglomerated nanometric powder was used as a feedstock. In one case argon was used as a powder-feeding as well as coating-cooling gas whereas in the other case nitrogen was used. Stainless steel was used as a substrate and the coatings were released after the cooling. Over one millimeter thick self-supporting bodies were studied by XRD, HR-TEM, XPS, Raman spectroscopy, UV-VIS spectrophotometry and photocatalytic tests. Selected tests were done at the surface as well as at the bottom side representing the contact surface with the substrate during the spray process. Porosity was studied by image analysis on polished cross sections where also microhardness was measured. The dominant phase present in the sprayed samples was rutile, whereas anatase was only a minor component. The hydrogen content in the nitrogen-assisted coating was higher, but the character of the optical absorption edge remained the same for both samples. Photoelectron spectroscopy revealed differences in the character of the O1s peak between both samples. The photocatalytic activity was tested by decomposition of acetone at UV illumination, whereas also the end products—CO and CO2—were monitored. The nitrogen-assisted coating was revealed as a more efficient photocatalyst. Certain aspects of a thermal post-treatment on the coatings are discussed as well. Color and electrical conductivity are markedly changed at annealing at 760 °C, whereas only very small changes of the as-sprayed coating character correspond to annealing at 500 °C.

Mechanical properties, electrochemical corrosion and in-vitro bioactivity of yttria stabilized zirconia reinforced hydroxyapatite coatings prepared by gas tunnel type plasma spraying.

PubMed

Yugeswaran, S; Yoganand, C P; Kobayashi, A; Paraskevopoulos, K M; Subramanian, B

2012-05-01

Yttria stabilized zirconia reinforced hydroxyapatite coatings were deposited by a gas tunnel type plasma spray torch under optimum spraying conditions. For this purpose, 10, 20 and 30 wt% of yttria stabilized zirconia (YSZ) powders were premixed individually with hydroxyapatite (HA) powder and were used as the feedstocks for the coatings. The effect of YSZ reinforcement on the phase formation and mechanical properties of the coatings such as hardness, adhesive strength and sliding wear rates was examined. The results showed that the reinforcement of YSZ in HA could significantly enhance the hardness and adhesive strength of the coatings. The potentiodynamic polarization and impedance measurements showed that the reinforced coatings exhibited superior corrosion resistance compared to the HA coating in SBF solution. Further the results of the bioactivity test conducted by immersion of coatings in SBF showed that after 10 days of immersion of the obtained coatings with all the above compositions commonly exhibited the onset of bioactive apatite formation except for HA+10%YSZ coating. The cytocompatibility was investigated by culturing the green fluorescent protein (GFP)-labeled marrow stromal cells (MSCs) on the coating surface. The cell culture results revealed that the reinforced coatings have superior cell growth than the pure HA coatings. Copyright © 2012. Published by Elsevier Ltd.

Transparent electrodes made with ultrasonic spray coating technique for flexible heaters

NASA Astrophysics Data System (ADS)

Wroblewski, G.; Krzemiński, J.; Janczak, D.; Sowiński, J.; Jakubowska, M.

2017-08-01

Transparent electrodes are one of the basic elements of various electronic components. The paper presents the preliminary results related to novel method of ultrasonic spray coating used for fabrication of transparent flexible electrodes. Experiments were conducted by means of specially made laboratory setup composed of ultrasonic spray generator and XYZ plotter. In the first part of the paper diverse solvents were used to determine the crucial technological parameters such as atomization voltage and fluid flow velocity. Afterwards paint containing carbon nanotubes suspended in the two solvent system was prepared and deposited on the polyethylene terephthalate foil. Thickness, roughness and electrical measurements were performed to designate the relations of technological parameters of ultrasonic spray coating on thickness, roughness, sheet resistance and optical transmission of fabricated samples.

Tribological Properties of Ti(Al,O)/Al2O3 Composite Coating by Thermal Spraying

NASA Astrophysics Data System (ADS)

Salman, Asma; Gabbitas, Brian; Cao, Peng; Zhang, Deliang

The use of thermal spray coatings provides protection to the surfaces operating in severe environments. The main goal of the current work is to investigate the possibility of using a high velocity air fuel (HVAF) thermally sprayed wear resistant Ti(Al,O)/Al2O3 coating on tool steel (H13) which is used for making dies for aluminium high pressure die casting and dummy blocks aluminium extrusion. A feedstock of Ti(Al,O)/Al2O3 composite powder was produced from a mixture of Al and TiO2 powders by high energy mechanical milling, followed by a thermal reaction process. The feedstock was then thermally sprayed using a high velocity air-fuel (HVAF) technique onto H13 steel substrates to produce a composite coating. The present study describes and compares the tribological properties such as friction and sliding wear rate of the coating both at room and high temperature (700°C). The wear resistance of the coating was investigated by a tribometer using a spherical ended alumina pin as a counter body under dry and lubricating conditions. The results showed that composite coating has lower wear rate at high temperature than at room temperature without using lubricant. The composite coating was characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD). This paper reports the experimental observations and discusses the wear resistance performance of the coatings at room and high temperatures.

Activity of plasma sprayed yttria stabilized zirconia reinforced hydroxyapatite/Ti-6Al-4V composite coatings in simulated body fluid.

PubMed

Gu, Y W; Khor, K A; Pan, D; Cheang, P

2004-07-01

Hydroxyapatite (HA)/yttria stabilized zirconia/Ti-6Al-4V bio-composite coatings deposited onto Ti-6Al-4V substrate through a plasma spray technique were immersed in simulated body fluid (SBF) to investigate their behavior in vitro. Surface morphologies and structural changes in the coatings were analyzed by scanning electron microscopy, thin-film X-ray diffractometer, and X-ray photoelectron spectroscopy. The tensile bond strength of the coatings after immersion was also conducted through the ASTM C-633 standard for thermal sprayed coatings. Results showed that carbonate-containing hydroxyapatite (CHA) layer formed on the surface of composite coatings after 4 weeks immersion in SBF solution, indicating the composite coating possessed excellent bioactivity. The mechanical properties were found to decrease with immersion duration of maximum 56 days. However, minimal variation in mechanical properties was found subsequent to achieving supersaturation of the calcium ions, which was attained with the precipitation of the calcium phosphate layers. The mechanical properties of the composite coating were found to be significantly higher than those of pure HA coatings even after immersion in the SBF solution, indicating the enhanced mechanical properties of the composite coatings.

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.

Protection of 310l Stainless Steel from Wear at Elevated Temperatures using Conicraly Thermal Spray Coatings with and without Sic Addition

NASA Astrophysics Data System (ADS)

Zhang, Yan; Zhang, Tao; Li, Kaiyang; Li, Dongyang

2017-10-01

Due to its high oxidation resistance, 310L stainless steel is often used for thermal facilities working at high-temperatures. However, the steel may fail prematurely at elevated temperatures when encounter surface mechanical attacks such as wear. Thermal spray coatings have been demonstrated to be effective in protecting the steel from wear at elevated temperatures. In this study, we investigated the effectiveness of high velocity oxy-fuel(HVOF) spraying CoNiCrAlY/SiC coatings in resisting wear of 310L stainless steel at elevated temperature using a pin-on-disc wear tester. In order to further improve the performance of the coating, 5%SiC was added to the coating. It was demonstrated that the CoNiCrAlY/SiC coating after heat treatment markedly suppressed wear. However, the added SiC particles did not show benefits to the wear resistance of the coating. Microstructures of CoNiCrAlY coatings with and without the SiC addition were characterized in order to understand the mechanism responsible for the observed phenomena.

Influence of the powder mixture composition on the deposition coefficient and the properties of NI+B4C CGDS coatings

NASA Astrophysics Data System (ADS)

Kosarev, V. F.; Polukhin, A. A.; Ryashin, N. S.; Fomin, V. M.; Shikalov, V. S.

2017-07-01

The cold gas dynamic spray (CGDS) method used to form composite Ni+B4C coatings from mechanical powder mixture with various content of abrasive components is investigated, and the surface and microstructure of these coatings are considered. An experimental dependence of the deposition coefficient on the abrasive content in the mechanical powder mixture is obtained. The coatings are studied by interference profilometry, optical microscopy, and microindentation methods. The dependence of the bulk and mass B4C content in the sprayed material on the abrasive content in the sprayed powder mixture is obtained. The bulk B4C content in the coating c V ≈ 0.27 is attained. The dependence of the microhardness of composite CGDS coatings on the boron carbide content in them is investigated. The results of this paper demonstrate that the powder mixture composition significantly affects the CGDS coating growth and the properties of these coatings and can be used to control the properties of the CGDS cermet materials.

