Polyethylene-Carbon Nanotube Composite Film Deposited by Cold Spray Technique

NASA Astrophysics Data System (ADS)

Ata, Nobuhisa; Ohtake, Naoto; Akasaka, Hiroki

2017-10-01

Carbon nanotubes (CNTs) are high-performance materials because of their superior electrical conductivity, thermal conductivity, and self-lubrication, and they have been studied for application to polymer composite materials as fillers. However, the methods of fabricating polymer composites with CNTs, such as injection molding, are too complicated for industrial applications. We propose a simple cold spray (CS) technique to obtain a polymer composite of polyethylene (PE) and CNTs. The composite films were deposited by CS on polypropylene and nano-porous structured aluminum substrates. The maximum thickness of the composite film was approximately 1 mm. Peaks at G and D bands were observed in the Raman spectra of the films. Scanning electron microscopy images of the film surface revealed that PE particles were melted by the acceleration gas and CNTs were attached with melted PE. The PE particles solidified after contact with the substrate. These results indicate that PE-CNT composite films were successfully deposited on polypropylene and nano-porous structured aluminum substrates by CS.

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.

Carbon Nanotube Thermal Interfaces Enhanced with Sprayed on Nanoscale Polymer Coatings

DTIC Science & Technology

2013-02-20

temperature of the growth stage was lowered to 750 ◦C (a pyrometer measured the actual sample temperature to be approximately 630 ◦C, which is less than the...the heat is absorbed at the sample surface it is conducted both downward through the sample and upward into an acoustic chamber filled with He gas. The

Microstructure, Tensile Adhesion Strength and Thermal Shock Resistance of TBCs with Different Flame-Sprayed Bond Coat Materials Onto BMI Polyimide Matrix Composite

NASA Astrophysics Data System (ADS)

Abedi, H. R.; Salehi, M.; Shafyei, A.

2017-10-01

In this study, thermal barrier coatings (TBCs) composed of different bond coats (Zn, Al, Cu-8Al and Cu-6Sn) with mullite top coats were flame-sprayed and air-plasma-sprayed, respectively, onto bismaleimide matrix composites. These polyimide matrix composites are of interest to replace PMR-15, due to concerns about the toxicity of the MDA monomer from which PMR-15 is made. The results showed that pores and cracks appeared at the bond coat/substrate interface for the Al-bonded TBC because of its high thermal conductivity and diffusivity resulting in transferring of high heat flux and temperature to the polymeric substrate during top coat deposition. The other TBC systems due to the lower conductivity and diffusivity of bonding layers could decrease the adverse thermal effect on the polymer substrate during top coat deposition and exhibited adhesive bond coat/substrate interfaces. The tensile adhesion test showed that the adhesion strength of the coatings to the substrate is inversely proportional to the level of residual stress in the coatings. However, the adhesion strength of Al bond-coated sample decreased strongly after mullite top coat deposition due to thermal damage at the bond coat/substrate interface. TBC system with the Cu-6Sn bond coat exhibited the best thermal shock resistance, while Al-bonded TBC showed the lowest. It was inferred that thermal mismatch stresses and oxidation of the bond coats were the main factors causing failure in the thermal shock test.

Process for preparing essentially colorless polyimide film containing phenoxy-linked diamines

NASA Technical Reports Server (NTRS)

Stclair, A. K.; Stclair, T. L.

1986-01-01

A polyimide film that is approximately 90% transparent at 500 nm, useful for thermal protective coatings and solar cells, and the processes for preparing the same by thermal and chemical conversion are disclosed. An essential feature for achieving maximum optical transparency films requires utilizing recrystallized and/or sublimated specific aromatic diamines and dianhydride monomers and introducing phenoxy or thiophenyl separator groups and isomeric m,m' or o,p'-oriented diamines into the polymer molecular structure. The incorporation of these groups in the polymer structure serves to separate the chromaphoric centers and reduce the formation of inter-chain and intra-chain charge transfer complexes which normally cause absorptions in the UV-visible range. The films may be obtained by hand, brushing, casting, or spraying a layer of polyamic acid solutions onto a surface and thermally converting the applied layer to the polyimide, or the polyamic acid solution can be chemically converted to the polyimide, subsequentially dissolved in an organic solvent, and applied as a polyimide film layer with the solvent therein thermally removed.

Demonstration of Thermally Sprayed Metal and Polymer Coatings for Steel Structures at Fort Bragg, NC

DTIC Science & Technology

2017-09-01

for Steel Structures at Fort Bragg, NC Final Report on Project F07-AR10 Co ns tr uc tio n En gi ne er in g R es ea rc h La bo ra to ry Larry D...and Polymer Coatings for Steel Structures at Fort Bragg, NC Final Report on Project F07-AR10 Larry D. Stephenson, Alfred D. Beitelman, Richard G...recently been estimated that at least 25 U.S. Army in- stallations have severe corrosion problems with above-ground steel stor- age tanks. Coatings are

Abstracts of AF Materials Laboratory Reports. January 1973 - December 1973

DTIC Science & Technology

1974-07-01

substituted polymers with aryl ether , ketone and sulfone units in the backbone has been studied. The best resins seem to have come from simple...exposed to hostile environments such as heat aging plus salt spray, humid aging , humid aging and elevated temperature cycling, and fatigue...unclassified results of materials and process and radome characterization effort. Environmental exposure including thermal aging resulted in significant

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.

Enabling thermal processing of ritonavir-polyvinyl alcohol amorphous solid dispersions by KinetiSol® Dispersing.

PubMed

LaFountaine, Justin S; Jermain, Scott V; Prasad, Leena Kumari; Brough, Chris; Miller, Dave A; Lubda, Dieter; McGinity, James W; Williams, Robert O

2016-04-01

Polyvinyl alcohol has received little attention as a matrix polymer in amorphous solid dispersions (ASDs) due to its thermal and rheological limitations in extrusion processing and limited organic solubility in spray drying applications. Additionally, in extrusion processing, the high temperatures required to process often exclude thermally labile APIs. The purpose of this study was to evaluate the feasibility of processing polyvinyl alcohol amorphous solid dispersions utilizing the model compound ritonavir with KinetiSol® Dispersing (KSD) technology. The effects of KSD rotor speed and ejection temperature on the physicochemical properties of the processed material were evaluated. Powder X-ray diffraction and modulated differential scanning calorimetry were used to confirm amorphous conversion. Liquid chromatography-mass spectroscopy was used to characterize and identify degradation pathways of ritonavir during KSD processing and (13)C nuclear magnetic resonance spectroscopy was used to investigate polymer stability. An optimal range of processing conditions was found that resulted in amorphous product and minimal to no drug and polymer degradation. Drug release of the ASD produced from the optimal processing conditions was evaluated using a non-sink, pH-shift dissolution test. The ability to process amorphous solid dispersions with polyvinyl alcohol as a matrix polymer will enable further investigations of the polymer's performance in amorphous systems for poorly water-soluble compounds. Copyright © 2016 Elsevier B.V. All rights reserved.

Preparation of polymer-blended quinine nanocomposite particles by spray drying and assessment of their instrumental bitterness-masking effect using a taste sensor.

PubMed

Taki, Moeko; Tagami, Tatsuaki; Ozeki, Tetsuya

2017-05-01

The development of taste-masking technologies for foods and drugs is essential because it would enable people to consume and receive healthy and therapeutic effect without distress. In the current study, in order to develop a novel method to prepare nanocomposite particles (microparticles containing bitter nanoparticles) in only one step, by using spray drying, a two-solution mixing nozzle-equipped spray dryer that we previously reported was used. The nanocomposite particles with or without poorly water-soluble polymers prepared using our spray-drying technique were characterized. (1) The organic solution containing quinine, a model of bitter compound and poorly water-soluble polymers and (2) sugar alcohol (mannitol) aqueous solution were separately flown in tubes and two solutions were spray dried through two-solution type spray nozzle to prepare polymer-blended quinine nanocomposite particles. Mean diameters of nanoparticles, taste-masking effect and dissolution rate of quinine were evaluated. The results of taste masking by taste sensor suggested that the polymer (Eudragit EPO, Eudragit S100 or Ethyl cellulose)-blended quinine nanocomposite particles exhibited marked masking of instrumental quinine bitterness compared with the quinine nanocomposite particles alone. Quinine nanocomposite formulations altered the quinine dissolution rate, indicating that they can control intestinal absorption of quinine. These results suggest that polymer-blended quinine composite particles prepared using our spray-drying technique are useful for masking bitter tastes in the field of food and pharmaceutical industry.

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.

Nanoscale surface characterization and miscibility study of a spray-dried injectable polymeric matrix consisting of poly(lactic-co-glycolic acid) and polyvinylpyrrolidone.

PubMed

Meeus, Joke; Chen, Xinyong; Scurr, David J; Ciarnelli, Valeria; Amssoms, Katie; Roberts, Clive J; Davies, Martyn C; van Den Mooter, Guy

2012-09-01

Injectable controlled-release formulations are of increasing interest for the treatment of chronic diseases. This study aims to develop and characterize a polymeric matrix for intramuscular or subcutaneous injection, consisting of two biocompatible polymers, particularly suitable for formulating poorly soluble drugs. For this matrix, the water-insoluble polymer poly(lactic-co-glycolic acid) (PLGA) is combined with the water-soluble polymer polyvinylpyrrolidone (PVP). Microparticles of these two polymers were prepared by spray drying. The phase behavior of the samples was studied by means of modulated differential scanning calorimetry and the results showed that phase separation occurred in the bulk sample through evidence of two mixed amorphous phases, namely, a PLGA-rich phase and a PVP-rich phase. Characterization of the samples by scanning electron microscopy demonstrated that the spray-dried particles were hollow with a thin shell. Because of the importance in relation to stability and drug release, information about the surface of the microparticles was collected by different complementary surface analysis techniques. Atomic force microscopy gathered information about the morphology and phase behavior of the microparticle surface. Time-of-flight secondary ion mass spectrometry analysis of the particles revealed that the surface consisted mainly of the PLGA-rich phase. This was confirmed by X-ray photoelectron spectroscopy at an increased sampling depth (≈ 10 nm). Nanothermal analysis proved to be an innovative way to thermally detect the presence of the PLGA-dominated surface layer and the underlying PVP phase. Taken together, this information provides a rational basis for predicting the likely drug release behavior this formulation will display. Copyright © 2012 Wiley Periodicals, Inc.

Thermal sprayed composite melt containment tubular component and method of making same

DOEpatents

Besser, Matthew F.; Terpstra, Robert L.; Sordelet, Daniel J.; Anderson, Iver E.

2002-03-19

A tubular thermal sprayed melt containment component for transient containment of molten metal or alloy wherein the tubular member includes a thermal sprayed inner melt-contacting layer for contacting molten metal or alloy to be processed, a thermal sprayed heat-generating layer deposited on the inner layer, and an optional thermal sprayed outer thermal insulating layer. The thermal sprayed heat-generating layer is inductively heated as a susceptor of an induction field or electrical resistively heated by passing electrical current therethrough. The tubular thermal sprayed melt containment component can comprise an elongated melt pour tube of a gas atomization apparatus where the melt pour tube supplies molten material from a crucible to an underlying melt atomization nozzle.

Development of potential novel cushioning agents for the compaction of coated multi-particulates by co-processing micronized lactose with polymers.

PubMed

Lin, Xiao; Chyi, Chin Wun; Ruan, Ke-feng; Feng, Yi; Heng, Paul Wan Sia

2011-10-01

This work aimed to explore the potential of lactose as novel cushioning agents with suitable physicomechanical properties by micronization and co-spray drying with polymers for protecting coated multi-particulates from rupture when they are compressed into tablets. Several commercially available lactose grades, micronized lactose (ML) produced by jet milling, spray-dried ML (SML), and polymer-co-processed SMLs, were evaluated for their material characteristics and tableting properties. Hydroxypropylcellulose (HPC), hydroxypropylmethylcellulose (HPMC), and polyvinylpyrrolidone (PVP) at three different levels were evaluated as co-processed polymers for spray drying. Sugar multi-particulates layered with chlorpheniramine maleate followed by an ethylcellulose coat were tableted using various lactose types as fillers. Drug release from compacted multi-particulate tablets was used to evaluate the cushioning effect of the fillers. The results showed that the cushioning effect of lactose principally depended on its particle size. Micronization can effectively enhance the protective action of lactose. Although spray drying led to a small reduction in the cushioning effect of ML, it significantly improved the physicomechanical properties of ML. Co-spray drying with suitable polymers improved both the cushioning effect and the physicomechanical properties of SML to a certain degree. Among the three polymers studied, HPC was the most effective in terms of enhancing the cushioning effect of SML. This was achieved by reducing yield pressure, and enhancing compressibility and compactibility. The combination of micronization and co-spray drying with polymers is a promising method with which new applications for lactose can be developed. Copyright © 2011 Elsevier B.V. All rights reserved.

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.

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.

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

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).

Early change in thermal perception is not a driver of anticipatory exercise pacing in the heat.

PubMed

Barwood, Martin James; Corbett, Jo; White, Danny; James, Jason

2012-10-01

Initial power output declines significantly during exercise in hot conditions on attaining a rapid increase in skin temperature when exercise commences. It is unclear whether this initial reduced power is mediated consciously, through thermal perceptual cues, or is a subconscious process. The authors tested the hypothesis that improved thermal perception (feeling cooler and more comfortable) in the absence of a change in thermal state (ie, similar deep-body and skin temperatures between spray conditions) would alter pacing and 40 km cycling time trial (TT) performance. Eleven trained participants (mean (SD): age 30 (8.1) years; height 1.78 (0.06) m; mass 76.0 (8.3) kg) completed three 40 km cycling TTs in standardised conditions (32°C, 50% RH) with thermal perception altered prior to exercise by application of cold-receptor-activating menthol spray (MENTHOL SPRAY), in contrast to a separate control spray (CONTROL SPRAY) and no spray control (CON). Thermal perception, perceived exertion, thermal responses and cycling TT performance were measured. MENTHOL SPRAY induced feelings of coolness and improved thermal comfort before and during exercise. Skin temperature profile at the start of exercise was similar between sprays (CON-SPRAY 33.3 (1.1)°C and MENTHOL SPRAY 33.4 (0.4)°C, but different to CON 34.5 (0.5)°C), but there was no difference in the pacing strategy adopted. There was no performance benefit using MENTHOL SPRAY; cycling TT completion time for CON is 71.58 (6.21) min, for CON-SPRAY is 70.94 (6.06) min and for MENTHOL SPRAY is 71.04 (5.47) min. The hypothesis is rejected. Thermal perception is not a primary driver of early pacing during 40 km cycling TT in hot conditions in trained participants.

Microstructured Polymer Blend Surfaces Produced by Spraying Functional Copolymers and Their Blends

PubMed Central

Vargas-Alfredo, Nelson; Rodríguez Hernández, Juan

2016-01-01

We described the fabrication of functional and microstructured surfaces from polymer blends by spray deposition. This simple technique offers the possibility to simultaneously finely tune the microstructure as well as the surface chemical composition. Whereas at lower polymer concentration, randomly distributed surface micropatterns were observed, an increase of the concentration leads to significant changes on these structures. On the one hand, using pure homopolystyrene fiber-like structures were observed when the polymer concentration exceeded 30 mg/mL. Interestingly, the incorporation of 2,3,4,5,6-pentafluorostyrene changed the morphology, and, instead of fibers, micrometer size particles were identified at the surface. These fluorinated microparticles provide superhydrophobic properties leading to surfaces with contact angles above 165°. Equally, in addition to the microstructures provided by the spray deposition, the use of thermoresponsive polymers to fabricate interfaces with responsive properties is also described. Contact angle measurements revealed variations on the surface wettability upon heating when blends of polystyrene and polystyrene-b-poly(dimethylaminoethyl methacrylate) are employed. Finally, the use of spraying techniques to fabricate gradient surfaces is proposed. Maintaining a constant orientation, the surface topography and thus the contact angle varies gradually from the center to the edge of the film depending on the spray angle. PMID:28773555

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

Preparation and characterization of microparticles of β-cyclodextrin/glutathione and chitosan/glutathione obtained by spray-drying.

PubMed

Webber, Vanessa; de Siqueira Ferreira, Daniel; Barreto, Pedro Luis Manique; Weiss-Angeli, Valeria; Vanderlinde, Regina

2018-03-01

Reduced glutathione (GSH) is an efficient antioxidant on limitation of browning, of the loss of aromas and off-flavor formation in white wines. The encapsulation of GSH in a polymer system to be added in white wines may prolong its antioxidant action. The aim of this work was to prepare and characterize spray-dried microparticles using β-cyclodextrin (β-CD) or chitosan as polymers for encapsulation of GSH for its addition to wine to prevent oxidation. The microparticles obtained after the drying process were characterized regarding morphology, chemical interaction between GSH and polymers, thermal stability, microstructure, encapsulation efficiency and in vitro GSH release. SEM showed spherical microparticles, with wrinkled surfaces for β-CD/GSH and smooth surfaces for chitosan/GSH. A wide distribution of particle size was observed. In general, β-CD/GSH showed an average diameter smaller than the chitosan/GSH microparticles. FT-IR showed a possible interaction between GSH and both polymers. DSC and DRX showed that encapsulation process produced a marked decrease in GSH crystallinity. The encapsulation efficiency was 25.0% for chitosan/GSH and 62.4% for β-CD/GSH microparticles. The GSH release profiles from microparticles showed that β-CD can control the release behaviors of GSH better than chitosan in a model wine. Cumulative release data were fitted to an empirical equation to compute diffusional exponent (n), which indicates a trend the non-Fickian release of GSH. Copyright © 2017 Elsevier Ltd. All rights reserved.

Identifying Indicators of Progress in Thermal Spray Research Using Bibliometrics Analysis

NASA Astrophysics Data System (ADS)

Li, R.-T.; Khor, K. A.; Yu, L.-G.

2016-12-01

We investigated the research publications on thermal spray in the period of 1985-2015 using the data from Web of Science, Scopus and SciVal®. Bibliometrics analysis was employed to elucidate the country and institution distribution in various thermal spray research areas and to characterize the trends of topic change and technology progress. Results show that China, USA, Japan, Germany, India and France were the top countries in thermal spray research, and Xi'an Jiaotong University, Universite de Technologie Belfort-Montbeliard, Shanghai Institute of Ceramics, ETH Zurich, National Research Council of Canada, University of Limoges were among the top institutions that had high scholarly research output during 2005-2015. The terms of the titles, keywords and abstracts of the publications were analyzed by the Latent Dirichlet Allocation model and visually mapped using the VOSviewer software to reveal the progress of thermal spray technology. It is found that thermal barrier coating was consistently the main research area in thermal spray, and high-velocity oxy-fuel spray and cold spray developed rapidly in the last 10 years.

Ketoprofen spray-dried microspheres based on Eudragit RS and RL: study of the manufacturing parameters.

PubMed

Rassu, Giovanna; Gavini, Elisabetta; Spada, Gianpiera; Giunchedi, Paolo; Marceddu, Salvatore

2008-11-01

The preparation of ketoprofen spray-dried microspheres can be affected by the long drug recrystallization time. Polymer type and drug-polymer ratio as well as manufacturing parameters affect the preparation. The purpose of this work was to evaluate the possibility to obtain ketoprofen spray-dried microspheres using the Eudragit RS and RL; the influence of the spray-drying parameters on morphology, dimension, and physical stability of microspheres was studied. Ketoprofen microspheres based on Eudragit blend can be prepared by spray-drying and the nebulization parameters do not influence significantly particle properties; nevertheless, they can be affected by drying and storage methods. No effect of the container material is found.

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.

Application of a novel 3-fluid nozzle spray drying process for the microencapsulation of therapeutic agents using incompatible drug-polymer solutions.

PubMed

Sunderland, Tara; Kelly, John G; Ramtoola, Zebunnissa

2015-04-01

The aim of this study was to evaluate a novel 3-fluid concentric nozzle (3-N) spray drying process for the microencapsulation of omeprazole sodium (OME) using Eudragit L100 (EL100). Feed solutions containing OME and/or EL100 in ethanol were assessed visually for OME stability. Addition of OME solution to EL100 solution resulted in precipitation of OME followed by degradation of OME reflected by a colour change from colourless to purple and brown. This was related to the low pH of 2.8 of the EL100 solution at which OME is unstable. Precipitation and progressive discoloration of the 2-fluid nozzle (2-N) feed solution was observed over the spray drying time course. In contrast, 3-N solutions of EL100 or OME in ethanol were stable over the spray drying period. Microparticles prepared using either nozzle showed similar characteristics and outer morphology however the internal morphology was different. DSC showed a homogenous matrix of drug and polymer for 2-N microparticles while 3-N microparticles had defined drug and polymer regions distributed as core and coat. The results of this study demonstrate that the novel 3-N spray drying process can allow the microencapsulation of a drug using an incompatible polymer and maintain the drug and polymer in separate regions of the microparticles.

A comparative study of the effect of spray drying and hot-melt extrusion on the properties of amorphous solid dispersions containing felodipine.

PubMed

Mahmah, Osama; Tabbakh, Rami; Kelly, Adrian; Paradkar, Anant

2014-02-01

To compare the properties of solid dispersions of felodipine for oral bioavailability enhancement using two different polymers, polyvinylpyrrolidone (PVP) and hydroxypropyl methylcellulose acetate succinate (HPMCAS), by hot-melt extrusion (HME) and spray drying. Felodipine solid dispersions were prepared by HME and spray drying techniques. PVP and HPMCAS were used as polymer matrices at different drug : polymer ratios (1 : 1, 1 : 2 and 1 : 3). Detailed characterization was performed using differential scanning calorimetry, powder X-ray diffractometry, scanning electron microscopy and in-vitro dissolution testing. Dissolution profiles were evaluated in the presence of sodium dodecyl sulphate. Stability of different solid dispersions was studied under accelerated conditions (40°C/75% RH) over 8 weeks. Spray-dried formulations were found to release felodipine faster than melt extruded formulations for both polymer matrices. Solid dispersions containing HMPCAS exhibited higher drug release rates and better wettability than those produced with a PVP matrix. No significant differences in stability were observed except with HPMCAS at a 1 : 1 ratio, where crystallization was detected in spray-dried formulations. Solid dispersions of felodipine produced by spray drying exhibited more rapid drug release than corresponding melt extruded formulations, although in some cases improved stability was observed for melt extruded formulations. © 2013 Royal Pharmaceutical Society.

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.

Toughening Fe-based Amorphous Coatings by Reinforcement of Amorphous Carbon.

PubMed

Wang, Wei; Zhang, Cheng; Zhang, Zhi-Wei; Li, Yi-Cheng; Yasir, Muhammad; Wang, Hai-Tao; Liu, Lin

2017-06-22

Toughening of Fe-based amorphous coatings meanwhile maintaining a good corrosion resistance remains challenging. This work reports a novel approach to improve the toughness of a FeCrMoCBY amorphous coating through in-situ formation of amorphous carbon reinforcement without reducing the corrosion resistance. The Fe-based composite coating was prepared by high velocity oxy-fuel (HVOF) thermal spraying using a pre-mixed Fe-based amorphous/nylon-11 polymer feedstock powders. The nylon-11 powders were in-situ carbonized to amorphous carbon phase during thermal spraying process, which homogeneously distributed in the amorphous matrix leading to significant enhancement of toughness of the coating. The mechanical properties, including hardness, impact resistance, bending and fatigue strength, were extensively studied by using a series of mechanical testing techniques. The results revealed that the composite coating reinforced by amorphous carbon phase exhibited enhanced impact resistance and nearly twice-higher fatigue strength than that of the monolithic amorphous coating. The enhancement of impact toughness and fatigue properties is owed to the dumping effect of the soft amorphous carbon phase, which alleviated stress concentration and decreased crack propagation driving force.

Microstructure and Properties of Thermally Sprayed Functionally Graded Coatings for Polymeric Substrates

NASA Technical Reports Server (NTRS)

Ivosevic, M.; Knight, R.; Kalidindi, S. R.; Palmese, G. R.; Sutter, J. K.

2003-01-01

The use of polymer matrix composites (PMCs) in the gas flow path of advanced turbine engines offers significant benefits for aircraft engine performance but their useful lifetime is limited by their poor erosion resistance. High velocity oxy-fuel (HVOF) sprayed polymer/cermet functionally graded (FGM) coatings are being investigated as a method to address this technology gap by providing erosion and oxidation protection to polymer matrix composites. The FGM coating structures are based on a polyimide matrix filled with varying volume fractions of WC-Co. The graded coating architecture was produced using a combination of internal and external feedstock injection, via two computer-controlled powder feeders and controlled substrate preheating. Porosity, coating thickness and volume fraction of the WC-Co filler retained in the coatings were determined using standard metallographic techniques and computer image analysis. The pull-off strength (often referred to as the adhesive strength) of the coatings was evaluated according to the ASTM D 4541 standard test method, which measured the greatest normal tensile force that the coating could withstand. Adhesive/cohesive strengths were determined for three different types of coating structures and compared based on the maximum indicated load and the surface area loaded. The nature and locus of the fractures were characterized according to the percent of adhesive and/or cohesive failure, and the tested interfaces and layers involved were analyzed by Scanning Electron Microscopy.

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

NASA Technical Reports Server (NTRS)

Shiembob, L. T.

1978-01-01

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

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.

Thermal Spray Applications in Electronics and Sensors: Past, Present, and Future

NASA Astrophysics Data System (ADS)

Sampath, Sanjay

2010-09-01

Thermal spray has enjoyed unprecedented growth and has emerged as an innovative and multifaceted deposition technology. Thermal spray coatings are crucial to the enhanced utilization of various engineering systems. Industries, in recognition of thermal spray's versatility and economics, have introduced it into manufacturing environments. The majority of modern thermal spray applications are "passive" protective coatings, and they rarely perform an electronic function. The ability to consolidate dissimilar material multilayers without substrate thermal loading has long been considered a virtue for thick-film electronics. However, the complexity of understanding/controlling materials functions especially those resulting from rapid solidification and layered assemblage has stymied expansion into electronics. That situation is changing: enhancements in process/material science are allowing reconsideration for novel electronic/sensor devices. This review critically examines past efforts in terms of materials functionality from a device perspective, along with ongoing/future concepts addressing the aforementioned deficiencies. The analysis points to intriguing future possibilities for thermal spray technology in the world of thick-film sensors.

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.

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

Preparation and evaluation of posaconazole-loaded enteric microparticles in rats.

PubMed

Yang, Min; Dong, Zhonghua; Zhang, Yongchun; Zhang, Fang; Wang, Yongjie; Zhao, Zhongxi

2017-04-01

Posaconazole (POS) is an antifungal compound which has a low oral bioavailability. The aim of this study was to prepare POS enteric microparticles to enhance its oral bioavailability. POS enteric microparticles were prepared with hypromellose acetate succinate (HPMCAS) via the spray drying method. The solvent mixtures of acetone and ethanol used in the preparation of the microparticles were optimized to produce the ideal POS enteric microparticles. Multivariate data analysis using a principal component analysis (PCA) was used to find the relationship among the HPMCAS molecular characteristics, particle properties and drug release kinetics from the spray dried microparticles. The optimal spray solvent mixtures were critical to produce the POS microparticles with the defined polymer entanglement index, drug surface enrichment, particle size and drug loading. The HPMCAS molecular characteristics affected the microscopic connectivity and diffusivity of polymer matrix and eventually influenced the drug release behavior, and enhanced the bioavailability of POS. These studies suggested that the selection of suitable solvent mixtures of acetone and ethanol used in the spray drying of the microparticles was quite important to produce the entangled polymer structures with preferred polymer molecular properties of polymer coiling, overlap concentration and entanglement index. Additional studies on particle size and surface drug enrichment eventually produced HPMCAS-based enteric microparticles to enhance the oral bioavailability of POS.

Drag reduction - Jet breakup correlation with kerosene-based additives

NASA Technical Reports Server (NTRS)

Hoyt, J. W.; Altman, R. L.; Taylor, J. J.

1980-01-01

The drag-reduction effectiveness of a number of high-polymer additives dissolved in aircraft fuel has been measured in a turbulent-flow rheometer. These solutions were further subjected to high elongational stress and breakup forces in a jet discharging in air. The jet was photographed using a high-resolution camera with special lighting. The object of the work was to study the possible spray-suppression ability of high-polymer additives to aircraft fuel and to correlate this with the drag-reducing properties of the additives. It was found, in fact, that the rheometer results indicate the most effective spray-suppressing additives. Using as a measure the minimum polymer concentration to give a maximum friction-reducing effect, the order of effectiveness of eight different polymer additives as spray-suppressing agents was predicted. These results may find application in the development of antimisting additives for aircraft fuel which may increase fire safety in case of crash or accident.