Biocomposite Plasma-Sprayed Coatings Based on Zinc-Substituted Hydroxyapatite: Structure, Properties, and Prospects of Application

NASA Astrophysics Data System (ADS)

Lyasnikova, A. V.; Markelova, O. A.; Lyasnikov, V. N.; Dudareva, O. A.

2016-01-01

The method of synthesis of a zinc-substituted hydroxyapatite powder is presented, and the technology of creating coatings by its spraying is described. The results of studies on the morphological, physical, and chemical parameters of a zinc-substituted hydroxyapatite coating by using X-ray analysis, infrared spectroscopy, transmission electron microscopy, optical microscopy, SEM, and other methods are given.

Structural Assessment of Tungsten-Epoxy Bonding in Spacecraft Composite Enclosures with Enhanced Radiation Protection

NASA Astrophysics Data System (ADS)

Kanerva, M.; Koerselman, J. R.; Revitzer, H.; Johansson, L.-S.; Sarlin, E.; Rautiainen, A.; Brander, T.; Saarela, O.

2014-06-01

Spacecraft include sensitive electronics that must be protected against radiation from the space environment. Hybrid laminates consisting of tungsten layers and carbon- fibre-reinforced epoxy composite are a potential solution for lightweight, efficient, and protective enclosure material. Here, we analysed six different surface treatments for tungsten foils in terms of the resulting surface tension components, composition, and bonding strength with epoxy. A hydrofluoric-nitric-sulfuric-acid method and a diamond-like carbon-based DIARC® coating were found the most potential surface treatments for tungsten foils in this study.

Development of Oxidation Resistant Coatings on GRCop-84 Substrates by Cold Spray Process

NASA Technical Reports Server (NTRS)

Karthikeyan, J.

2007-01-01

GRCop-84, a Cu-CR-Nb alloy, has been developed for rocket engine liner applications. For maximum life additional oxidation protection is required to prevent blanching. NiCrAlY was identified as a suitable coating, and efforts were initiated to develop suitable coating techniques. Cold spray is one technique under consideration. Efforts at ASB Industries to produce dense, adherent coatings are detailed. The work culminated in the production of samples for testing at NASA Glenn Research Center.

Role of carbon nanotube dispersion in fracture toughening of plasma sprayed aluminum oxide-carbon nanotube nanocomposite coating

NASA Astrophysics Data System (ADS)

Balani, Kantesh

Aluminum oxide (Al2O3, or alumina) is a conventional ceramic known for applications such as wear resistant coatings, thermal liners, heaters, crucibles, dielectric systems, etc. However applications of Al 2O3 are limited owing to its inherent brittleness. Due to its excellent mechanical properties and bending strength, carbon nanotubes (CNT) is an ideal reinforcement for Al2O3 matrix to improve its fracture toughness. The role of CNT dispersion in the fracture toughening of the plasma sprayed Al2O3-CNT nanocomposite coating is discussed in the current work. Pretreatment of powder feedstock is required for dispersing CNTs in the matrix. Four coatings namely spray dried Al2O 3 (A-SD), Al2O3 blended with 4wt.% CNT (A4C-B), composite spray dried Al2O3-4wt.% CNT (A4C-SD) and composite spray dried A1203-8wt.% CNT (A8C-SD), are synthesized by plasma spraying. Owing to extreme temperatures and velocities involved in the plasma spraying of ceramics, retention of CNTs in the resulting coatings necessitates optimizing plasma processing parameters using an inflight particle diagnostic sensor. A bimodal microstructure was obtained in the matrix that consists of fully melted and resolidified structure and solid state sintered structure. CNTs are retained both in the fully melted region and solid-state sintered regions of processed coatings. Fracture toughness of A-SD, A4C-B, A4C-SD and A8C-SD coatings was 3.22, 3.86, 4.60 and 5.04 MPa m1/2 respectively. This affirms the improvement of fracture toughness from 20% (in A4C-B coating) to 43% (in A4C-SD coating) when compared to the A-SD coating because of the CNT dispersion. Fracture toughness improvement from 43% (in A4C-SD) to 57% (in A8C-SD) coating is evinced because of the CNT content. Reinforcement by CNTs is described by its bridging, anchoring, hook formation, impact alignment, fusion with splat, and mesh formation. The Al2O3/CNT interface is critical in assisting the stress transfer and utilizing excellent mechanical properties of CNTs. Mathematical and computational modeling using ab-initio principle is applied to understand the wetting behavior at the Al2O 3/CNT interface. Contrasting storage modulus was obtained by nanoindentation (˜210, 250, 250-350 and 325-420 GPa in A-SD, A4C-B, A4C-SD, and A8C-SD coatings respectively) depicting the toughening associated with CNT content and dispersion.

Effect of Laser Remelting on Friction-Wear Behaviors of Cold Sprayed Al Coatings in 3.5% NaCl Solution

PubMed Central

Jing, Zhang; Dejun, Kong

2018-01-01

A cold sprayed Al coating on S355 structural steel was processed using a laser remelting (LR). The surface and cross-section morphologies, chemical compositions, and phases of as-obtained Al coating before and after LR were analyzed using a scanning electronic microscope (SEM), energy dispersive spectrometer (EDS), and X-ray diffractometer (XRD), respectively, and their hardness was measured using a micro-hardness tester. The friction-wear behaviors of Al coating before and after LR in 3.5% NaCl solution were conducted to simulate the sand and gravel scouring on its surface in seawater, the effects of wear loads and speeds on the tribological properties of Al coating were analyzed, and the wear mechanisms under different wear loads and speeds were also discussed. The results show that the Al coating after LR is primarily composed of an Al phase and its hardness is 104.66 HV, increasing 54.70 HV than the cold sprayed Al coating. The average coefficient of friction (COF) of cold sprayed Al coating at the wear load of 0.5, 1.0 and 1.5 N is 0.285, 0.239, and 0.435, respectively, while that after LR is 0.243, 0.227, and 0.327, respectively, decreased by 14.73%, 5.02% and 24.83% compared to the cold sprayed Al coating. The wear rate of cold sprayed Al coating at the wear load of 0.5, 1.0 and 1.5 N is 1.60 × 10−4, 2.36 × 10−4, and 2.40 × 10−4 mm3/m·N, respectively, while that after LR is 1.59 × 10−4, 1.70 × 10−4, and 1.94 × 10–4 mm3/m·N, respectively, decreased by 1%, 32%, and 23%, respectively, indicating that LR has high anti-friction performance. Under the wear load action of 1.0 N, the average COF of laser remelted Al coating at the wear speeds of 300, 400 and 500 times/min is 0.294, 0.279, and 0.239, respectively, and the corresponding wear rate is 1.06 × 10−4, 1.24 × 10−4, and 1.70 × 10−4 mm3/m·N, respectively. The wear mechanism of cold sprayed Al coating is primarily corrosion wear at the loads of 0.5 and 1.0 N, and that at the load of 1.5 N is abrasive wear and fatigue wear; while that after LR is abrasive wear and fatigue wear, with no corrosion wear, showing that LR improves its corrosion and wear resistance. PMID:29439485

Effect of Laser Remelting on Friction-Wear Behaviors of Cold Sprayed Al Coatings in 3.5% NaCl Solution.

PubMed

Jing, Zhang; Dejun, Kong

2018-02-11

A cold sprayed Al coating on S355 structural steel was processed using a laser remelting (LR). The surface and cross-section morphologies, chemical compositions, and phases of as-obtained Al coating before and after LR were analyzed using a scanning electronic microscope (SEM), energy dispersive spectrometer (EDS), and X-ray diffractometer (XRD), respectively, and their hardness was measured using a micro-hardness tester. The friction-wear behaviors of Al coating before and after LR in 3.5% NaCl solution were conducted to simulate the sand and gravel scouring on its surface in seawater, the effects of wear loads and speeds on the tribological properties of Al coating were analyzed, and the wear mechanisms under different wear loads and speeds were also discussed. The results show that the Al coating after LR is primarily composed of an Al phase and its hardness is 104.66 HV, increasing 54.70 HV than the cold sprayed Al coating. The average coefficient of friction (COF) of cold sprayed Al coating at the wear load of 0.5, 1.0 and 1.5 N is 0.285, 0.239, and 0.435, respectively, while that after LR is 0.243, 0.227, and 0.327, respectively, decreased by 14.73%, 5.02% and 24.83% compared to the cold sprayed Al coating. The wear rate of cold sprayed Al coating at the wear load of 0.5, 1.0 and 1.5 N is 1.60 × 10 -4 , 2.36 × 10 -4 , and 2.40 × 10 -4 mm³/m·N, respectively, while that after LR is 1.59 × 10 -4 , 1.70 × 10 -4 , and 1.94 × 10 -4 mm³/m·N, respectively, decreased by 1%, 32%, and 23%, respectively, indicating that LR has high anti-friction performance. Under the wear load action of 1.0 N, the average COF of laser remelted Al coating at the wear speeds of 300, 400 and 500 times/min is 0.294, 0.279, and 0.239, respectively, and the corresponding wear rate is 1.06 × 10 -4 , 1.24 × 10 -4 , and 1.70 × 10 -4 mm³/m·N, respectively. The wear mechanism of cold sprayed Al coating is primarily corrosion wear at the loads of 0.5 and 1.0 N, and that at the load of 1.5 N is abrasive wear and fatigue wear; while that after LR is abrasive wear and fatigue wear, with no corrosion wear, showing that LR improves its corrosion and wear resistance.

Mechanised spraying device a novel technology for spraying fire protective coating material in the benches of opencast coal mines for preventing spontaneous combustion

DOE Office of Scientific and Technical Information (OSTI.GOV)

R.V.K. Singh; V.K. Singh

2004-10-15

Spontaneous combustion in coal mines plays a vital role in occurrences of fire. Fire in coal, particularly in opencast mines, not only causes irreparable loss of national wealth but damages the surface structure and pollutes the environment. The problem of spontaneous combustion/fire in opencast coal benches is acute. Presently over 75% of the total production of coal in Indian mines is being carried out by opencast mining. Accordingly a mechanised spraying device has been developed for spraying the fire protective coating material for preventing spontaneous combustion in coal benches of opencast mines jointly by Central Mining Research Institute, Dhanbad andmore » M/s Signum Fire Protection (India) Pvt. Ltd., Nagpur under Science & Technology (S&T) project funded by Ministry of Coal, Govt. of India. The objective of this paper is to describe in detail about the mechanised spraying device and its application for spraying fire protective coating material in the benches of opencast coal mines for preventing spontaneous combustion/fire.« less

Internal Diameter HVAF Spraying for Wear and Corrosion Applications

NASA Astrophysics Data System (ADS)

Lyphout, C.; Björklund, S.

2015-01-01

Electrolytic hard chrome (EHC) methods are still widely utilized in the printing, automotive and off-shore industries. Alternative methods to EHC have been widely developed in the past decade by conventional HVOF processes and more recently HVAF systems, which are processing at higher kinetic energy and more particularly at lower temperature, significantly increasing wear and corrosion resistance properties. A dedicated internal diameter HVAF system is here presented, and coatings characteristics are compared to the one obtained by standard HVAF coatings. Specially R&D designed fixtures with inside bore of 200 mm have been manufactured for this purpose, with a possibility to spray samples at increasing depth up to 400 mm while simulating closed bottom bore spraying. WC-based and Cr3C2-based powder feedstock materials have been deposited onto high-strength steel substrates. Respective coating microstructures, thermally induced stresses and corrosion resistance are discussed for further optimization of coating performances. The fact that the ID-HVAF system is utilized both for spraying and gritblasting procedures is also given a particular interest.

Liquid Feedstock Plasma Spraying: An Emerging Process for Advanced Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Markocsan, Nicolaie; Gupta, Mohit; Joshi, Shrikant; Nylén, Per; Li, Xin-Hai; Wigren, Jan

2017-08-01

Liquid feedstock plasma spraying (LFPS) involves deposition of ultrafine droplets of suspensions or solution precursors (typically ranging from nano- to submicron size) and permits production of coatings with unique microstructures that are promising for advanced thermal barrier coating (TBC) applications. This paper reviews the recent progress arising from efforts devoted to development of high-performance TBCs using the LFPS approach. Advancements in both suspension plasma spraying and solution precursor plasma spraying, which constitute the two main variants of LFPS, are presented. Results illustrating the different types of the microstructures that can be realized in LFPS through appropriate process parameter control, model-assisted assessment of influence of coating defects on thermo-mechanical properties and the complex interplay between pore coarsening, sintering and crystallite growth in governing thermal conductivity are summarized. The enhancement in functional performances/lifetime possible in LFPS TBCs with multilayered architectures and by incorporating new pyrochlore chemistries such as gadolinium zirconate, besides the conventional single 8 wt.% yttria-stabilized zirconia insulating ceramic layer, is specifically highlighted.

Advanced Microstructural Study of Suspension Plasma Sprayed Hydroxyapatite Coatings

NASA Astrophysics Data System (ADS)

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

2010-03-01

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

The Influence of the Coating Deposition Process on the Interdiffusion Behavior Between Nickel-Based Superalloys and MCrAlY Bond Coats

NASA Astrophysics Data System (ADS)

Elsaß, M.; Frommherz, M.; Oechsner, M.

2018-02-01

In this work, interdiffusion between two nickel-based superalloys and two MCrAlY bond coats is investigated. The MCrAlY bond coats were applied using two different spraying processes, high velocity oxygen fuel spraying (HVOF) and low-pressure plasma spraying. Of primary interest is the evolution of Kirkendall porosity, which can form at the interface between substrate and bond coat and depends largely on the chemical compositions of the coating and substrate. Experimental evidence further suggested that the formation of Kirkendall porosity depends on the coating deposition process. Formation of porosity at the interface causes a degradation of the bonding strength between substrate and coating. After coating deposition, the samples were annealed at 1050 °C for up to 2000 h. Microstructural and compositional analyses were performed to determine and evaluate the Kirkendall porosity. The results reveal a strong influence of both the coating deposition process and the chemical compositions. The amount of Kirkendall porosity formed, as well as the location of appearance, is largely influenced by the coating deposition process. In general, samples with bond coats applied by means of HVOF show accelerated element diffusion. It is hypothesized that recrystallization of the substrate material is a main root cause for these observations.

Development of improved high temperature coatings for IN-792 + HF

NASA Technical Reports Server (NTRS)

Profant, D. D.; Naik, S. K.

1981-01-01

The development for t-55 l712 engine of high temperature for integral turbine nozzles with improved thermal fatigue resistance without sacrificing oxidation/corrosion protection is discussed. The program evaluated to coating systems which comprised one baseline plasma spray coating (12% Al-NiCoCrALY), three aluminide coatings including the baseline aluminide (701), two CoNiCrAly (6% Al) + aluminide systems and four NiCoCrY + aluminide coating were evaluated. The two-step coating processes were investigated since it offered the advantage of tailoring the composition as well as properly coating surfaces of an integral or segmented nozzle. Cyclic burner rig thermal fatigue and oxidation/corrosion tests were used to evaluate the candidate coating systems. The plasma sprayed 12% Al-NiCoCrAlY was rated the best coating in thermal fatigue resistance and outperformed all coatings by a factor between 1.4 to 2.5 in cycles to crack initiation. However, this coatings is not applicable to integral or segmented nozzles due to the line of sight limitation of the plasma spray process. The 6% Al-CoNiCrAlY + Mod. 701 aluminide (32 w/o Al) was rated the best coating in oxidation/corrosion resistance and was rated the second best in thermal fatigue resistance.

Oxidation-Resistant Coating For Bipolar Lead/Acid Battery

NASA Technical Reports Server (NTRS)

Bolstad, James J.

1993-01-01

Cathode side of bipolar substrate coated with nonoxidizable conductive layer. Coating prepared as water slurry of aqueous dispersion of polyethylene copolymer plus such conductive fillers as tin oxide, titanium, tantalum, or tungsten oxide. Applied easily to substrate of polyethylene carbon plastic. As slurry dries, conductive, oxidation-resistant coating forms on positive side of substrate.

Tribological properties of thermally sprayed TiAl-Al2O3 composite coating

NASA Astrophysics Data System (ADS)

Salman, A.; Gabbitas, B.; Li, J.; Zhang, D.