Structure and properties of polymer nanocomposite coatings applied by the HVOF process

NASA Astrophysics Data System (ADS)

Petrovicova, Elena

1999-11-01

A high velocity oxy-fuel (HVOF) combustion spray process was used to produce coatings from nylon 11 powders with average starting particle diameters of 30 and 60 gin. Silica and carbon black were used as nanosized reinforcements, and their nominal content was varied from 0 to 15 vol. %. Optimization of the HVOF processing parameters was based on an assessment of the degree of splatting of polymer particles, and was accomplished by varying the jet temperature (via the hydrogen/oxygen ratio). Gas mixtures with low hydrogen contents minimized polymer particle degradation. Analytical modeling of particle temperature profiles confirmed the effect of the gas velocity and temperature on the particle heating and resulting coating properties. The morphology of the polymer and the microstructure of the coatings depended on the reinforcement surface chemistry and the volume fraction of the reinforcement, as well as the initial nylon 11 particle size. Although all reinforced coatings had higher crystallinities than pure nylon 11 coatings, coatings produced from a smaller starting polymer particle size (30 mum) exhibited improved spatial distribution of the silica in the matrix and lower crystallinity. In addition, coatings produced from the smaller polymer particles had a higher density and lower porosity due to a higher degree of melting and splatting compared to coatings produced from larger particles (60 mum). Nanoreinforced coatings exhibited increased scratch and sliding wear resistance and improved mechanical and barrier properties. Improvements of up to 35% in scratch and 67% in wear resistance were obtained for coatings with nominal 15 vol. % contents of hydrophobic silica or carbon black, relative to nonreinforced coatings. Reinforcement of the polymer matrix resulted in increases of ca. 200% in the storage modulus both below and above the glass transition temperature. The increase in crystallinity seemed to further enhance the reinforcement provided by the nanoparticulates. Results also showed a decrease in the water vapor transmission rate through nanoreinforced coatings by up to 50% compared to pure polymer coatings. The aqueous permeability of coatings produced from 30 mum polymer particles was lower due to the decrease in porosity. Crystallinity seemed to have a strong influence on the mechanical properties, whereas permeability of thermally sprayed coatings was dominated by coating porosity.

INEL Spray-forming Research

NASA Technical Reports Server (NTRS)

Mchugh, Kevin M.; Key, James F.

1993-01-01

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described.

Hot Melt Extrusion and Spray Drying of Co-amorphous Indomethacin-Arginine With Polymers.

PubMed

Lenz, Elisabeth; Löbmann, Korbinian; Rades, Thomas; Knop, Klaus; Kleinebudde, Peter

2017-01-01

Co-amorphous drug-amino acid systems have gained growing interest as an alternative to common amorphous formulations which contain polymers as stabilizers. Several preparation methods have recently been investigated, including vibrational ball milling on a laboratory scale or spray drying in a larger scale. In this study, the feasibility of hot melt extrusion for continuous manufacturing of co-amorphous drug-amino acid formulations was examined, challenging the fact that amino acids melt with degradation at high temperatures. Furthermore, the need for an addition of a polymer in this process was evaluated. After a polymer screening via the solvent evaporation method, co-amorphous indomethacin-arginine was prepared by a melting-solvent extrusion process without and with copovidone. The obtained products were characterized with respect to their solid-state properties, non-sink dissolution behavior, and stability. Results were compared to those of spray-dried formulations with the same compositions and to spray-dried indomethacin-copovidone. Overall, stable co-amorphous systems could be prepared by extrusion without or with copovidone, which exhibited comparable molecular interaction properties to the respective spray-dried products, while phase separation was detected by differential scanning calorimetry in several cases. The formulations containing indomethacin in combination with arginine and copovidone showed enhanced dissolution behavior over the formulations with only copovidone or arginine. Copyright © 2016 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.

Synthesis and characterization of Cu3(BTC)2 membranes by thermal spray seeding and secondary growth.

PubMed

Noh, Seung-Jun; Kwon, Hyuk Taek; Kim, Jinsoo

2013-08-01

Crack-free Cu3(BTC)2 membranes were successfully prepared by thermal spray seeding and secondary growth method. Thermal spray seeding method, combining thermal seeding and pressurized spraying, uniformly distributed seed solution on the support, anchoring seed crystals tightly on the support. After secondary growth of the seeded support in the autoclave, continuous crack-free membrane was obtained by controlling cooling and drying steps. The gas permeation test was conducted at various temperatures using H2, CO2, CH4 and N2 gases.

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.

Zinc thermal spray coatings for reinforced concrete: An AWS process standard

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

Sulit, R.A.

Zinc and aluminum thermal spray coatings (TSC) have been used for lining concrete weir in Great Britain since the 1950`s to maintain the dimensions of the weir for flow control concomitant with reduced wear and erosion of the concrete surfaces. This paper reports the development and the content of the ANSI/AWS C2.20-XX standard for the application of An TSC on concrete using flame and arc spray processes. This standard is formatted as an industrial process instruction: job description; safety; feedstock materials; equipment; a step-by-step method for surface preparation, thermal spraying; quality control; repair and maintenance of surface preparation, thermal spraying;more » quality control; repair and maintenance of Zn TSC on concrete; and a Job Control Record. Job planning and training and certification requirements are presented for An TSC inspectors and thermal spray operators. Four annexes are included in the standard: (a) historical summary of Zn TSC on concrete (b) sample job control record; (c) thermal spray operator qualification; and (d) portable adhesion testing for An TSC on concrete. This standard is based on the current literature and industrial equipment, process, and practices.« less

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

NASA Technical Reports Server (NTRS)

Shiembob, L. T.

1977-01-01

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

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.

Physical Properties and Effect in a Battery of Safety Pharmacology Models for Three Structurally Distinct Enteric Polymers Employed as Spray-Dried Dispersion Carriers

PubMed Central

Fryer, Ryan M.; Patel, Mita; Zhang, Xiaomei; Baum-Kroker, Katja S.; Muthukumarana, Akalushi; Linehan, Brian; Tseng, Yin-Chao

2016-01-01

Establishing a wide therapeutic index (TI) for pre-clinical safety is important during lead optimization (LO) in research, prior to clinical development, although is often limited by a molecules physiochemical characteristics. Recent advances in the application of the innovative vibrating mesh spray-drying technology to prepare amorphous solid dispersions may offer an opportunity to achieve high plasma concentrations of poorly soluble NCEs to enable testing and establishment of a wide TI in safety pharmacology studies. While some of the amorphous solid dispersion carriers are generally recognized as safe for clinical use, whether they are sufficiently benign to enable in vivo pharmacology studies has not been sufficiently demonstrated. Thus, the physical properties, and effect in a battery of in vivo safety pharmacology models, were assessed in three classes of polymers employed as spray-dried dispersion carriers. The polymers (HPMC-AS, Eudragit, PVAP) displayed low affinity with acetone/methanol, suitable for solvent-based spray drying. The water sorption of the polymers was moderate, and the degree of hysteresis of HPMC-AS was smaller than Eudragit and PVAP indicating the intermolecular interaction of water-cellulose molecules is weaker than water-acrylate or water-polyvinyl molecules. The polymer particles were well-suspended without aggregation with a mean particle size less than 3 μm in an aqueous vehicle. When tested in conscious Wistar Han rats in safety pharmacology models (n = 6–8/dose/polymer) investigating effects on CNS, gastrointestinal, and cardiovascular function, no liabilities were identified at any dose tested (30–300 mg/kg PO, suspension). In brief, the polymers had no effect in a modified Irwin test that included observational and evoked endpoints related to stereotypies, excitation, sedation, pain/anesthesia, autonomic balance, reflexes, and others. No effect of the polymers on gastric emptying or intestinal transit was observed when measured using a barium sulfate tracer material. Finally, in telemetry-instrumented rats the polymers had no effect on acute or 24-h mean blood pressure and heart rate values at doses up to 300 mg/kg. Thus, the properties of the three enteric polymers are appropriate as spray-dried dispersion carriers and were benign in a battery of safety pharmacology studies, demonstrating their applicability to enable in vivo safety pharmacology profiling of poorly soluble molecules during LO. PMID:27790142

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.

Clear, Conductive, Transparent, Flexible Space Durable Composite Films for Electrostatic Charge Mitigation

NASA Technical Reports Server (NTRS)

Watson, Kent A.; Connell, John W.; Delozier, Donavon M.; Smith, Joseph G., Jr.

2004-01-01

Space environmentally durable polymeric films with low color and sufficient electrical conductivity to mitigate electrostatic charge (ESC) build-up have been under investigation as part of a materials development activity. These materials have potential applications on advanced spacecraft, particularly on large, deployable, ultra-light weight Gossamer spacecraft. The approach taken to impart sufficient electrical conductivity into the polymer film while maintaining flexibility is to use single wall carbon nanotubes (SWNTs) as conductive additives. Approaches investigated in our lab involved an in-situ polymerization method, addition of SWNTs to a polymer containing reactive end-groups, and spray coating of polymer surfaces. The work described herein is a summary of the current status of this project. Surface conductivities (measured as surface resistance) in the range sufficient for ESC mitigation were achieved with minimal effects on the physical, thermal, mechanical and optical properties of the films. Additionally, the electrical conductivity was not affected by harsh mechanical manipulation of the films. The chemistry and physical properties of these nanocomposites will be discussed.

NASA Astrophysics Data System (ADS)

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

1994-06-01

Spray forming is a near- net- shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or pattern to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing, often while substantially improving product quality. Spray forming is applicable to a wide range of metals and nonmetals and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities, and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray forming technology for producing near- net- shape solids and coatings of a variety of metals, polymers, and composite materials using de Laval nozzles. This article briefly describes the atomization behavior of liquid metals in linear de Laval nozzles and illustrates the versatility of the process by summarizing results from two spray forming programs. In one program, low-carbon steel strip >0.75 mm thick was produced; in the other, polymer membranes ˜5 μm thick were spray formed.

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.

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.

Kinematic Optimization of Robot Trajectories for Thermal Spray Coating Application

NASA Astrophysics Data System (ADS)

Deng, Sihao; Liang, Hong; Cai, Zhenhua; Liao, Hanlin; Montavon, Ghislain

2014-12-01

Industrial robots are widely used in the field of thermal spray nowadays. Due to their characteristics of high-accuracy and programmable flexibility, spraying on complex geometrical workpieces can be realized in the equipped spray room. However, in some cases, the robots cannot guarantee the process parameters defined by the robot movement, such as the scanning trajectory, spray angle, relative speed between the torch and the substrate, etc., which have distinct influences on heat and mass transfer during the generation of any thermally sprayed coatings. In this study, an investigation on the robot kinematics was proposed to find the rules of motion in a common case. The results showed that the motion behavior of each axis of robot permits to identify the motion problems in the trajectory. This approach allows to optimize the robot trajectory generation in a limited working envelop. It also minimizes the influence of robot performance to achieve a more constant relative scanning speed which is represented as a key parameter in thermal spraying.

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.

Relieving thermal discomfort: Effects of sprayed L-menthol on perception, performance, and time trial cycling in the heat.

PubMed

Barwood, M J; Corbett, J; Thomas, K; Twentyman, P

2015-06-01

L-menthol stimulates cutaneous thermoreceptors and induces cool sensations improving thermal comfort, but has been linked to heat storage responses; this could increase risk of heat illness during self-paced exercise in the heat. Therefore, L-menthol application could lead to a discrepancy between behavioral and autonomic thermoregulatory drivers. Eight male participants volunteered. They were familiarized and then completed two trials in hot conditions (33.5 °C, 33% relative humidity) where their t-shirt was sprayed with CONTROL-SPRAY or MENTHOL-SPRAY after 10 km (i.e., when they were hot and uncomfortable) of a 16.1-km cycling time trial (TT). Thermal perception [thermal sensation (TS) and comfort (TC)], thermal responses [rectal temperature (Trec ), skin temperature (Tskin )], perceived exertion (RPE), heart rate, pacing (power output), and TT completion time were measured. MENTHOL-SPRAY made participants feel cooler and more comfortable and resulted in lower RPE (i.e., less exertion) yet performance was unchanged [TT completion: CONTROL-SPRAY 32.4 (2.9) and MENTHOL-SPRAY 32.7 (3.0) min]. Trec rate of increase was 1.40 (0.60) and 1.45 (0.40) °C/h after CONTROL-SPRAY and MENTHOL-SPRAY application, which were not different. Spraying L-menthol toward the end of self-paced exercise in the heat improved perception, but did not alter performance and did not increase heat illness risk. © 2015 John Wiley & Sons A/S. Published by John Wiley & Sons Ltd.

A Sensitive Technique Using Atomic Force Microscopy to Measure the Low Earth Orbit Atomic Oxygen Erosion of Polymers

NASA Technical Reports Server (NTRS)

deGroh, Kim K.; Banks, Bruce A.; Clark, Gregory W.; Hammerstrom, Anne M.; Youngstrom, Erica E.; Kaminski, Carolyn; Fine, Elizabeth S.; Marx, Laura M.