2009-08-01

The use of thermal spray coatings provides protection to the surfaces operating in severe environments. The main goal of the current work is to investigate the possibility of using a high velocity oxy fuel (HVOF) thermally sprayed wear resistant TiAl/Al2O3 coating on tool steel (H13) which is used for making dies for aluminium high pressure die casting. A feedstock of TiAl/Al2O3 composite powder was produced from a mixture of Al and TiO2 powders by high energy mechanical milling, followed by a thermal reaction process. The feedstock was then thermally sprayed using a high velocity oxy-fuel (HVOF) technique onto H13 steel substrates to produce a composite coating. The present study describes and compares the tribological properties such as friction and sliding wear rate of the coating both at room and high temperature (700°C). The results showed that the composite coating has lower wear rate at high temperature (700°C) than the uncoated H13 sample. At Room temperature without using lubricant there is no much significant difference between the wear rate of the coated and uncoated samples. The experimental results showed that the composite coating has great potential for high temperature application due to its lower wear rate at high temperature in comparison with the uncoated sample at the same temperature. The composite coating was characterized using scanning electron microscopy (SEM), optical microscopy and X-ray diffractometry (XRD). This paper reports the experimental observations and discusses the wear resistance performance of the coatings at room and high temperatures.

The Effect of CFRP Surface Treatment on the Splat Morphology and Coating Adhesion Strength

NASA Astrophysics Data System (ADS)

Ganesan, Amirthan; Yamada, Motohiro; Fukumoto, Masahiro

2014-01-01

Metallization of Carbon Fiber-Reinforced Polymer (CFRP) composites aggrandized their application to aircraft, automobile, and wind power industries. Recently, the metallization of CFRP surface using thermal spray technique, especially the cold spray, a solid state deposition technique, is a topic of research. However, a direct cold spray deposition on the CFRP substrate often imposes severe erosion on the surface owing to the high-impact energy of the sprayed particles. This urges the requirement of an interlayer on the CFRP surface. In the present study, the effect of surface treatment on the interlayer adhesion strength is evaluated. The CFRP samples were initially treated mechanically, chemically, and thermally and then an interlayer was developed by atmospheric plasma spray system. The quality of the coating is highly dependent on the splat taxonomy; therefore the present work also devoted to study the splat formation behavior using the splat-collection experiments, where the molten Cu particles impinged on the treated CFRP substrates. These results were correlated with the coating adhesion strength. The coating adhesion strength was measured by pull-out test. The results showed that the surface treatment, particularly the chemical treatment, was fairly successful in improving the adhesion strength.

Effect of Porosity Content of Arc-Sprayed Alloy 625 Skins on the Flexural Behavior of Nickel Foam Core Sandwich Structures

NASA Astrophysics Data System (ADS)

Salavati, S.; Pershin, L.; Coyle, T. W.; Mostaghimi, J.

2015-01-01

Metallic foam core sandwich structures have been of particular interest for engineering applications in recent decades because of their unique mechanical and physical properties. Thermal spraying techniques have been recently introduced as a novel low-cost method for production of these structures with complex shapes. One of the potential applications of the metallic foam core sandwich structures prepared by thermal spray techniques is as heat shield devices. Open porosity in the microstructure of the coating may allow the cooling efficiency of the heat shield to be improved through the film cooling phenomenon. A modified twin wire-arc spraying process was employed to deposit high temperature resistant alloy 625 coatings with a high percentage of the open porosity. The effect of skin porosity on the mechanical properties (flexural rigidity) of the sandwich structures was studied using a four-point bending test. It was concluded from the four-point bending test results that increase in the porosity content of the coatings leads to decrease in the flexural rigidity of the sandwich panels. The ductility of the porous and conventional arc-sprayed alloy 625 coatings was improved after heat treatment at 1100 °C for 3 h.

Latest Researches Advances of Plasma Spraying: From Splat to Coating Formation

NASA Astrophysics Data System (ADS)

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

2016-12-01

The plasma spray process with solid feedstock, mainly ceramics powders, studied since the sixties is now a mature technology. The plasma jet and particle in-flight characterizations are now well established. The use of computer-aided robot trajectory allows spraying on industrial parts with complex geometries. Works about splat formation have shown the importance of: the substrate preheating over the transition temperature to get rid of adsorbates and condensates, substrate chemistry, crystal structure and substrate temperature during the whole coating process. These studies showed that coating properties strongly depend on the splat formation and layering. The first part of this work deals with a summary of conventional plasma spraying key points. The second part presents the current knowledge in plasma spraying with liquid feedstock, technology developed for about two decades with suspensions of particles below micrometers or solutions of precursors that form particles a few micrometers sized through precipitation. Coatings are finely structured and even nanostructured with properties arousing the interest of researchers. However, the technology is by far more complex than the conventional ones. The main conclusions are that models should be developed further, plasma torches and injection setups adapted, and new measuring techniques to reliably characterize these small particles must be designed.

Research of Adhesion Bonds Between Gas-Thermal Coating and Pre-Modified Base

NASA Astrophysics Data System (ADS)

Kovalevskaya, Z.; Zaitsev, K.; Klimenov, V.

2016-08-01

Nature of adhesive bonds between gas-thermal nickel alloy coating and carbon steel base was examined using laser profilometry, optical metallography, transmission and scanning electron microscopy. The steel surface was plastically pre-deformed by an ultrasonic tool. Proved that ultrasound pre-treatment modifies the steel surface. Increase of dislocation density and formation of sub micro-structure are base elements of surface modification. While using high-speed gas-flame, plasma and detonation modes of coatings, surface activation occurs and durable adhesion is formed. Ultrasonic pre-treatment of base material is effective when sprayed particles and base material interact through physical-chemical bond formation. Before applying high-speed gas flame and plasma sprayed coatings, authors recommend ultrasonic pretreatment, which creates periodic wavy topography with a stroke of 250 microns on the steel surface. Before applying detonation sprayed coatings, authors recommend ultrasound pretreatment that create modified surface with a uniform micro-topography.

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

NASA Astrophysics Data System (ADS)

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

2016-06-01

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

Investigation on MoS2 and graphite coatings and their effects on the tribological properties of the radial spherical plain bearings

NASA Astrophysics Data System (ADS)

Qiu, Ming; Lu, Jianjun; Li, Yingchun; Lv, Guisen

2016-07-01

With constant enlargement of the application areas of the spherical plain bearings, higher quality lubrication of the bearings is required. To solve the lubricating problems of spherical plain bearings under high temperature, high vacuum, high speed, heavy loads and strong oxidation conditions, it is urgent for us to develop more excellent self-lubricating technologies. In this paper, the bonded solid lubricant coatings, which use inorganic phosphate as the binder, the mixture of MoS2 and graphite with two different weight proportions as the solid lubricant, are prepared by spraying under three different spray gun pressures. The bonding strength tests on the coatings show that the best spraying pressure is 0.2 MPa and the better mixing proportion of MoS2 to Graphite is 3:1. Then for the radial spherical plain bearings with steel/steel friction pair, after the coatings are made on the inner ring outer surfaces, the friction coefficient, the wear loss and the friction temperature of the bearings under four oscillating frequencies are investigated by a self-made tribo-tester. The test results, SEM of the worn morphologies and EDS of worn areas show that tribological properties of the bearing are obviously improved by the bonded solid lubricant coatings. When sprayed under the spray gun pressure of 0.2 MPa, the bearings have better anti-friction and anti-wear properties than those sprayed under 0.1 MPa and 0.3 MPa. Further as proved from the XPS analysis, between the coating with 3:1 mixing ratio of MoS2 to Graphite and the coating with 1:1 ratio, the former has less oxidation occurred on the surface and therefore has better tribological characteristics than the latter. This paper provides a reference to developing a new product of the radial spherical plain bearings with high bonding strength, oxidation resistance and abrasion resistance.