2001-01-01

Polymers such as polyimide Kapton and Teflon FEP (fluorinated ethylene propylene) are commonly used spacecraft materials due to their desirable properties such as flexibility, low density, and in the case of FEP low solar absorptance and high thermal emittance. Polymers on the exterior of spacecraft in the low Earth orbit (LEO) environment are exposed to energetic atomic oxygen. Atomic oxygen erosion of polymers occurs in LEO and is a threat to spacecraft durability. It is therefore important to understand the atomic oxygen erosion yield (E, the volume loss per incident oxygen atom) of polymers being considered in spacecraft design. Because long-term space exposure data is rare and very costly, short-term exposures such as on the shuttle are often relied upon for atomic oxygen erosion determination. The most common technique for determining E is through mass loss measurements. For limited duration exposure experiments, such as shuttle experiments, the atomic oxygen fluence is often so small that mass loss measurements can not produce acceptable uncertainties. Therefore, a recession measurement technique has been developed using selective protection of polymer samples, combined with postflight atomic force microscopy (AFM) analysis, to obtain accurate erosion yields of polymers exposed to low atomic oxygen fluences. This paper discusses the procedures used for this recession depth technique along with relevant characterization issues. In particular, a polymer is salt-sprayed prior to flight, then the salt is washed off postflight and AFM is used to determine the erosion depth from the protected plateau. A small sample was salt-sprayed for AFM erosion depth analysis and flown as part of the Limited Duration Candidate Exposure (LDCE-4,-5) shuttle flight experiment on STS-51. This sample was used to study issues such as use of contact versus non-contact mode imaging for determining recession depth measurements. Error analyses were conducted and the percent probable error in the erosion yield when obtained by the mass loss and recession depth techniques has been compared. The recession depth technique is planned to be used to determine the erosion yield of 42 different polymers in the shuttle flight experiment PEACE (Polymer Erosion And Contamination Experiment) planned to fly in 2002 or 2003.

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.

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.

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.

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.

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.

Super-hydrophobic coatings based on non-solvent induced phase separation during electro-spraying.

PubMed

Gao, Jiefeng; Huang, Xuewu; Wang, Ling; Zheng, Nan; Li, Wan; Xue, Huaiguo; Li, Robert K Y; Mai, Yiu-Wing

2017-11-15

The polymer solution concentration determines whether electrospinning or electro-spraying occurs, while the addition of the non-solvent into the polymer solution strongly influences the surface morphology of the obtained products. Both smooth and porous surfaces of the electro-sprayed microspheres can be harvested by choosing different non-solvent and its amount as well as incorporating polymeric additives. The influences of the solution concentration, weight ratio between the non-solvent and the copolymer, and the polymeric additives on the surface morphology and the wettability of the electro-sprayed products were systematically studied. Surface pores and/or asperities on the microsphere surface were mainly caused by the non-solvent induced phase separation (NIPS) and subsequent evaporation of the non-solvent during electro-spraying. With increasing polymer solution concentration, the microsphere was gradually changed to the bead-on-string geometry and finally to a nanofiber form, leading to a sustained decrease of the contact angle (CA). It was found that the substrate coatings derived from the microspheres possessing hierarchical surface pores or dense asperities had high surface roughness and super-hydrophobicity with CAs larger than 150° while sliding angles smaller than 10°; but coatings composed of microspheres with smooth surfaces gave relatively low CAs. Copyright © 2017 Elsevier Inc. All rights reserved.

IPMC paints

NASA Astrophysics Data System (ADS)

Park, Il-Seok; Tiwari, Rashi; Kim, Kwang J.

2008-03-01

In this paper we are reporting a newely developed IPMC fabrication method, "IPMC Paint", which can be directly sprayed onto any complex surface. In order to fabricate the IPMC paint, liquid Nafion TM was used for the ionic conducting polymer instead of the typical film/sheet type Nafion TM. The viscosity of liquid Nafion TM was adjusted by adding Polyvinylpyrrolidone (PVP) to perform spray painting. Modified Nafion was sprayed onto the conducting substrate, Polyfoil TM which acts as base electrode layer. After three times spraying, ionic polymer layer has 45 μm thickness and 10 μm of surface roughness. Sensing tests show that IPMC paint sensor has more sensitivity (+/- 0.06 of producing voltage) than that of the typical IPMC (+/- 0.005 of producing voltage) when dynamic bending with 10 Hz frequency and 1.3 cm of displacement is applied to.

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.

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

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

Thermophysical properties of plasma sprayed coatings

NASA Technical Reports Server (NTRS)

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

1973-01-01

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

Adaptation of pharmaceutical excipients to FDM 3D printing for the fabrication of patient-tailored immediate release tablets.

PubMed

Sadia, Muzna; Sośnicka, Agata; Arafat, Basel; Isreb, Abdullah; Ahmed, Waqar; Kelarakis, Antonios; Alhnan, Mohamed A

2016-11-20

This work aims to employ fused deposition modelling 3D printing to fabricate immediate release pharmaceutical tablets with several model drugs. It investigates the addition of non-melting filler to methacrylic matrix to facilitate FDM 3D printing and explore the impact of (i) the nature of filler, (ii) compatibility with the gears of the 3D printer and iii) polymer: filler ratio on the 3D printing process. Amongst the investigated fillers in this work, directly compressible lactose, spray-dried lactose and microcrystalline cellulose showed a level of degradation at 135°C whilst talc and TCP allowed consistent flow of the filament and a successful 3D printing of the tablet. A specially developed universal filament based on pharmaceutically approved methacrylic polymer (Eudragit EPO) and thermally stable filler, TCP (tribasic calcium phosphate) was optimised. Four model drugs with different physicochemical properties were included into ready-to-use mechanically stable tablets with immediate release properties. Following the two thermal processes (hot melt extrusion (HME) and fused deposition modelling (FDM) 3D printing), drug contents were 94.22%, 88.53%, 96.51% and 93.04% for 5-ASA, captopril, theophylline and prednisolone respectively. XRPD indicated that a fraction of 5-ASA, theophylline and prednisolone remained crystalline whilst captopril was in amorphous form. By combining the advantages of thermally stable pharmaceutically approved polymers and fillers, this unique approach provides a low cost production method for on demand manufacturing of individualised dosage forms. Copyright © 2016 Elsevier B.V. All rights reserved.

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.

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.

Synthetic vascular graft fabrication by a precipitation-flotation method.

PubMed

Kowligi, R R; von Maltzahn, W W; Eberhart, R C

1988-01-01

The authors report a new technique for fabricating synthetic vascular grafts. It involves spraying a polymer solution (generated by mixing polymer solution and nitrogen gas in a spray nozzle) onto the surface of a flowing nonsolvent liquid (water): polymer fibers form during precipitation of the spray drops as they travel on the water surface, until picked up by a partially submerged rotating mandrel. Depending on process conditions, these fibers may aggregate to form a continuous layer or remain separated until they are picked up. A number of independent process variables allow control of characteristics of the conduits: gas and polymer solution feed rates, nozzle traverse speed, nonsolvent (water) flow rate, spray-mandrel spacing, and mandrel rpm. The SEM reveals that the graft wall consists of numerous fused polymeric fibers arrayed in both the circumferential and axial directions. The inner surface resembles a mesh of closely spaced fused fibers. The conduits have walls with interconnected pores (water permeabilities between 0.05 to 7.0 ml/min-cm2); nonporous surfaces also can be made. Tensile stress of the grafts at failure (in radial direction) varied between 0.05 to 2.3 MPa, whereas elongation at break ranged between 150 to 600%, depending on the porosity and fabrication conditions. A major advantage of this technique is its ability to produce grafts of a wide variety of fiber sizes and fusion characteristics in an inexpensive, safe, and reliable fashion.

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.

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

Thermal spray manual for machinery components

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

Travis, R.; Ginther, C.; Herbstritt, M.

1995-12-31

The Thermal Spray Manual For Machinery Components is a National Shipbuilding Research (SP-7) Project. This Manual is being developed by Puget Sound Naval Shipyard with the help of other government thermal spray facilities and SP-7 panel members. The purpose of the manual is to provide marine repair facilities with a ``how to do`` document that will be ``user friendly`` and known to be technically sound through production experience. The manual`s intent is to give marine repair facilities the ability to maximize the thermal spray process as a repair method for machinery components and to give these facilities guidelines on howmore » to become qualified to receive certification that they meet the requirements of Military Standard 1687A.« less

Large-scale self-assembled zirconium phosphate smectic layers via a simple spray-coating process

NASA Astrophysics Data System (ADS)

Wong, Minhao; Ishige, Ryohei; White, Kevin L.; Li, Peng; Kim, Daehak; Krishnamoorti, Ramanan; Gunther, Robert; Higuchi, Takeshi; Jinnai, Hiroshi; Takahara, Atsushi; Nishimura, Riichi; Sue, Hung-Jue

2014-04-01

The large-scale assembly of asymmetric colloidal particles is used in creating high-performance fibres. A similar concept is extended to the manufacturing of thin films of self-assembled two-dimensional crystal-type materials with enhanced and tunable properties. Here we present a spray-coating method to manufacture thin, flexible and transparent epoxy films containing zirconium phosphate nanoplatelets self-assembled into a lamellar arrangement aligned parallel to the substrate. The self-assembled mesophase of zirconium phosphate nanoplatelets is stabilized by epoxy pre-polymer and exhibits rheology favourable towards large-scale manufacturing. The thermally cured film forms a mechanically robust coating and shows excellent gas barrier properties at both low- and high humidity levels as a result of the highly aligned and overlapping arrangement of nanoplatelets. This work shows that the large-scale ordering of high aspect ratio nanoplatelets is easier to achieve than previously thought and may have implications in the technological applications for similar materials.

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.

Microfabricated polymer injector for direct mass spectrometry coupling.

PubMed

Gobry, Véronique; van Oostrum, Jan; Martinelli, Marco; Rohner, Tatiana C; Reymond, Frédéric; Rossier, Joël S; Girault, Hubert H

2002-04-01

This paper demonstrates the coupling of a plasma etched polymer microfluidic system with an electrospray mass spectrometer by generation of a nanospray. Taking advantage of the microtechnology processes and polymer properties, high volume production with good reproducibility of hydrophobic interfaces could be obtained. The nanospray was directly produced from the outlet of the plastic microfabricated chip positioned in front of the capillary entrance of the mass spectrometer. No chemical background due to the polymer has been observed under standard nanospray conditions. The performances of the spray as well as its efficiency have been demonstrated by flow measurements, stability establishment and tandem mass spectrometry experiment on angiotensin II. The spray was actuated without additional flow in methanol: water:acetic acid (50:49:1%) solution. A 40 fmol/microL detection limit could be reached.

Facile and scalable fabrication of polymer-ceramic composite electrolyte with high ceramic loadings

NASA Astrophysics Data System (ADS)

Pandian, Amaresh Samuthira; Chen, X. Chelsea; Chen, Jihua; Lokitz, Bradley S.; Ruther, Rose E.; Yang, Guang; Lou, Kun; Nanda, Jagjit; Delnick, Frank M.; Dudney, Nancy J.

2018-06-01

Solid state electrolytes are a promising alternative to flammable liquid electrolytes for high-energy lithium battery applications. In this work polymer-ceramic composite electrolyte membrane with high ceramic loading (greater than 60 vol%) is fabricated using a model polymer electrolyte poly(ethylene oxide) + lithium trifluoromethane sulfonate and a lithium-conducting ceramic powder. The effects of processing methods, choice of plasticizer and varying composition on ionic conductivity of the composite electrolyte are thoroughly investigated. The physical, structural and thermal properties of the composites are exhaustively characterized. We demonstrate that aqueous spray coating followed by hot pressing is a scalable and inexpensive technique to obtain composite membranes that are amazingly dense and uniform. The ionic conductivity of composites fabricated using this protocol is at least one order of magnitude higher than those made by dry milling and solution casting. The introduction of tetraethylene glycol dimethyl ether further increases the ionic conductivity. The composite electrolyte's interfacial compatibility with metallic lithium and good cyclability is verified by constructing lithium symmetrical cells. A remarkable Li+ transference number of 0.79 is discovered for the composite electrolyte.

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

PubMed

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

2015-08-01

A central composite design approach was applied to study the effect of polymer concentration, inlet temperature and air flow rate on the spray drying process of the Büchi B-90 nano spray dryer (B-90). Hypromellose acetate succinate-LF was used for the Design of Experiment (DoE) study. Statistically significant models to predict the yield, spray rate, and drying efficiency were generated from the study. The spray drying conditions were optimized according to the models to maximize the yield and efficiency of the process. The models were further validated using a poorly water-soluble investigational compound (BI064) from Boehringer Ingelheim Pharmaceuticals. The polymer/drug ratio ranged from 1/1 to 3/1w/w. The spray dried formulations were amorphous determined by differential scanning calorimetry and X-ray powder diffraction. The particle size of the spray dried formulations was 2-10 μm under polarized light microscopy. All the formulations were physically stable for at least 3h when suspended in an aqueous vehicle composed of 1% methyl cellulose. This study demonstrates that DoE is a useful tool to optimize the spray drying process, and the B-90 can be used to efficiently produce amorphous solid dispersions with a limited quantity of drug substance available during drug discovery stages. Copyright © 2015 Elsevier B.V. All rights reserved.

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

NASA Astrophysics Data System (ADS)

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

2016-06-01

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

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.

Development of process data capturing, analysis and controlling for thermal spray techniques - SprayTracker

NASA Astrophysics Data System (ADS)

Kelber, C.; Marke, S.; Trommler, U.; Rupprecht, C.; Weis, S.

2017-03-01

Thermal spraying processes are becoming increasingly important in high-technology areas, such as automotive engineering and medical technology. The method offers the advantage of a local layer application with different materials and high deposition rates. Challenges in the application of thermal spraying result from the complex interaction of different influencing variables, which can be attributed to the properties of different materials, operating equipment supply, electrical parameters, flow mechanics, plasma physics and automation. In addition, spraying systems are subject to constant wear. Due to the process specification and the high demands on the produced coatings, innovative quality assurance tools are necessary. A central aspect, which has not yet been considered, is the data management in relation to the present measured variables, in particular the spraying system, the handling system, working safety devices and additional measuring sensors. Both the recording of all process-characterizing variables, their linking and evaluation as well as the use of the data for the active process control presuppose a novel, innovative control system (hardware and software) that was to be developed within the scope of the research project. In addition, new measurement methods and sensors are to be developed and qualified in order to improve the process reliability of thermal spraying.

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

In situ X-ray study of the structural evolution of gold nano-domains by spray deposition on thin conductive P3HT films.

PubMed

Al-Hussein, M; Schindler, M; Ruderer, M A; Perlich, J; Schwartzkopf, M; Herzog, G; Heidmann, B; Buffet, A; Roth, S V; Müller-Buschbaum, P

2013-02-26

Gold (Au) nanoparticles are deposited from aqueous solution onto one of the most used conductive polymers, namely poly(3-hexylthiophene) (P3HT), using airbrush deposition. We report on the structure formation and packing of the Au nanoparticles after a 5 s spray cycle. In situ grazing incidence small-angle X-ray scattering (GISAXS) measurements with 20 ms time resolution allow a real-time observation of the emergence and evolution of the microstructure during a spray cycle and subsequent solvent evaporation. The results reveal multistage nanoscale ordering of the Au nanoparticles during the spray cycle. Further ex situ atomic force microscopy measurements of the sprayed films showed the formation of Au monolayer islands on top of the polymer film. Our study suggests that the solvent-substrate interaction as well as solvent evaporation kinetics are important factors that need to be taken into consideration in order to grow a compact uniform monolayer film for the fabrication of ultrathin films using airbrush deposition.

Method for thermally spraying crack-free mullite coatings on ceramic-based substrates

NASA Technical Reports Server (NTRS)

Spitsberg, Irene T. (Inventor); Wang, Hongyu (Inventor); Heidorn, Raymond W. (Inventor)

2001-01-01

A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.

Method for thermally spraying crack-free mullite coatings on ceramic-based substrates

NASA Technical Reports Server (NTRS)

Spitsberg, Irene T. (Inventor); Wang, Hongyu (Inventor); Heidorn, Raymond W. (Inventor)

2000-01-01

A process for depositing a mullite coating on a silicon-based material, such as those used to form articles exposed to high temperatures and including the hostile thermal environment of a gas turbine engine. The process is generally to thermally spray a mullite powder to form a mullite layer on a substrate, in which the thermal spraying process is performed so that the mullite powder absorbs a sufficient low level of energy from the thermal source to prevent evaporation of silica from the mullite powder. Processing includes deposition parameter adjustments or annealing to maintain or reestablish phase equilibrium in the mullite layer, so that through-thickness cracks in the mullite layer are avoided.

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.

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

NASA Technical Reports Server (NTRS)

Leissler, George W.; Yuhas, John S.

1988-01-01

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

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

NASA Astrophysics Data System (ADS)

Khan, Mohammed N.; Shamim, Tariq

2014-08-01

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

Ultrasonic spray coating polymer and small molecular organic film for organic light-emitting devices.

PubMed

Liu, Shihao; Zhang, Xiang; Zhang, Letian; Xie, Wenfa

2016-11-22

Ultrasonic spray coating process (USCP) with high material -utilization, low manufacture costs and compatibility to streamline production has been attractive in researches on photoelectric devices. However, surface tension exists in the solvent is still a huge obstacle to realize smooth organic film for organic light emitting devices (OLEDs) by USCP. Here, high quality polymer anode buffer layer and small molecular emitting layer are successfully realized through USCP by introducing extra-low surface tension diluent and surface tension control method. The introduction of low surface tension methyl alcohol is beneficial to the formation of poly (3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) films and brings obvious phase separation and improved conductivity to PEDOT:PSS film. Besides, a surface tension control method, in which new stable tension equilibrium is built at the border of wetting layer, is proposed to eliminate the effect of surface tension during the solvent evaporation stage of ultrasonic spray coating the film consists of 9,9-Spirobifluoren-2-yl-diphenyl-phosphine oxide doped with 10 wt% tris [2-(p -tolyl) pyridine] iridium (III). A smooth and homogenous small molecular emitting layer without wrinkles is successfully realized. The effectiveness of the ultrasonic spray coating polymer anode buffer layer and small molecular emitting layer are also proved by introducing them in OLEDs.

Ultrasonic spray coating polymer and small molecular organic film for organic light-emitting devices

NASA Astrophysics Data System (ADS)

Liu, Shihao; Zhang, Xiang; Zhang, Letian; Xie, Wenfa

2016-11-01

Ultrasonic spray coating process (USCP) with high material -utilization, low manufacture costs and compatibility to streamline production has been attractive in researches on photoelectric devices. However, surface tension exists in the solvent is still a huge obstacle to realize smooth organic film for organic light emitting devices (OLEDs) by USCP. Here, high quality polymer anode buffer layer and small molecular emitting layer are successfully realized through USCP by introducing extra-low surface tension diluent and surface tension control method. The introduction of low surface tension methyl alcohol is beneficial to the formation of poly (3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) films and brings obvious phase separation and improved conductivity to PEDOT:PSS film. Besides, a surface tension control method, in which new stable tension equilibrium is built at the border of wetting layer, is proposed to eliminate the effect of surface tension during the solvent evaporation stage of ultrasonic spray coating the film consists of 9,9-Spirobifluoren-2-yl-diphenyl-phosphine oxide doped with 10 wt% tris [2-(p -tolyl) pyridine] iridium (III). A smooth and homogenous small molecular emitting layer without wrinkles is successfully realized. The effectiveness of the ultrasonic spray coating polymer anode buffer layer and small molecular emitting layer are also proved by introducing them in OLEDs.

Ultrasonic spray coating polymer and small molecular organic film for organic light-emitting devices

PubMed Central

Liu, Shihao; Zhang, Xiang; Zhang, Letian; Xie, Wenfa

2016-01-01

Ultrasonic spray coating process (USCP) with high material -utilization, low manufacture costs and compatibility to streamline production has been attractive in researches on photoelectric devices. However, surface tension exists in the solvent is still a huge obstacle to realize smooth organic film for organic light emitting devices (OLEDs) by USCP. Here, high quality polymer anode buffer layer and small molecular emitting layer are successfully realized through USCP by introducing extra-low surface tension diluent and surface tension control method. The introduction of low surface tension methyl alcohol is beneficial to the formation of poly (3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) films and brings obvious phase separation and improved conductivity to PEDOT:PSS film. Besides, a surface tension control method, in which new stable tension equilibrium is built at the border of wetting layer, is proposed to eliminate the effect of surface tension during the solvent evaporation stage of ultrasonic spray coating the film consists of 9,9-Spirobifluoren-2-yl-diphenyl-phosphine oxide doped with 10 wt% tris [2-(p -tolyl) pyridine] iridium (III). A smooth and homogenous small molecular emitting layer without wrinkles is successfully realized. The effectiveness of the ultrasonic spray coating polymer anode buffer layer and small molecular emitting layer are also proved by introducing them in OLEDs. PMID:27874030

Eco-friendly spray coating of organic solar cells through water-based nanoparticles ink (Presentation Recording)

NASA Astrophysics Data System (ADS)

Stryckers, Jeroen; D'Olieslaeger, Lien; Manca, Jean; Ethirajan, Anitha; Deferme, Wim

2015-09-01

Ultrasonic spray coating is currently proven to be a reliable, flexible and cost efficient fabrication method for printed electronics [1-2]. Ultrasonic nozzles are by design especially well-suited to deposit nano-suspension dispersions. Due to the ultrasonic vibration of the nozzle, droplets having a median diameter of 20 μm are created in a homogeneous droplet cloud and directed towards the substrate. When one prepares an ink having the right wetting properties, thin and homogeneous layers, fully covering the surface, can be achieved. Together with conjugated polymer nanoparticles (NPs), emerging as a new class of nanomaterials, [3] it opens possibilities towards eco-friendly roll-to-roll processing of state-of-the-art organic bulk heterojunction solar cells. A ultrasonic spray coater was used to print the conjugated polymer NP layers under different conditions. A first optimization of the spray coater settings (flow rate, spray speed and temperature) and the ink formulation (water and co-solvent mixture and NP content) was performed for polystyrene particles dissolved in a water-ethanol mixture. As a next step, the low bandgap donor polymer poly[9-(1-octylnonyl)-9H-carbazole-2,7-diyl]-2,5-thiophenediyl-2,1,3-benzothiadiazole-4,7-diyl-2,5-thiophene-diyl] (PCDTBT) [4] and the fullerene acceptor phenyl-C71-butyric acid methyl ester (PCBM[70]) were combined in a water-based blend NP dispersion which was prepared using the mini-emulsion technique. [5,6] Optical Microscopy, profilometry and Scanning Electron Microscopy (SEM) are performed to study the roughness, surface structure, thickness and coverage of the spray coated layers. Finally the printed NP layers are integrated in organic bulk heterojunction solar cells and compared to spin coated reference devices.

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

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.

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.

Revealing facts behind spray dried solid dispersion technology used for solubility enhancement

PubMed Central

Patel, Bhavesh B.; Patel, Jayvadan K.; Chakraborty, Subhashis; Shukla, Dali

2013-01-01

Poor solubility and bioavailability of an existing or newly synthesized drug always pose challenge in the development of efficient pharmaceutical formulation. Numerous technologies can be used to improve the solubility and among them amorphous solid dispersion based spray drying technology can be successfully useful for development of product from lab scale to commercial scale with a wide range of powder characteristics. Current review deals with the importance of spray drying technology in drug delivery, basically for solubility and bioavailability enhancement. Role of additives, selection of polymer, effect of process and formulation parameters, scale up optimization, and IVIVC have been covered to gain the interest of readers about the technology. Design of experiment (DoE) to optimize the spray drying process has been covered in the review. A lot more research work is required to evaluate spray drying as a technology for screening the right polymer for solid dispersion, especially to overcome the issue related to drug re-crystallization and to achieve a stable product both in vitro and in vivo. Based on the recent FDA recommendation, the need of the hour is also to adopt Quality by Design approach in the manufacturing process to carefully optimize the spray drying technology for its smooth transfer from lab scale to commercial scale. PMID:27134535

Revealing facts behind spray dried solid dispersion technology used for solubility enhancement.

PubMed

Patel, Bhavesh B; Patel, Jayvadan K; Chakraborty, Subhashis; Shukla, Dali

2015-09-01

Poor solubility and bioavailability of an existing or newly synthesized drug always pose challenge in the development of efficient pharmaceutical formulation. Numerous technologies can be used to improve the solubility and among them amorphous solid dispersion based spray drying technology can be successfully useful for development of product from lab scale to commercial scale with a wide range of powder characteristics. Current review deals with the importance of spray drying technology in drug delivery, basically for solubility and bioavailability enhancement. Role of additives, selection of polymer, effect of process and formulation parameters, scale up optimization, and IVIVC have been covered to gain the interest of readers about the technology. Design of experiment (DoE) to optimize the spray drying process has been covered in the review. A lot more research work is required to evaluate spray drying as a technology for screening the right polymer for solid dispersion, especially to overcome the issue related to drug re-crystallization and to achieve a stable product both in vitro and in vivo. Based on the recent FDA recommendation, the need of the hour is also to adopt Quality by Design approach in the manufacturing process to carefully optimize the spray drying technology for its smooth transfer from lab scale to commercial scale.

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®

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.

Experimental Study on the Electrochemical Anti-Corrosion Properties of Steel Structures Applying the Arc Thermal Metal Spraying Method

PubMed Central

Choe, Hong-Bok; Lee, Han-Seung; Shin, Jun-Ho

2014-01-01

The arc thermal metal spraying method (ATMSM) provides proven long-term protective coating systems using zinc, aluminum and their alloys for steel work in a marine environment. This paper focuses on studying experimentally the anti-corrosion criteria of ATMSM on steel specimens. The effects of the types of spraying metal and the presence or absence of sealing treatment from the thermal spraying of film on the anti-corrosion performance of TMSM were quantitatively evaluated by electrochemical techniques. The results showed that ATMSM represented a sufficient corrosion resistance with the driving force based on the potential difference of more than approximately 0.60 V between the thermal spraying layer and the base substrate steel. Furthermore, it was found that the sealing treatment of specimens had suppressed the dissolution of metals, increased the corrosion potential, decreased the corrosion current density and increased the polarization resistance. Metal alloy Al–Mg (95%:5%) by mass with epoxy sealing coating led to the most successful anti-corrosion performance in these electrochemical experiments. PMID:28788271

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.

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.

Preparation of mucosal nanoparticles and polymer-based inactivated vaccine for Newcastle disease and H9N2 AI viruses

PubMed Central

Naggar, Heba M. El; Madkour, Mohamed Sayed; Hussein, Hussein Ali

2017-01-01

Aim: To develop a mucosal inactivated vaccines for Newcastle disease (ND) and H9N2 viruses to protect against these viruses at sites of infections through mucosal immunity. Materials and Methods: In this study, we prepared two new formulations for mucosal bivalent inactivated vaccine formulations for Newcastle and Avian Influenza (H9N2) based on the use of nanoparticles and polymer adjuvants. The prepared vaccines were delivered via intranasal and spray routes of administration in specific pathogen-free chickens. Cell-mediated and humoral immune response was measured as well as challenge trial was carried out. In addition, ISA71 water in oil was also evaluated. Results: Our results showed that the use of spray route as vaccination delivery method of polymer and nanoparticles Montanide™ adjuvants revealed that it enhanced the cell mediated immune response as indicated by phagocytic activity, gamma interferon and interleukin 6 responses and induced protection against challenge with Newcastle and Avian Influenza (H9N2) viruses. Conclusion: The results of this study demonstrate the potentiality of polymer compared to nanoparticles adjuvantes when used via spray route. Mass application of such vaccines will add value to improve the vaccination strategies against ND virus and Avian influenza viruses. PMID:28344402

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.

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.

Method and closing pores in a thermally sprayed doped lanthanum chromite interconnection layer

DOEpatents

Singh, Prabhakar; Ruka, Roswell J.

1995-01-01

A dense, substantially gas-tight electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an air electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO.sub.3 particles doped with an element or elements selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by thermal spraying doped LaCrO.sub.3 particles, either by plasma arc spraying or flame spraying; (C) depositing a mixture of CaO and Cr.sub.2 O.sub.3 on the surface of the thermally sprayed layer; and (D) heating the doped LaCrO.sub.3 layer coated with CaO and Cr.sub.2 O.sub.3 surface deposit at from about 1000.degree. C. to 1200.degree. C. to substantially close the pores, at least at a surface, of the thermally sprayed doped LaCrO.sub.3 layer. The result is a dense, substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the nonselected portion of the air electrode. A fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell, for example for generation of electrical power.

Method and closing pores in a thermally sprayed doped lanthanum chromite interconnection layer

DOEpatents

Singh, P.; Ruka, R.J.

1995-02-14

A dense, substantially gas-tight electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an air electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO{sub 3} particles doped with an element or elements selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by thermal spraying doped LaCrO{sub 3} particles, either by plasma arc spraying or flame spraying; (C) depositing a mixture of CaO and Cr{sub 2}O{sub 3} on the surface of the thermally sprayed layer; and (D) heating the doped LaCrO{sub 3} layer coated with CaO and Cr{sub 2}O{sub 3} surface deposit at from about 1,000 C to 1,200 C to substantially close the pores, at least at a surface, of the thermally sprayed doped LaCrO{sub 3} layer. The result is a dense, substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the nonselected portion of the air electrode. A fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell, for example for generation of electrical power. 5 figs.