Microstructure and Transparent Super-Hydrophobic Performance of Vacuum Cold-Sprayed Al2O3 and SiO2 Aerogel Composite Coating

NASA Astrophysics Data System (ADS)

Li, Jie; Zhang, Yu; Ma, Kai; Pan, Xi-De; Li, Cheng-Xin; Yang, Guan-Jun; Li, Chang-Jiu

2018-02-01

In this study, vacuum cold spraying was used as a simple and fast way to prepare transparent super-hydrophobic coatings. Submicrometer-sized Al2O3 powder modified by 1,1,2,2-tetrahydroperfluorodecyltriethoxysilane and mixed with hydrophobic SiO2 aerogel was employed for the coating deposition. The deposition mechanisms of pure Al2O3 powder and Al2O3-SiO2 mixed powder were examined, and the effects of powder structure on the hydrophobicity and light transmittance of the coatings were evaluated. The results showed that appropriate contents of SiO2 aerogel in the mixed powder could provide sufficient cushioning to the deposition of submicrometer Al2O3 powder during spraying. The prepared composite coating surface showed rough structures with a large number of submicrometer convex deposited particles, characterized by being super-hydrophobic. Also, the transmittance of the obtained coating was higher than 80% in the range of visible light.

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.

Thermal barrier coating life prediction model

NASA Technical Reports Server (NTRS)

Hillery, R. V.; Pilsner, B. H.

1985-01-01

This is the first report of the first phase of a 3-year program. Its objectives are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system, then to develop and verify life prediction models accounting for these degradation modes. The first task (Task I) is to determine the major failure mechanisms. Presently, bond coat oxidation and bond coat creep are being evaluated as potential TBC failure mechanisms. The baseline TBC system consists of an air plasma sprayed ZrO2-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene'80 substrate. Pre-exposures in air and argon combined with thermal cycle tests in air and argon are being utilized to evaluate bond coat oxidation as a failure mechanism. Unexpectedly, the specimens pre-exposed in argon failed before the specimens pre-exposed in air in subsequent thermal cycles testing in air. Four bond coats with different creep strengths are being utilized to evaluate the effect of bond coat creep on TBC degradation. These bond coats received an aluminide overcoat prior to application of the top coat to reduce the differences in bond coat oxidation behavior. Thermal cycle testing has been initiated. Methods have been selected for measuring tensile strength, Poisson's ratio, dynamic modulus and coefficient of thermal expansion both of the bond coat and top coat layers.

Thermal barrier coating life-prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J.; Liu, A.

1986-01-01

The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.

Effective Parameters in Axial Injection Suspension Plasma Spray Process of Alumina-Zirconia Ceramics

NASA Astrophysics Data System (ADS)

Tarasi, F.; Medraj, M.; Dolatabadi, A.; Oberste-Berghaus, J.; Moreau, C.

2008-12-01

Suspension plasma spray (SPS) is a novel process for producing nano-structured coatings with metastable phases using significantly smaller particles as compared to conventional thermal spraying. Considering the complexity of the system there is an extensive need to better understand the relationship between plasma spray conditions and resulting coating microstructure and defects. In this study, an alumina/8 wt.% yttria-stabilized zirconia was deposited by axial injection SPS process. The effects of principal deposition parameters on the microstructural features are evaluated using the Taguchi design of experiment. The microstructural features include microcracks, porosities, and deposition rate. To better understand the role of the spray parameters, in-flight particle characteristics, i.e., temperature and velocity were also measured. The role of the porosity in this multicomponent structure is studied as well. The results indicate that thermal diffusivity of the coatings, an important property for potential thermal barrier applications, is barely affected by the changes in porosity content.

Influence of Ceramic Powder Size on Process of Cermet Coating Formation by Cold Spray

NASA Astrophysics Data System (ADS)

Sova, A.; Papyrin, A.; Smurov, I.

2009-12-01

Influence of the ceramic particle size on the process of formation of cermet coatings by cold spray is experimentally studied. A specially developed nozzle with separate injection of ceramic and metal powders into the gas stream is used in the experiments. The results obtained demonstrate that fine ceramic powders (Al2O3, SiC) produce a strong activation effect on the process of spraying soft metal (Al, Cu) and increase deposition efficiency of the metal component of the mixture compared to the pure metal spraying. At the same time, coarse ceramic powder produces a strong erosion effect that considerably reduces coating mass growth and deposition efficiency of the metal component. It is experimentally shown that the addition of fine hard powder to soft metals as Al and Cu allows to significantly reduce the “critical” temperature (the minimum gas stagnation temperature at which a nonzero particle deposition is observed) for spraying these metals.

In situ spray deposition of cell-loaded, thermally and chemically gelling hydrogel coatings for tissue regeneration.

PubMed

Pehlivaner Kara, Meryem O; Ekenseair, Adam K

2016-10-01

In this study, the efficacy of creating cellular hydrogel coatings on warm tissue surfaces through the minimally invasive, sprayable delivery of thermoresponsive liquid solutions was investigated. Poly(N-isopropylacrylamide)-based (pNiPAAm) thermogelling macromers with or without addition of crosslinking polyamidoamine (PAMAM) macromers were synthesized and used to produce in situ forming thermally and chemically gelling hydrogel systems. The effect of solution and process parameters on hydrogel physical properties and morphology was evaluated and compared to poly(ethylene glycol) and injection controls. Smooth, fast, and conformal hydrogel coatings were obtained when pNiPAAm thermogelling macromers were sprayed with high PAMAM concentration at low pressure. Cellular hydrogel coatings were further fabricated by different spraying techniques: single-stream, layer-by-layer, and dual stream methods. The impact of spray technique, solution formulation, pressure, and spray solution viscosity on the viability of fibroblast and osteoblast cells encapsulated in hydrogels was elucidated. In particular, the early formation of chemically crosslinked micronetworks during bulk liquid flow was shown to significantly affect cell viability under turbulent conditions compared to injectable controls. The results demonstrated that sprayable, in situ forming hydrogels capable of delivering cell populations in a homogeneous therapeutic coating on diseased tissue surfaces offer promise as novel therapies for applications in regenerative medicine. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 104A: 2383-2393, 2016. © 2016 Wiley Periodicals, Inc.

High-power hybrid plasma spraying of large yttria-stabilized zirconia powder

NASA Astrophysics Data System (ADS)

Huang, Heji; Eguchi, Keisuke; Yoshida, Toyonobu

2006-03-01

To testify to the advantage of large ceramic powder spraying, numerical simulations and experimental studies on the behavior of large yttria-stabilized zirconia (YSZ) powder in a high-power hybrid plasma spraying process have been carried out. Numeric predictions and experimental results showed that, with the high radio frequency (RF) input power of 100 kW, the most refractory YSZ powder with particle sizes as large as 88 μm could be fully melted and well-flattened splats could be formed. A large degree of flattening (ξ) of 4.7 has been achieved. The improved adhesive strength between the large splat and the substrate was confirmed based on the measurement of the crack density inside of the splats. A thick YSZ coating >300 μm was successfully deposited on a large CoNiCrAlY-coated Inconel substrate (50×50×4 mm in size). The ultradense microstructure without clear boundaries between the splats and the clean and crack-free interface between the top-coat and the bond-coat also indicate the good adhesion. These results showed that highpower hybrid plasma spraying of large ceramic powder is a very promising process for deposition of highquality coatings, especially in the application of thermal barrier coatings (TBCs).

Tailoring the heat transfer on the injection moulding cavity by plasma sprayed ceramic coatings

NASA Astrophysics Data System (ADS)

Bobzin, K.; Hopmann, Ch; Öte, M.; Knoch, M. A.; Alkhasli, I.; Dornebusch, H.; Schmitz, M.

2017-03-01

Inhomogeneous material shrinkage in injection moulding can cause warpage in thermoplastic components. To minimise the deformations of the injection moulding parts, the heat transfer during the cooling phase can be adjusted according to the local cooling demand on the surface of the mould cavity by means of plasma sprayed coatings with locally variable thermal resistance over the surface of the mould. Thermal resistance is a function of thermal conductivity and thickness of the coatings, where thermal conductivity of thermal barrier coatings can be adjusted by altering the chemical composition and the microstructure, which is depending on the thickness. This work evaluates the application of plasma sprayed coatings with variable thickness as thermal barrier coatings in the mould cavity. The thermal resistance of the coating and thereby the heat transfer from the melt into the mould will be influenced locally by varying the coating thickness over the cavity area according to the local cooling demand. Using the laser flash method, the thermal conduction of coatings with different thicknesses will be determined. On the basis of the experimentally determined thermal conduction, the effect of the coatings on the temperature field of the mould cavity will be numerically calculated and the required thickness distribution of the coating for an optimal temperature gradient will be determined.