Solubility and dissolution performances of spray-dried solid dispersion of Efavirenz in Soluplus.

PubMed

Lavra, Zênia Maria Maciel; Pereira de Santana, Davi; Ré, Maria Inês

2017-01-01

Efavirenz (EFV), a first-line anti-HIV drug largely used as part of antiretroviral therapies, is practically insoluble in water and belongs to BCS class II (low solubility/high permeability). The aim of this study was to improve the solubility and dissolution performances of EFV by formulating an amorphous solid dispersion of the drug in polyvinyl caprolactam-polyvinyl acetate-polyethylene glycol graft copolymer (Soluplus ® ) using spray-drying technique. To this purpose, spray-dried dispersions of EFV in Soluplus ® at different mass ratios (1:1.25, 1:7, 1:10) were prepared and characterized using particle size measurements, SEM, XRD, DSC, FTIR and Raman microscopy mapping. Solubility and dissolution were determined in different media. Stability was studied at accelerated conditions (40 °C/75% RH) and ambient conditions for 12 months. DSC and XRD analyses confirmed the EFV amorphous state. FTIR spectroscopy analyses revealed possible drug-polymer molecular interaction. Solubility and dissolution rate of EFV was enhanced remarkably in the developed spray-dried solid dispersions, as a function of the polymer concentration. Spray-drying was concluded to be a proper technique to formulate a physically stable dispersion of amorphous EFV in Soluplus ® , when protected from moisture.

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.

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.

Antimisting kerosene atomization and flammability

NASA Technical Reports Server (NTRS)

Fleeter, R.; Petersen, R. A.; Toaz, R. D.; Jakub, A.; Sarohia, V.

1982-01-01

Various parameters found to affect the flammability of antimisting kerosene (Jet A + polymer additive) are investigated. Digital image processing was integrated into a technique for measurement of fuel spray characteristics. This technique was developed to avoid many of the error sources inherent to other spray assessment techniques and was applied to the study of engine fuel nozzle atomization performance with Jet A and antimisting fuel. Aircraft accident fuel spill and ignition dynamics were modeled in a steady state simulator allowing flammability to be measured as a function of airspeed, fuel flow rate, fuel jet Reynolds number and polymer concentration. The digital imaging technique was employed to measure spray characteristics in this simulation and these results were related to flammability test results. Scaling relationships were investigated through correlation of experimental results with characteristic dimensions spanning more than two orders of magnitude.

Facile and scalable fabrication of polymer-ceramic composite electrolyte with high ceramic loadings

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

Pandian, Amaresh Samuthira; Chen, Xi Chelsea; Chen, Jihua

Solid state electrolytes are a promising alternative to flammable liquid electrolytes for high-energy lithium battery applications. In this work polymer-ceramic composite electrolyte membrane with high ceramic loading (greater than 60 vol%) is fabricated using a model polymer electrolyte poly(ethylene oxide) + lithium trifluoromethane sulfonate and a lithium-conducting ceramic powder. The effects of processing methods, choice of plasticizer and varying composition on ionic conductivity of the composite electrolyte are thoroughly investigated. The physical, structural and thermal properties of the composites are exhaustively characterized. We demonstrate that aqueous spray coating followed by hot pressing is a scalable and inexpensive technique to obtainmore » composite membranes that are amazingly dense and uniform. The ionic conductivity of composites fabricated using this protocol is at least one order of magnitude higher than those made by dry milling and solution casting. The introduction of tetraethylene glycol dimethyl ether further increases the ionic conductivity. The composite electrolyte's interfacial compatibility with metallic lithium and good cyclability is verified by constructing lithium symmetrical cells. As a result, a remarkable Li + transference number of 0.79 is discovered for the composite electrolyte.« less

Facile and scalable fabrication of polymer-ceramic composite electrolyte with high ceramic loadings

DOE PAGES

Pandian, Amaresh Samuthira; Chen, Xi Chelsea; Chen, Jihua; ...

2018-04-24

Solid state electrolytes are a promising alternative to flammable liquid electrolytes for high-energy lithium battery applications. In this work polymer-ceramic composite electrolyte membrane with high ceramic loading (greater than 60 vol%) is fabricated using a model polymer electrolyte poly(ethylene oxide) + lithium trifluoromethane sulfonate and a lithium-conducting ceramic powder. The effects of processing methods, choice of plasticizer and varying composition on ionic conductivity of the composite electrolyte are thoroughly investigated. The physical, structural and thermal properties of the composites are exhaustively characterized. We demonstrate that aqueous spray coating followed by hot pressing is a scalable and inexpensive technique to obtainmore » composite membranes that are amazingly dense and uniform. The ionic conductivity of composites fabricated using this protocol is at least one order of magnitude higher than those made by dry milling and solution casting. The introduction of tetraethylene glycol dimethyl ether further increases the ionic conductivity. The composite electrolyte's interfacial compatibility with metallic lithium and good cyclability is verified by constructing lithium symmetrical cells. As a result, a remarkable Li + transference number of 0.79 is discovered for the composite electrolyte.« less

Optical study on thermal radiation energy of diesel spray combustion in a shock tube

NASA Astrophysics Data System (ADS)

Tsuboi, T.; Nagaya, K.; Ishii, K.

. A ``tailored'' interface shock tube was used to measure the thermal energy radiated from diesel-spray combustion. Experiments were performed in a steel shock tube with a seven m long low-pressure section filled with air and a six m long high-pressure section. Pre-compressed fuel was injected through a throttling nozzle into air behind a reflected shock wave. Monochromatic emissive powers and emissive powers of the whole IR-wavelengths were followed with IR-detectors set along the central axis of the tube. Time-dependent-radii, where soot particles radiate, were also determined. Results were : (1) the tailored interface shock tube could be applied to a study of diesel-spray combustion. (2) thermal radiation energy could be described well from the ignition delay of the fuel spray.

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.

Particle characterization of poorly water-soluble drugs using a spray freeze drying technique.

PubMed

Kondo, Masahiro; Niwa, Toshiyuki; Okamoto, Hirokazu; Danjo, Kazumi

2009-07-01

A spray freeze drying (SFD) method was developed to prepare the composite particles of poorly water-soluble drug. The aqueous solution dissolved drug and the functional polymer was sprayed directly into liquid nitrogen. Then, the iced droplets were lyophilized with freeze-dryer to prepare solid particles. Tolbutamide (TBM) and hydroxypropylmethylcellulose (HPMC) were used as a model drug and water-soluble polymeric carrier in this study, respectively. The morphological observation of particles revealed that the spherical particles having porous structure could be obtained by optimizing the loading amount of drug and polymer in the spray solution. Especially, SFD method was characterized that the prepared particles had significantly larger specific surface area comparing with those prepared by the standard spray drying technique. The physicochemical properties of the resultant particles were found to be dependent on the concentration of spray solution. When the solution with high content of drug and polymer was used, the particle size of the resulting composite particles increased and they became spherical. The specific surface area of the particles also increased as a result of higher concentration of solution. The evaluation of spray solution indicated that these results were dependent on the viscosity of spray solution. In addition, when composite particles of TBM were prepared using the SFD method with HPMC as a carrier, the crystallinity of TBM decreased as the proportion of HPMC increased. When the TBM : HPMC ratio reached 1 : 5, the crystallinity of the particles completely disappeared. The dissolution tests showed that the release profiles of poorly water-soluble TBM from SFD composite particles were drastically improved compared to bulk TBM. The 70% release time T(70) of composite particles prepared by the SFD method in a solution of pH 1.2 was quite smaller than that of bulk TBM, while in a solution of pH 6.8, it was slightly lower. In addition, the release rates were faster than those of standard spray dried (SD) composite particles for solutions of pH 1.2 and 6.8, respectively. When composite particles were prepared from mixtures with various composition ratios, T(70) was found to decrease as the proportion of HPMC increased; the release rate was faster than that of bulk TBM in a solution of pH 6.8, as well as solution of pH 1.2.

Nanoscale Reinforced, Polymer Derived Ceramic Matrix Coatings

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

Rajendra Bordia

The goal of this project was to explore and develop a novel class of nanoscale reinforced ceramic coatings for high temperature (600-1000 C) corrosion protection of metallic components in a coal-fired environment. It was focused on developing coatings that are easy to process and low cost. The approach was to use high-yield preceramic polymers loaded with nano-size fillers. The complex interplay of the particles in the polymer, their role in controlling shrinkage and phase evolution during thermal treatment, resulting densification and microstructural evolution, mechanical properties and effectiveness as corrosion protection coatings were investigated. Fe-and Ni-based alloys currently used in coal-firedmore » environments do not possess the requisite corrosion and oxidation resistance for next generation of advanced power systems. One example of this is the power plants that use ultra supercritical steam as the working fluid. The increase in thermal efficiency of the plant and decrease in pollutant emissions are only possible by changing the properties of steam from supercritical to ultra supercritical. However, the conditions, 650 C and 34.5 MPa, are too severe and result in higher rate of corrosion due to higher metal temperatures. Coating the metallic components with ceramics that are resistant to corrosion, oxidation and erosion, is an economical and immediate solution to this problem. Good high temperature corrosion protection ceramic coatings for metallic structures must have a set of properties that are difficult to achieve using established processing techniques. The required properties include ease of coating complex shapes, low processing temperatures, thermal expansion match with metallic structures and good mechanical and chemical properties. Nanoscale reinforced composite coatings in which the matrix is derived from preceramic polymers have the potential to meet these requirements. The research was focused on developing suitable material systems and processing techniques for these coatings. In addition, we investigated the effect of microstructure on the mechanical properties and oxidation protection ability of the coatings. Coatings were developed to provide oxidation protection to both ferritic and austentic alloys and Ni-based alloys. The coatings that we developed are based on low viscosity pre-ceramic polymers. Thus they can be easily applied to any shape by using a variety of techniques including dip-coating, spray-coating and painting. The polymers are loaded with a variety of nanoparticles. The nanoparticles have two primary roles: control of the final composition and phases (and hence the properties); and control of the shrinkage during thermal decomposition of the polymer. Thus the selection of the nanoparticles was the most critical aspect of this project. Based on the results of the processing studies, the performance of selected coatings in oxidizing conditions (both static and cyclic) was investigated.« less

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.

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.

Effects of plasma spray parameters on two layer thermal barrier

NASA Technical Reports Server (NTRS)

Stecura, S.

1981-01-01

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

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.

Validation of HVOF Thermal Spray Coatings as a Replacement for Hard Chrome Plating on Hydraulic/Pneumatic Actuators

DTIC Science & Technology

2007-12-01

Projects Agency (DARPA). The program evaluated HVOF, physical vapor deposition (PVD) and laser cladding , and concluded that HVOF was the best overall...components such as titanium flap tracks. 5 2.0 TECHNOLOGY DESCRIPTION 2.1 TECHNOLOGY DEVELOPMENT AND APPLICATION Technology background and...theory of operation: High-velocity oxygen-fuel (HVOF) is a standard commercial thermal spray process in which a powder of the material to be sprayed

A brief review on fly ash and its use in surface engineering

NASA Astrophysics Data System (ADS)

Bhajantri, Vishwanath; Krishna, Prasad; Jambagi, Sudhakar

2018-04-01

Fly ash is a by-product obtained from coal power plants. Over the past two decades, handling this industrial waste has been a great challenge for many developing countries. However, this menace can be used in many industrial applications viz., civil, automobile and aerospace applications. In civil industry, the fly ash has been used in concreate to enhance the porosity that increases the curing time of the concrete. The fly ash has been gaining importance these days as a feedstock material for many thermal spray processes. In automobile sector, the fly ash has been used as a thermal barrier coating in IC engines, whereas in aerospace industry, which demands lighter and stronger materials, the fly ash has been used as a reinforcement material. Hence, so far, fly ash has been used as an either single or a composite feed stock material in thermal spray processes. The fly ash with other materials like alumina, titania and red mud have been deposited using thermal spray processes. These coatings have exhibited higher wear, corrosion and erosion resistance as compared to the uncoated specimens. In this paper, a brief review on fly ash and its use, especially its use as a feed stock in thermal spray coating, is presented. Therefore, the use of fly ash has opened a new frontier of research in thermal spray coating area where economically viable coatings can be produced using industrial waste like fly ash.

Application of External Axis in Robot-Assisted Thermal Spraying

NASA Astrophysics Data System (ADS)

Deng, Sihao; Fang, Dandan; Cai, Zhenhua; Liao, Hanlin; Montavon, Ghislain

2012-12-01

Currently, industrial robots are widely used in the process of thermal spraying because of their high efficiency, security, and repeatability. Although robots are found suitable for use in industrial productions, they have some natural disadvantages because of their six-axis mechanical linkages. When a robot performs a series of stages of production, it could be hard to move from one to another because a few axes reach their limit value. For this reason, an external axis should be added to the robot system to extend the reachable space of the robots. This article concerns the application of external axis on ABB robots in thermal spraying and the different methods of off-line programming with external axis in the virtual environment. The developed software toolkit was applied to coat real workpiece with a complex geometry in atmospheric plasma spraying).

Metal ion reactive thin films using spray electrostatic LbL assembly.

PubMed

Krogman, Kevin C; Lyon, Katharine F; Hammond, Paula T

2008-11-20

By using the spray-layer-by-layer (Spray-LbL) technique, the number of metal counterions trapped within LbL coatings is significantly increased by kinetically freezing the film short of equilibrium, potentially limiting interchain penetration and forcing chains to remain extrinsically compensated to a much greater degree than observed in the traditional dipped LbL technique. The basis for the enhanced entrapment of metal ions such as Cu2+, Fe2+, and Ag+ is addressed, including the equilibrium driving force for extrinsic compensation by soft versus hard metal ions and the impact of Spray-LbL on the kinetics of polymer-ion complexation. These polymer-bound metal-ion coatings are also demonstrated to be effective treatments for air filtration, functionalizing existing filters with the ability to strongly bind toxic industrial compounds such as ammonia or cyanide gases, as well as chemical warfare agent simulants such as chloroethyl ethyl sulfide. On the basis of results reported here, future work could extend this method to include other toxic soft-base ligands such as carbon monoxide, benzene, or organophosphate nerve agents.