High-temperature chemical stability of plasma-sprayed Ca{sub 0.5}Sr{sub 0.5}Zr{sub 4}P{sub 6}O{sub 24} coatings on Nicalon/SiC ceramic matrix composite and Ni-based superalloy substrates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lee, W.Y.; Cooley, K.M.; Joslin, D.L.

The potential application of Ca{sub 0.5}Sr{sub 0.5}Zr{sub 4}P{sub 6}O{sub 24} (CS50) as a corrosion-resistant coating material for Si-based ceramics and as a thermal barrier coating material for Ni-based superalloys was explored. A {approximately}200 {micro}m thick CS50 coating was prepared by air plasma spray with commercially available powder. A Nicalon/SiC ceramic matrix composite and a Ni-based superalloy coated with a {approximately}200 {micro}m thick metallic bond coat layer were used as substrate materials. Both the powder and coating contained ZrP{sub 2}O{sub 7} as an impurity phase, and the coating was highly porous as-deposited. The coating deposited on the Nicalon/SiC substrate was chemicallymore » stable upon exposure to air and Na{sub 2}SO{sub 4}/O{sub 2} atmospheres at 1,000 C for 100 h. In contrast, the coating sprayed onto the superalloy substrate significantly reacted with the bond coat surface after similar oxidation in air.« less

Color deviation controlling of phosphor conformal coating by advanced spray painting technology for white LEDs.

PubMed

Yang, Liang; Wang, Simin; Lv, Zhicheng; Liu, Sheng

2013-04-01

An advanced phosphor conformal coating technology is proposed, good correlated color temperature (CCT) and chromaticity uniformity samples are fabricated through phosphor spray painting technology. Spray painting technology is also suitable for phosphor conformal coating of whole LED wafers. The samples of different CCTs are obtained through controlling the phosphor film thickness in the range of 6-80 μm; CCT variation of samples can be controlled in the range of ±200 K. The experimental Δuv reveals that the spray painting method can obtain a much smaller CCT variation (Δuv of 1.36e(-3)) than the conventional dispensing method (Δuv of 11.86e(-3)) when the light is emitted at angles from -90° to +90°, and chromaticity area uniformity is also improved significantly.

Method of fabricating silicon carbide coatings on graphite surfaces

DOEpatents

Varacalle, D.J. Jr.; Herman, H.; Burchell, T.D.

1994-07-26

The vacuum plasma spray process produces well-bonded, dense, stress-free coatings for a variety of materials on a wide range of substrates. The process is used in many industries to provide for the excellent wear, corrosion resistance, and high temperature behavior of the fabricated coatings. In this application, silicon metal is deposited on graphite. This invention discloses the optimum processing parameters for as-sprayed coating qualities. The method also discloses the effect of thermal cycling on silicon samples in an inert helium atmosphere at about 1,600 C which transforms the coating to silicon carbide. 3 figs.

Method of fabricating silicon carbide coatings on graphite surfaces

DOEpatents

Varacalle, Jr., Dominic J.; Herman, Herbert; Burchell, Timothy D.

1994-01-01

The vacuum plasma spray process produces well-bonded, dense, stress-free coatings for a variety of materials on a wide range of substrates. The process is used in many industries to provide for the excellent wear, corrosion resistance, and high temperature behavior of the fabricated coatings. In this application, silicon metal is deposited on graphite. This invention discloses the optimum processing parameters for as-sprayed coating qualities. The method also discloses the effect of thermal cycling on silicon samples in an inert helium atmosphere at about 1600.degree.C. which transforms the coating to silicon carbide.

Morphology of powders of tungsten carbide used in wear-resistant coatings and deposition on the PDC drill bits

NASA Astrophysics Data System (ADS)

Zakharova, E. S.; Markova, I. Yu; Maslov, A. L.; Polushin, N. I.; Laptev, A. I.

2017-05-01

Modern drill bits have high abrasive wear in the area of contact with the rock and removed sludge. Currently, these bits have a protective layer on the bit body, which consists of a metal matrix with inclusions of carbide particles. The research matrix of this coating and the wear-resistant particles is a prerequisite in the design and production of drill bits. In this work, complex investigation was made for various carbide powders of the grades Relit (tungsten carbide produced by Ltd “ROSNAMIS”) which are used as wear-resistant particles in the coating of the drill bit body. The morphology and phase composition of the chosen powders as well as the influence of a particle shape on prospects of their application in wear-resistance coating presented in this work.

Microstructure and Electrochemical Behavior of Fe-Based Amorphous Metallic Coatings Fabricated by Atmospheric Plasma Spraying

NASA Astrophysics Data System (ADS)

Zhou, Z.; Wang, L.; He, D. Y.; Wang, F. C.; Liu, Y. B.

2011-01-01

A Fe48Cr15Mo14C15B6Y2 alloy with high glass forming ability (GFA) was selected to prepare amorphous metallic coatings by atmospheric plasma spraying (APS). The as-deposited coatings present a dense layered structure and low porosity. Microstructural studies show that some nanocrystals and a fraction of yttrium oxides formed during spraying, which induced the amorphous fraction of the coatings decreasing to 69% compared with amorphous alloy ribbons of the same component. High thermal stability enables the amorphous coatings to work below 910 K without crystallization. The results of electrochemical measurement show that the coatings exhibit extremely wide passive region and relatively low passive current density in 3.5% NaCl and 1 mol/L HCl solutions, which illustrate their superior ability to resist localized corrosion. Moreover, the corrosion behavior of the amorphous coatings in 1 mol/L H2SO4 solution is similar to their performance under conditions containing chloride ions, which manifests their flexible and extensive ability to withstand aggressive environments.

Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings

NASA Astrophysics Data System (ADS)

Wang, Hsin; Muralidharan, Govindarajan; Leonard, Donovan N.; Haynes, J. Allen; Porter, Wallace D.; England, Roger D.; Hays, Michael; Dwivedi, Gopal; Sampath, Sanjay

2018-02-01

Multilayer, graded ceramic/metal coatings were prepared by an air plasma spray method on Ti-6Al-4V, 4140 steel and graphite substrates. The coatings were designed to provide thermal barriers for diesel engine pistons to operate at higher temperatures with improved thermal efficiency and cleaner emissions. A systematic, progressive variation in the mixture of yttria-stabilized zirconia and bondcoat alloys (NiCoCrAlYHfSi) was designed to provide better thermal expansion match with the substrate and to improve thermal shock resistance and cycle life. Heat transfer through the layers was evaluated by a flash diffusivity technique based on a model of one-dimensional heat flow. The aging effect of the as-sprayed coatings was captured during diffusivity measurements, which included one heating and cooling cycle. The hysteresis of thermal diffusivity due to aging was not observed after 100-h annealing at 800 °C. The measurements of coatings on substrate and freestanding coatings allowed the influence of interface resistance to be evaluated. The microstructure of the multilayer coating was examined using scanning electron microscope and electron probe microanalysis.

Cyclic Oxidation Behavior of Cold Sprayed CuCrAl-Coated and Uncoated GRCop-84 Substrates for Space Launch Vehicles

NASA Technical Reports Server (NTRS)

Raj, S. V.; Barrett, C.; Karthikeyan, J.; Garlick, R.

2006-01-01

A newly developed Cu-23 (wt %) Cr-5%Al (CuCrAl) alloy shown to resist hydridation and oxidation in an as-cast form is currently being considered as a protective coating for GRCop-84, which is an advanced copper alloy containing 8 (at.%) Cr and 4 (at.%) Nb. The coating was deposited on GRCop-84 substrates by the cold spray deposition technique. Cyclic oxidation tests conducted in air on both coated and uncoated substrates between 773 and 1073 K revealed that the coating remained intact and protected the substrate up to 1073 K. No significant weight loss of the coated specimens were observed at 773 and 873 K even after a cumulative cyclic time of 500 h. About a 10 percent weight loss observed at 973 and 1073 K was attributed to the excessive oxidation of the uncoated sides. In contrast, the uncoated substrate lost as much as 80 percent of its original weight under similar test conditions. It is concluded that the cold sprayed CuCrAl coating is suitable for protecting GRCop-84 substrates.

In Situ TiC-Reinforced Ni-Based Composite Coating Prepared by Flame Spraying Using Sucrose as the Source of Carbon

NASA Astrophysics Data System (ADS)

Wang, Haitao; Zhang, Shouquan; Zhu, Jinglei; Huang, Jihua; Liu, Huiyuan; Zhang, Hua

2009-03-01

A Ni-Ti-C composite powder for Reactive Thermal Spraying is made by heating a mixture of titanium, nickel, and sucrose to carbonize the sucrose, which is used as the source of carbon. The carbon obtained by pyrolysis of sucrose is a reactive constituent as well as the binder in the composite powder. The titanium and nickel particles are bound by the carbon to form granules of the composite powder. This powder feedstock was used to prepare in situ TiC-reinforced Ni-based composite coating by oxyacetylene flame spraying. The TiC-Ni composite coating is made of TiC, Ni, and some Ni3Ti. In the coating, a mass of fine TiC particles is uniformly distributed within the metallic matrix. The microhardness and surface hardness of the coating are, respectively, 1433 HV0.2kg and 62 ± 6 (HR30N). The wear resistance is much better for the TiC-Ni composite coating than for the substrate and Ni60 coating.

ENVIRONMENTAL TECHNOLOGY VERIFICATION REPORT, HVLP COATING EQUIPMENT, SHARPE MANUFACTURING COMPANY PLATINUM 2012 HVLP SPRAY GUN

EPA Science Inventory

This report presents the results of the verification test of the Sharpe Platinum 2013 high-volume, low-pressure gravity-feed spray gun, hereafter referred to as the Sharpe Platinum, which is designed for use in automotive refinishing. The test coating chosen by Sharpe Manufacturi...

iMAST Quarterly, 2007 Number 1

DTIC Science & Technology

2007-01-01

deposit the CP Al powders . Characterization of the coatings included microstructural analysis, hardness...Aluminum on Al 7075 using Kinetic Metallization and Cold Spray Processes ”, submitted to the Journal of Thermal Spray ... processing have lead to the ability to deposit very dense coatings using the HVPC process . Aluminum, aluminum alloys , copper, stainless steel

Intergranular metal phase increases thermal shock resistance of ceramic coating

NASA Technical Reports Server (NTRS)

Carpenter, H. W.

1966-01-01

Dispersed copper phase increases the thermal shock resistance of a plasma-arc-sprayed coating of zirconia used as a heat barrier on a metal substrate. A small amount of copper is deposited on the granules of the zirconia powder before arc-spraying the resultant powder composite onto the substrate.

Corrosion behavior of an HVOF-sprayed Fe3Al coating in a high-temperature oxidizing/sulfidizing environment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Covino, Bernard S., Jr.; Bullard, Sophie J.; Cramer, Stephen D.

An iron aluminide (Fe3Al) intermetallic coating was deposited onto a F22 (2.25Cr-1Mo) steel substrate using a JP-5000 high velocity oxy-fuel (HVOF) thermal spray system. The as-sprayed coating was examined by electron microscopy and X-ray diffraction and was characterized in terms of oxidation and adhesion. Fe3Al-coated steel specimens were exposed to a mixed oxidizing/sulfidizing environment at 500, 600, 700, and 800DGC for approximately seven days. The gaseous environment consisted of N2-10%CO-5%CO2-2%H2O-0.12%H2S (by volume). All specimens gained mass after exposure to the environment and the mass gains were found to be inversely proportional to temperature increases. Representative specimens exposed at each temperaturemore » were cross-sectioned and subjected to examination under a scanning electron microscope (SEM) and X-ray mapping. Results are presented in terms of corrosion weight gain and corrosion product formation. The purpose of the research presented here was to evaluate the effectiveness of an HVOF-sprayed Fe3Al coating in protecting a steel substrate exposed to a fossil energy environment.« less

Optimization of the laser remelting process for HVOF-sprayed Stellite 6 wear resistant coatings

NASA Astrophysics Data System (ADS)

Ciubotariu, Costel-Relu; Frunzăverde, Doina; Mărginean, Gabriela; Șerban, Viorel-Aurel; Bîrdeanu, Aurel-Valentin

2016-03-01

Cobalt base alloys are used in all industrial areas due to their excellent wear resistance. Several studies have shown that Stellite 6 coatings are suitable not only for protection against sliding wear, but also in case of exposure to impact loading. In this respect, a possible application is the protection of hydropower plant components affected by cavitation. The main problem in connection with Stellite 6 is the deposition procedure of the protective layers, both welding and thermal spraying techniques requesting special measures in order to prevent the brittleness of the coating. In this study, Stellite 6 layers were HVOF thermally sprayed on a martensitic 13-4 stainless steel substrate, as usually used for hydraulic machinery components. In order to improve the microstructure of the HVOF-sprayed coatings and their adhesion to the substrate, laser remelting was applied, using a TRUMPF Laser type HL 124P LCU and different working parameters. The microstructure of the coatings, obtained for various remelting conditions, was evaluated by light microscopy, showing the optimal value of the pulse power, which provided a homogenous Stellite 6 layer with good adhesion to the substrate.

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

PubMed

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

2014-01-01

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

Thermal barrier coating life-prediction model development

NASA Technical Reports Server (NTRS)

Strangman, T. E.; Neumann, J.

1985-01-01

Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.

77 FR 40550 - Approval and Promulgation of Air Quality Implementation Plans; Maryland; Revision for the Control...

Federal Register 2010, 2011, 2012, 2013, 2014

2012-07-10

... filtered spray booth and enclosed spray gun cleaner. Maryland's 1997 SIP-approved regulation COMAR 26.11.19... equipment and materials storage such as spray booths, spray guns, and sealed containers for cleaning rags... standards include procedures for cleaning the spray gun equipment for applying automotive coatings. Affected...

Plasma-sprayed coatings for lubrication of a titanium alloy in air at 430 deg C

NASA Technical Reports Server (NTRS)

Sliney, H. E.; Wisander, D. H.

1979-01-01

Plasma sprayed coatings of pure silver and of composite materials containing silver were investigated as possible self lubricating coatings for titanium alloys in air at 430 C. Pure silver provided low friction but was prone to severe plastic deformation and excessive transfer except in coating thicknesses of 0.02 mm or less. Additions of nichrome, calcium fluoride, and glass to silver were all beneficial in reducing plastic deformation and otherwise improving the coatings. The longest coating wear life, low wear of Ti alloy pins in sliding contact with the coatings, and a steady friction coefficient of 0.19 were obtained with a four component coating of 0.17 mm thickness. The coating composition, in weight percent is 30 nichrome-30 Ag-25 CaF2-15 glass.

Spray pattern analysis in TWAS using photogrammetry and digital image correlation

NASA Astrophysics Data System (ADS)

Tillmann, W.; Rademacher, H. G.; Hagen, L.; Abdulgader, M.; El Barad’ei, M.

2018-06-01

In terms of arc spraying processes, the spray plume characteristic is mainly affected by the flow characteristic of the atomization gas at the nozzle inlet and intersection point of the wire tips, which in turn affect the particle distribution at the moment of impact when molten spray particles splash onto the substrate. With respect to the route of manufacturing of near net-shaped coatings on complex geometries, the acquisition of the spray patterns is pressingly necessary to determine the produced coating thickness. Within the scope of this study, computer fluid dynamics (CFD) simulations were carried out to determine the distribution of spray particles for different spray parameter settings. The results were evaluated by three-dimensional spray spot analyses using an optical measurement based on photogrammetry and digital image correlation. The optical measurement represents a promising and much faster candidate to measure spray patterns compared to the tactile measurement system but with an equal accuracy. For given nozzle configurations and spray parameter settings, numerous spray patterns were examined to their shape factors, demonstrating the potential of an online analysis, which encompasses a “fast sample loop” and a data processing system to generate a three-dimensional surface of the spray spot profile.

Improved Orifice Plate for Spray Gun

NASA Technical Reports Server (NTRS)

Cunningham, W.