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.

Airfield Damage Repair (ADR); Polymer Repair of Airfields Summary of Research

DTIC Science & Technology

2007-12-01

reported in section 4.3.1. Prior to mixing, the stainless steel bowl, paddle and molds were sprayed with an industrial silicone release agent, Zip-Slip...aggressive foaming and segregation problems. airfield damage repair, (ADR), polymer, concrete, polymer concrete, crater repair U U U UU 30 R. Craig...Polymer Technology for Agile Combat Support to develop a rapid crater repair using resin binders for indigenous materials. The research team consisted of

Intermetallic Al-, Fe-, Co- and Ni-Based Thermal Barrier Coatings Prepared by Cold Spray for Applications on Low Heat Rejection Diesel Engines

NASA Astrophysics Data System (ADS)

Leshchinsky, E.; Sobiesiak, A.; Maev, R.

2018-02-01

Conventional thermal barrier coating (TBC) systems consist of a duplex structure with a metallic bond coat and a ceramic heat insulating topcoat. They possess the desired low thermal conductivity, but at the same time they are very brittle and sensitive to thermal shock and thermal cycling due to the inherently low coefficient of thermal expansion. Recent research activities are focused on the developing of multilayer TBC structures obtained using cold spraying and following annealing. Aluminum intermetallics have demonstrated thermal and mechanical properties that allow them to be used as the alternative TBC materials, while the intermetallic layers can be additionally optimized to achieve superior thermal physical properties. One example is the six layer TBC structure in which cold sprayed Al-based intermetallics are synthesized by annealing in nitrogen atmosphere. These multilayer coating systems demonstrated an improved thermal fatigue capability as compared to conventional ceramic TBC. The microstructures and properties of the coatings were characterized by SEM, EDS and mechanical tests to define the TBC material properties and intermetallic formation mechanisms.

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.

Performance Analysis and Modeling of Thermally Sprayed Resistive Heaters

NASA Astrophysics Data System (ADS)

Lamarre, Jean-Michel; Marcoux, Pierre; Perrault, Michel; Abbott, Richard C.; Legoux, Jean-Gabriel

2013-08-01

Many processes and systems require hot surfaces. These are usually heated using electrical elements located in their vicinity. However, this solution is subject to intrinsic limitations associated with heating element geometry and physical location. Thermally spraying electrical elements directly on surfaces can overcome these limitations by tailoring the geometry of the heating element to the application. Moreover, the element heat transfer is maximized by minimizing the distance between the heater and the surface to be heated. This article is aimed at modeling and characterizing resistive heaters sprayed on metallic substrates. Heaters were fabricated by using a plasma-sprayed alumina dielectric insulator and a wire flame-sprayed iron-based alloy resistive element. Samples were energized and kept at a constant temperature of 425 °C for up to 4 months. SEM cross-sectional observations revealed the formation of cracks at very specific locations in the alumina layer after thermal use. Finite-element modeling shows that these cracks originate from high local thermal stresses and can be predicted according to the considered geometry. The simulation model was refined using experimental parameters obtained by several techniques such as emissivity and time-dependent temperature profile (infra-red camera), resistivity (four-probe technique), thermal diffusivity (laser flash method), and mechanical properties (micro and nanoindentation). The influence of the alumina thickness and the substrate material on crack formation was evaluated.

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.

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.

Molecularly imprinted polymer (MIP) membrane assisted direct spray ionization mass spectrometry for agrochemicals screening in foodstuffs.

PubMed

Pereira, Igor; Rodrigues, Marcella Ferreira; Chaves, Andréa Rodrigues; Vaz, Boniek Gontijo

2018-02-01

Paper spray ionization (PSI) has some limitations such as low sensitivity and ionization suppression when complex samples are analyzed. The use of sample preparation devices directly coupled to MS can avoid these restrictions. Molecularly imprinted polymers (MIPs) are materials widely used as adsorbent in sample preparation methods such as solid-phase extraction and solid-phase microextraction, and they can provide specifics cavities with affinity to a target molecule. Here, we introduce a new MIP membrane spray ionization method combining MIP and PSI. MIP was synthesized directly on a cellulose membrane. Monuron and 2,4,5-T (2,4,5-trichlorophenoxyacetic acid) were used as template molecules in MIP synthesis for diuron and 2,4-D (2,4-dichlorophenoxyacetic acid) analyte sequesters, respectively. Apple, banana and grape methanolic extracts were used as matrices. The MIP membrane spray showed signal intensities of diuron and 2,4-D that were much higher compared to those obtained by non-imprinted polymers(NIP). Calibration curves exhibited R 2 > 0.99 for diuron and 2,4-D in all fruit extracts analyzed. LODs were found less than 0.60µgL -1 and LLOQs were found less than 2.00µgL -1 . The coefficients of variation and relative errors were less than 15% for almost all analyses. The apparent recovery test results ranged between 92,5% and 116.9%. Finally, the MIP membrane spray method was employed for the quantification of diuron and 2,4-D in real samples. Diuron contents were only found in three bananas (4.0, 6.5, and 9.9µgL -1 ). The proposed MIP membrane spray ionization method was straightforward, fast to carry out and provided satisfactory results for analyses of diuron and 2,4-D in apple, banana and grape samples. Copyright © 2017 Elsevier B.V. All rights reserved.

Spray and High-Pressure Flow Computations in the National Combustion Code (NCC) Improved

NASA Technical Reports Server (NTRS)

Raju, Manthena S.

2002-01-01

Sprays occur in a wide variety of industrial and power applications and in materials processing. A liquid spray is a two-phase flow with a gas as the continuous phase and a liquid as the dispersed phase in the form of droplets or ligaments. The interactions between the two phases--which are coupled through exchanges of mass, momentum, and energy--can occur in different ways at disparate time and length scales involving various thermal, mass, and fluid dynamic factors. An understanding of the flow, combustion, and thermal properties of a rapidly vaporizing spray requires careful modeling of the ratecontrolling processes associated with turbulent transport, mixing, chemical kinetics, evaporation, and spreading rates of the spray, among many other factors. With the aim of developing an efficient solution procedure for use in multidimensional combustor modeling, researchers at the NASA Glenn Research Center have advanced the state-of-the-art in spray computations in several important ways.

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.

Load responsive multilayer insulation performance testing

NASA Astrophysics Data System (ADS)

Dye, S.; Kopelove, A.; Mills, G. L.

2014-01-01

Cryogenic insulation designed to operate at various pressures from one atmosphere to vacuum, with high thermal performance and light weight, is needed for cryogenically fueled space launch vehicles and aircraft. Multilayer insulation (MLI) performs well in a high vacuum, but the required vacuum shell for use in the atmosphere is heavy. Spray-on foam insulation (SOFI) is often used in these systems because of its light weight, but can have a higher heat flux than desired. We report on the continued development of Load Responsive Multilayer Insulation (LRMLI), an advanced thermal insulation system that uses dynamic beam discrete spacers that provide high thermal performance both in atmosphere and vacuum. LRMLI consists of layers of thermal radiation barriers separated and supported by micromolded polymer spacers. The spacers have low thermal conductance, and self-support a thin, lightweight vacuum shell that provides internal high vacuum in the insulation. The dynamic load responsive spacers compress to support the external load of a vacuum shell in one atmosphere, and decompress under reduced atmospheric pressure for lower heat leak. Structural load testing was performed on the spacers with various configurations. LRMLI was installed on a 400 liter tank and boil off testing with liquid nitrogen performed at various chamber pressures from one atmosphere to high vacuum. Testing was also performed with an MLI blanket on the outside of the LRMLI.

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.

Field application of a thermal-sprayed titanium anode for cathodic protection of reinforcing steel in concrete : final report

DOT National Transportation Integrated Search

1999-01-01

This study provided the first field trial of a catalyzed, thermal-sprayed titanium anode for cathodic protection of steel reinforced concrete structures. Catalyzed titanium as an anode material offers the advantage of long life due to the inherent no...

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.

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.

Use of Spray-Dried Dispersions in Early Pharmaceutical Development: Theoretical and Practical Challenges.

PubMed

Li, Jinjiang; Patel, Dhaval; Wang, George

2017-03-01

Spray-dried dispersions (SDDs) have become an important formulation technology for the pharmaceutical product development of poorly water-soluble (PWS) compounds. Although this technology is now widely used in the industry, especially in the early-phase development, the lack of mechanistic understanding still causes difficulty in selecting excipients and predicting stability of SDD-based drug products. In this review, the authors aim to discuss several principles of polymer science pertaining to the development of SDDs, in terms of selecting polymers and solvents, optimizing drug loading, as well as assessing physical stability on storage and supersaturation maintenance after dissolution, from both thermodynamic and kinetic considerations. In order to choose compatible solvents with both polymers and active pharmaceutical ingredients (APIs), a symmetric Flory-Huggins interaction (Δχ ∼0) approach was introduced. Regarding spray drying of polymer-API solutions, low critical solution temperature (LCST) was discussed for setting the inlet temperature for drying. In addition, after being exposed to moisture, SDDs are practically converted to ternary systems with asymmetric Flory-Huggins interactions, which are thermodynamically not favored. In this case, the kinetics of phase separation plays a significant role during the storage and dissolution of SDD-based drug products. The impact of polymers on the supersaturation maintenance of APIs in dissolution media was also discussed. Moreover, the nature of SDDs, with reference to solid solution and the notion of solid solubility, was examined in the context of pharmaceutical application. Finally, the importance of robust analytical techniques to characterize the SDD-based drug products was emphasized, considering their complexity.

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.

Spray-dried mucoadhesives for intravesical drug delivery using N-acetylcysteine- and glutathione-glycol chitosan conjugates.

PubMed

Denora, Nunzio; Lopedota, Angela; Perrone, Mara; Laquintana, Valentino; Iacobazzi, Rosa M; Milella, Antonella; Fanizza, Elisabetta; Depalo, Nicoletta; Cutrignelli, Annalisa; Lopalco, Antonio; Franco, Massimo

2016-10-01

This work describes N-acetylcysteine (NAC)- and glutathione (GSH)-glycol chitosan (GC) polymer conjugates engineered as potential platform useful to formulate micro-(MP) and nano-(NP) particles via spray-drying techniques. These conjugates are mucoadhesive over the range of urine pH, 5.0-7.0, which makes them advantageous for intravesical drug delivery and treatment of local bladder diseases. NAC- and GSH-GC conjugates were generated with a synthetic approach optimizing reaction times and purification in order to minimize the oxidation of thiol groups. In this way, the resulting amount of free thiol groups immobilized per gram of NAC- and GSH-GC conjugates was 6.3 and 3.6mmol, respectively. These polymers were completely characterized by molecular weight, surface sulfur content, solubility at different pH values, substitution and swelling degree. Mucoadhesion properties were evaluated in artificial urine by turbidimetric and zeta (ζ)-potential measurements demonstrating good mucoadhesion properties, in particular for NAC-GC at pH 5.0. Starting from the thiolated polymers, MP and NP were prepared using both the Büchi B-191 and Nano Büchi B-90 spray dryers, respectively. The resulting two formulations were evaluated for yield, size, oxidation of thiol groups and ex-vivo mucoadhesion. The new spray drying technique provided NP of suitable size (<1μm) for catheter administration, low degree of oxidation, and sufficient mucoadhesion property with 9% and 18% of GSH- and NAC-GC based NP retained on pig mucosa bladder after 3h of exposure, respectively. The aim of the present study was first to optimize the synthesis of NAC-GC and GSH-GC, and preserve the oxidation state of the thiol moieties by introducing several optimizations of the already reported synthetic procedures that increase the mucoadhesive properties and avoid pH-dependent aggregation. Second, starting from these optimized thiomers, we studied the feasibility of manufacturing MP and NP by spray-drying techniques. The aim of this second step was to produce mucoadhesive drug delivery systems of adequate size for vesical administration by catheter, and comparable mucoadhesive properties with respect to the processed polymers, avoiding thiolic oxidation during the formulation. MP with acceptable size produced by spray-dryer Büchi B-191 were compared with NP made with the apparatus Nano Büchi B-90. Copyright © 2016 Acta Materialia Inc. All rights reserved.

Self-sharpening-effect of nickel-diamond coatings sprayed by HVOF

NASA Astrophysics Data System (ADS)

Tillmann, W.; Brinkhoff, A.; Schaak, C.; Zajaczkowski, J.

2017-03-01

The durability of stone working and drilling tools is an increasingly significant requirement in industrial applications. These tools are mainly produced by brazing diamond metal matrix composites inserts to the tool body. These inserts are produced by sintering diamonds and metal powder (e.g. nickel). If the wear is too high, the diamonds will break out of the metal matrix and other diamonds will be uncovered. This effect is called self-sharpening. But diamonds are difficult to handle because of their thermal sensitivity. Due to their high thermal influence, manufacturing costs, and complicate route of manufacturing (first sintering, then brazing), there is a great need for alternative production methods for such tools. One alternative to produce wear-resistant and self-sharpening coatings are thermal spray processes as examined in this paper. An advantage of thermal spray processes is their smaller thermal influence on the diamond, due to the short dwelling time in the flame. To reduce the thermal influence during spraying, nickel coated diamonds were used in the HVOF-process (high velocity oxygen fuel process). The wear resistance was subsequently investigated by means of a standardized ball-on-disc test. Furthermore, a SEM (scanning electron microscope) was used to gain information about the wear-mechanism and the self-sharpening effect of the coating.

Modeling metal droplet sprays in spray forming

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

Muoio, N.G.; Crowe, C.T.; Fritsching, U.

1995-12-31

Spray casting is a process whereby a molten metal stream is atomized and deposited on a substrate. The rapid solidification of the metal droplets gives rise to a fine grain structure and improved material properties. This paper presents a simulation for the fluid and thermal interaction of the fluid and droplets in the spray and the effect on the droplet spray pattern. Good agreement is obtained between the measured and predicted droplet mass flux distribution in the spray.

Evaluation of the efficacy of lambda-cyhalothrin applied as ultra-low volume and thermal fog for emergency control of Aedes aegypti in Honduras.