1986-01-01

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

Microstructure and thermal properties of copper–diamond composites with tungsten carbide coating on diamond particles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kang, Qiping; He, Xinbo, E-mail: xb_he@163.com; Ren, Shubin

2015-07-15

An effective method for preparing tungsten carbide coating on diamond surfaces was proposed to improve the interface bonding between diamond and copper. The WC coating was formed on the diamond surfaces with a reaction medium of WO{sub 3} in mixed molten NaCl–KCl salts and the copper–diamond composites were obtained by vacuum pressure infiltration of WC-coated diamond particles with pure copper. The microstructure of interface bonding between diamond and copper was discussed. Thermal conductivity and thermal expansion behavior of the obtained copper–diamond composites were investigated. Results indicated that the thermal conductivity of as-fabricated composite reached 658 W m{sup −} {sup 1}more » K{sup −} {sup 1}. Significant reduction in coefficient of thermal expansion of the composite compared with that of pure copper was obtained. - Highlights: • WC coating was successfully synthesized on diamond particles in molten salts. • WC coating obviously promoted the wettability of diamond and copper matrix. • WC coating greatly enhanced the thermal conductivity of Cu–diamond composite. • The composites are suitable candidates for heat sink applications.« less

Electrical properties of transparent conductive ATO coatings obtained by spray pyrolysis

NASA Astrophysics Data System (ADS)

Zinchenko, T. O.; Kondrashin, V. I.; Pecherskaya, E. A.; Kozlyakov, A. S.; Nikolaev, K. O.; Shepeleva, J. V.

2017-08-01

Transparent conductive coatings based on thin films of metal oxides have been widely spread in various optoelectronic devices and appliances. It is necessary to determine the influence of preparation conditions on coatings properties for their use in the solution of certain tasks. Thin films of tin dioxide were obtained by the method of spray pyrolysis on glass substrates. Surface resistance and resistivity, concentration and mobility of charge carriers, the conductivity were measured, and the dependences showing the effect of preparation conditions on electrical properties of optically transparent coatings.

Collaborative Research and Development (CR&D). Delivery Order 0014: Anti-Fretting Coatings Research Development

DTIC Science & Technology

2006-12-01

properties Deposition Cu / Al in At% Roughness Ra (µm) Nano Hardness (GPa) Modulus (GPa) Thickness (µm) 1 Plasma ≈ 6 ≈ 12 ≈ 1.8 ≈ 89.6 ≈ 300 2... sprayed coatings of different copper to aluminum ( Cu / Al ) ratios and one cathodic arc coating. Bench level gross slip fretting experiments and post...some of Ti6Al4V disks were commercially grit blasted and then plasma sprayed with Al -bronze coatings 1 and 2, which have different Cu / Al

Recent developments in plasma spray processes for applications in energy technology

NASA Astrophysics Data System (ADS)

Mauer, G.; Jarligo, M. O.; Marcano, D.; Rezanka, S.; Zhou, D.; Vaßen, R.

2017-03-01

This work focuses on recent developments of plasma spray processes with respect to specific demands in energy technology. High Velocity Atmospheric Plasma Spraying (HV-APS) is a novel variant of plasma spraying devoted to materials which are prone to oxidation or decomposition. It is shown how this process can be used for metallic bondcoats in thermal barrier coating systems. Furthermore, Suspension Plasma Spraying (SPS) is a new method to process submicron-sized feedstock powders which are not sufficiently flowable to feed them in dry state. SPS is presently promoted by the development of novel torch concepts with axial feedstock injection. An example for a columnar structured double layer thermal barrier coating is given. Finally, Plasma Spray-Physical Vapor Deposition (PS-PVD) is a novel technology operating in controlled atmosphere at low pressure and high plasma power. At such condition, vaporization even of high-melting oxide ceramics is possible enabling the formation of columnar structured, strain tolerant coatings with low thermal conductivity. Applying different conditions, the deposition is still dominated by liquid splats. Such process is termed Low Pressure Plasma Spraying-Thin Film (LPPS-TF). Two examples of applications are gas-tight and highly ionic and electronic conductive electrolyte and membrane layers which were deposited on porous metallic substrates.

Transfer of Wire Arc-Sprayed Metal Coatings onto Plastic Parts

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.; Liao, X.; Hopmann, Ch.; Ochotta, P.

2018-01-01

By means of In-Mold-Metal-Spraying (IMMS), metal coatings deposited by means of arc spraying process (ASP) can be transferred onto plastic parts during injection molding, thus realizing an efficient production of metallized plastic parts. Parts produced by means of IMMS can be used in electrical applications. In the current study, the electrical resistivity of coatings applied with different feedstock materials was determined. As a starting point, pressurized air is used as atomizing gas for ASP. In contrast to Zn coatings, Cu coatings applied with pressurized air exhibit a significantly higher electrical resistivity in comparison with massive material. One possible reason is the more pronounced oxidation of Cu particles during ASP. Therefore, N2 and a mixture of N2 and H2 were used as atomizing gas. As a result, the electrical resistivity of coatings applied by means of IMMS could be significantly reduced. Furthermore, standoff distance, current and pressure of the atomizing gas were varied to investigate the influence of these process parameters on the electrical resistivity of Zn coatings using a full factorial experiment design with center point. It can be observed that the electrical resistivity of the Zn coatings increases with decreasing current and increasing standoff distance and pressure.

Transfer of Wire Arc-Sprayed Metal Coatings onto Plastic Parts

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.; Liao, X.; Hopmann, Ch.; Ochotta, P.

2017-12-01

By means of In-Mold-Metal-Spraying (IMMS), metal coatings deposited by means of arc spraying process (ASP) can be transferred onto plastic parts during injection molding, thus realizing an efficient production of metallized plastic parts. Parts produced by means of IMMS can be used in electrical applications. In the current study, the electrical resistivity of coatings applied with different feedstock materials was determined. As a starting point, pressurized air is used as atomizing gas for ASP. In contrast to Zn coatings, Cu coatings applied with pressurized air exhibit a significantly higher electrical resistivity in comparison with massive material. One possible reason is the more pronounced oxidation of Cu particles during ASP. Therefore, N2 and a mixture of N2 and H2 were used as atomizing gas. As a result, the electrical resistivity of coatings applied by means of IMMS could be significantly reduced. Furthermore, standoff distance, current and pressure of the atomizing gas were varied to investigate the influence of these process parameters on the electrical resistivity of Zn coatings using a full factorial experiment design with center point. It can be observed that the electrical resistivity of the Zn coatings increases with decreasing current and increasing standoff distance and pressure.

Thermal barrier coating life prediction model

NASA Technical Reports Server (NTRS)

Hillery, R. V.; Pilsner, B. H.; Cook, T. S.; Kim, K. S.

1986-01-01

This is the second annual report of the first 3-year phase of a 2-phase, 5-year program. The objectives of the first phase are to determine the predominant modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consists of an air plasma sprayed ZrO-Y2O3 top coat, a low pressure plasma sprayed NiCrAlY bond coat, and a Rene' 80 substrate. Task I was to evaluate TBC failure mechanisms. Both bond coat oxidation and bond coat creep have been identified as contributors to TBC failure. Key property determinations have also been made for the bond coat and the top coat, including tensile strength, Poisson's ratio, dynamic modulus, and coefficient of thermal expansion. Task II is to develop TBC life prediction models for the predominant failure modes. These models will be developed based on the results of thermmechanical experiments and finite element analysis. The thermomechanical experiments have been defined and testing initiated. Finite element models have also been developed to handle TBCs and are being utilized to evaluate different TBC failure regimes.

Robust Hydrophobic Surfaces from Suspension HVOF Thermal Sprayed Rare-Earth Oxide Ceramics Coatings.

PubMed

Bai, M; Kazi, H; Zhang, X; Liu, J; Hussain, T

2018-05-03

This study has presented an efficient coating method, namely suspension high velocity oxy-fuel (SHVOF) thermal spraying, to produce large super-hydrophobic ceramic surfaces with a unique micro- and nano-scale hierarchical structures to mimic natural super-hydrophobic surfaces. CeO 2 was selected as coatings material, one of a group of rare-earth oxide (REO) ceramics that have recently been found to exhibit intrinsic hydrophobicity, even after exposure to high temperatures and abrasive wear. Robust hydrophobic REO ceramic surfaces were obtained from the deposition of thin CeO 2 coatings (3-5 μm) using an aqueous suspension with a solid concentration of 30 wt.% sub-micron CeO 2 particles (50-200 nm) on a selection of metallic substrates. It was found that the coatings' hydrophobicity, microstructure, surface morphology, and deposition efficiency were all determined by the metallic substrates underneath. More importantly, it was demonstrated that the near super-hydrophobicity of SHVOF sprayed CeO 2 coatings was achieved not only by the intrinsic hydrophobicity of REO but also their unique hierarchically structure. In addition, the coatings' surface hydrophobicity was sensitive to the O/Ce ratio, which could explain the 'delayed' hydrophobicity of REO coatings.