PubMed

Perich, M J; Sherman, C; Burge, R; Gill, E; Quintana, M; Wirtz, R A

2001-12-01

An extended-duration formulation of lambda-cyhalothrin (Demand CS) applied as either an ultra-low volume (ULV) or thermal fog spray from a new handheld sprayer (Terrier) against Aedes aegypti was evaluated in Honduras. Spray applications were made at the front door for 1 min or to each room for 15 sec, both for the ULV and thermal fog applications to houses in separate blocks for each treatment. The efficacy and duration of effectiveness of the spray was determined from sentinel caged mosquito mortality and collection of mosquitoes within houses with a backpack power aspirator. Sentinel caged mosquito mortality in both open and sequestered locations was 97-100% for all spray treatments, with control mortality less than 2%. Both ULV applications (front door and each room) provided 4 wk of significant control (P < 0.01) based on adult Ae. aegypti house collections.

Failure Analysis of Multilayered Suspension Plasma-Sprayed Thermal Barrier Coatings for Gas Turbine Applications

NASA Astrophysics Data System (ADS)

Gupta, M.; Markocsan, N.; Rocchio-Heller, R.; Liu, J.; Li, X.-H.; Östergren, L.

2018-02-01

Improvement in the performance of thermal barrier coatings (TBCs) is one of the key objectives for further development of gas turbine applications. The material most commonly used as TBC topcoat is yttria-stabilized zirconia (YSZ). However, the usage of YSZ is limited by the operating temperature range which in turn restricts the engine efficiency. Materials such as pyrochlores, perovskites, rare earth garnets are suitable candidates which could replace YSZ as they exhibit lower thermal conductivity and higher phase stability at elevated temperatures. The objective of this work was to investigate different multilayered TBCs consisting of advanced topcoat materials fabricated by suspension plasma spraying (SPS). The investigated topcoat materials were YSZ, dysprosia-stabilized zirconia, gadolinium zirconate, and ceria-yttria-stabilized zirconia. All topcoats were deposited by TriplexPro-210TM plasma spray gun and radial injection of suspension. Lifetime of these samples was examined by thermal cyclic fatigue and thermal shock testing. Microstructure analysis of as-sprayed and failed specimens was performed with scanning electron microscope. The failure mechanisms in each case have been discussed in this article. The results show that SPS could be a promising route to produce multilayered TBCs for high-temperature applications.

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.

Protective Skins for Aerogel Monoliths

NASA Technical Reports Server (NTRS)

Leventis, Nicholas; Johnston, James C.; Kuczmarski, Maria A.; Meador, Ann B.

2007-01-01

A method of imparting relatively hard protective outer skins to aerogel monoliths has been developed. Even more than aerogel beads, aerogel monoliths are attractive as thermal-insulation materials, but the commercial utilization of aerogel monoliths in thermal-insulation panels has been inhibited by their fragility and the consequent difficulty of handling them. Therefore, there is a need to afford sufficient protection to aerogel monoliths to facilitate handling, without compromising the attractive bulk properties (low density, high porosity, low thermal conductivity, high surface area, and low permittivity) of aerogel materials. The present method was devised to satisfy this need. The essence of the present method is to coat an aerogel monolith with an outer polymeric skin, by painting or spraying. Apparently, the reason spraying and painting were not attempted until now is that it is well known in the aerogel industry that aerogels collapse in contact with liquids. In the present method, one prevents such collapse through the proper choice of coating liquid and process conditions: In particular, one uses a viscous polymer precursor liquid and (a) carefully controls the amount of liquid applied and/or (b) causes the liquid to become cured to the desired hard polymeric layer rapidly enough that there is not sufficient time for the liquid to percolate into the aerogel bulk. The method has been demonstrated by use of isocyanates, which, upon exposure to atmospheric moisture, become cured to polyurethane/polyurea-type coats. The method has also been demonstrated by use of commercial epoxy resins. The method could also be implemented by use of a variety of other resins, including polyimide precursors (for forming high-temperature-resistant protective skins) or perfluorinated monomers (for forming coats that impart hydrophobicity and some increase in strength).

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.

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.

Integration of process diagnostics and three dimensional simulations in thermal spraying

NASA Astrophysics Data System (ADS)

Zhang, Wei

Thermal spraying is a group of processes in which the metallic or ceramic materials are deposited in a molten or semi-molten state on a prepared substrate. In atmospheric plasma spray process, a thermal plasma jet is used to heat up and accelerate loading particles. The process is inherently complex due to the deviation from equilibrium conditions, three dimensional nature, multitude of interrelated variables involved, and stochastic variability at different stages. This dissertation is aimed at understanding the in-flight particle state and plasma plume characteristics in atmospheric plasma spray process through the integration of process diagnostics and three-dimensional simulation. Effects of injection angle and carrier gas flow rate on in-flight particle characteristics are studied experimentally and interpreted through numerical simulation. Plasma jet perturbation by particle injection angle, carrier gas, and particle loading are also identified. Maximum particle average temperature and velocity at any given spray distance is systematically quantified. Optimum plasma plume position for particle injection which was observed in experiments was verified numerically along with description of physical mechanisms. Correlation of spray distance with in-flight particle behavior for various kinds of materials is revealed. A new strategy for visualization and representation of particle diagnostic results for thermal spray processes has been presented. Specifically, 1 st order process maps (process-particle interactions) have been addressed by converting the Temperature-Velocity of particles obtained via diagnostics into non-dimensional group parameters [Melting Index-Reynolds number]. This approach provides an improved description of the thermal and kinetic energy of particles and allows for cross-comparison of diagnostic data within a given process for different materials, comparison of a single material across different thermal spray processes, and detailed assessment of the melting behavior through recourse to analysis of the distributions. An additional group parameter, Oxidation Index, has been applied to relatively track the oxidation extent of metallic particles under different operating conditions. The new mapping strategies have also been proposed in circumstances where only ensemble particle diagnostics are available. Through the integration of process diagnostics and numerical simulation, key issues concerning in-flight particle status as well as the controlling physical mechanisms have been analyzed. A scientific and intellectual strategy for universal description of particle characteristics has been successfully developed.

Preparation of MgO/B₂O₃ coatings by plasma spraying on SUS304 surface and effects of heat-resistant.

PubMed

Song, Bo; Zhou, Ningning; Ju, Dongying

2013-12-01

This study mainly deals with the preparation of MgO/B2O3 coatings by plasma spraying on the SUS304 surface and the effects of heat-resistant. The power materials of low thermal conductivity were selected to control the heat divergent performance of high temperature parts. The reticular micro-structure between the cover thermal layer and the substrate was prepared by using the plasma spraying method. The powder mixture of MgO and B2O3 were selected as spraying materials and the SUS304 was used as the substrate material. The MgO/B2O3 coating was prepared on the surface of the SUS304 to provide better cover thermal performance. The properties of the microstructures and the morphologies were studied by Optical Microscope, Scanning Electron Microscope, Electron Probe Microanalyzer, and X-ray Diffraction. The results showed that the cover thermal performance has been improved. Copyright © 2013 The Research Centre for Eco-Environmental Sciences, Chinese Academy of Sciences. Published by Elsevier B.V. All rights reserved.

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.

Characterization of Thermal, Mechanical and Tribological Properties of Fluoropolymer Composite Coatings

NASA Astrophysics Data System (ADS)

He, Y.; Farokhzadeh, K.; Edrisy, A.

2017-04-01

Perfluoroalkoxy (PFA) is a potential polymer coating material for low-temperature waste heat recovery in heat exchangers. Nonetheless, poor thermal conductivity, low strength and susceptibility to surface degradation by erosion/wear pose restrictions in its application. In this study, four types of fillers, namely graphite, silicon carbide, alumina and boron nitride, were introduced to enhance the thermal, mechanical and tribological properties in PFA coatings. The thermal diffusivity and specific heat capacity of the composites (reinforced with 20 wt.% filler) were also measured using laser flash and differential scanning calorimetry techniques, respectively. The results indicated that the addition of graphite or boron nitride increased the thermal conductivity of PFA by at least 2.8 orders of magnitude, while the composites with the same weight fraction of alumina or silicon carbide showed 20-80% rise in thermal conductivity. The micromechanical deformation and tribological behavior of composite coatings, electrostatically sprayed on steel substrates, were investigated by means of instrumented indentation and scratch tests. The deformation response and friction characteristics were investigated, and the failure mechanisms were identified. Surface hardness, roughness and structure of fillers influenced the sliding performance of the composite coatings. PFA coatings filled with Al2O3 or SiC particles showed high load-bearing capacity under sliding conditions. Conversely, BN- and graphite-filled PFA coatings exhibited lower interfacial adhesion to steel substrate and were prone to failure at relatively lower applied loads.

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.

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

Nondestructive evaluation of plasma-sprayed thermal barrier coatings

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

Andrews, D.J.; Taylor, J.A.T.

Acoustic emission has been used as a nondestructive evaluation technique to examine the thermal shock response of thermal barrier coatings. In this study, samples of partially stabilized zirconia powder were sprayed and acoustic emission (AE) data were taken in a series of thermal shock tests in an effort to correlate AE with a given failure mechanism. Microstructural evidence was examined using parallel beam x-ray diffraction and optical microscopy. The AE data are discussed in terms of cumulative amplitude distributions and the use of this technique to characterize fracture events.

Thermal-Responsive Polymers for Enhancing Safety of Electrochemical Storage Devices.

PubMed

Yang, Hui; Leow, Wan Ru; Chen, Xiaodong

2018-03-01

Thermal runway constitutes the most pressing safety issue in lithium-ion batteries and supercapacitors of large-scale and high-power density due to risks of fire or explosion. However, traditional strategies for averting thermal runaway do not enable the charging-discharging rate to change according to temperature or the original performance to resume when the device is cooled to room temperature. To efficiently control thermal runaway, thermal-responsive polymers provide a feasible and reversible strategy due to their ability to sense and subsequently act according to a predetermined sequence when triggered by heat. Herein, recent research progress on the use of thermal-responsive polymers to enhance the thermal safety of electrochemical storage devices is reviewed. First, a brief discussion is provided on the methods of preventing thermal runaway in electrochemical storage devices. Subsequently, a short review is provided on the different types of thermal-responsive polymers that can efficiently avoid thermal runaway, such as phase change polymers, polymers with sol-gel transitions, and polymers with positive temperature coefficients. The results represent the important development of thermal-responsive polymers toward the prevention of thermal runaway in next-generation smart electrochemical storage devices. © 2018 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Biomimetic Dissolution: A Tool to Predict Amorphous Solid Dispersion Performance.

PubMed

Puppolo, Michael M; Hughey, Justin R; Dillon, Traciann; Storey, David; Jansen-Varnum, Susan

2017-11-01

The presented study describes the development of a membrane permeation non-sink dissolution method that can provide analysis of complete drug speciation and emulate the in vivo performance of poorly water-soluble Biopharmaceutical Classification System class II compounds. The designed membrane permeation methodology permits evaluation of free/dissolved/unbound drug from amorphous solid dispersion formulations with the use of a two-cell apparatus, biorelevant dissolution media, and a biomimetic polymer membrane. It offers insight into oral drug dissolution, permeation, and absorption. Amorphous solid dispersions of felodipine were prepared by hot melt extrusion and spray drying techniques and evaluated for in vitro performance. Prior to ranking performance of extruded and spray-dried felodipine solid dispersions, optimization of the dissolution methodology was performed for parameters such as agitation rate, membrane type, and membrane pore size. The particle size and zeta potential were analyzed during dissolution experiments to understand drug/polymer speciation and supersaturation sustainment of felodipine solid dispersions. Bland-Altman analysis was performed to measure the agreement or equivalence between dissolution profiles acquired using polymer membranes and porcine intestines and to establish the biomimetic nature of the treated polymer membranes. The utility of the membrane permeation dissolution methodology is seen during the evaluation of felodipine solid dispersions produced by spray drying and hot melt extrusion. The membrane permeation dissolution methodology can suggest formulation performance and be employed as a screening tool for selection of candidates to move forward to pharmacokinetic studies. Furthermore, the presented model is a cost-effective technique.

Fabrication of topical metered dose film forming sprays for pain management.

PubMed

Ranade, Sneha; Bajaj, Amrita; Londhe, Vaishali; Babul, Najib; Kao, Danny

2017-03-30

Topical film-forming metered dose spray formulations were designed for management of pain. Ropivacaine, a local anesthetic is explored for its topical efficacy in alleviating pain. Metered dose spray containers, organic solvents, film forming polymers and permeation enhancers were utilized to fabricate the Metered Dose topical spray. Factors like viscosity, spray pattern, spray angle, volume of actuation, droplet size distribution of the metered dose spray formulation and drying time, flexibility and wash-ability of the film formed after spraying were assessed. Permeation of the drug into the porcine skin was observed based on ex-vivo diffusion studies and confocal microscopy. The results indicated a high level of drug concentration in the skin layers. Anti-nociceptive efficacy of the formulations was assessed on Wistar rats by hot plate and tail flick tests, based on the response to pain perception. The results were comparable to the conventional lidocaine gel. Topical film forming sprays have the ability to provide an accurate, long lasting and patient compliant delivery of drugs on the skin as compared to conventional gels. Copyright © 2017 Elsevier B.V. All rights reserved.

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

Ctibor, Pavel; Kotlan, Jiri, E-mail: kotlan@ipp.cas.cz; Department of Electrotechnology, Faculty of Electrical Engineering, Czech Technical University in Prague, Technicka 2, Prague 6

Highlights: • Calcium titanate was sprayed by two different plasma spray systems. • Significant improvement of dielectric properties after annealing was observed. • Calcium titanate self-supporting parts can be fabricated by plasma spraying. - Abstract: This paper studies calcium titanate (CaTiO{sub 3}) dielectrics prepared by plasma spray technology. A water stabilized plasma gun (WSP) as well as a widely used gas stabilized plasma gun (GSP) were employed in this study to deposit three sample sets at different spray conditions. Prepared specimens were annealed in air at atmospheric pressure for 2 h at various temperatures from 530 to 1170 °C. X-raymore » diffraction (XRD), Raman spectroscopy and porosity measurements were used for sample characterization. Dielectric spectroscopy was applied to obtain relative permittivity, conductivity and loss factor frequency dependence. Band gap energy was estimated from reflectance measurements. The work is focused on the explanation of changes in microstructure and properties of a plasma sprayed deposit after thermal annealing. Obtained results show significant improvement of dielectric properties after thermal annealing.« less

Numerical Modeling of Turbulence Effects within an Evaporating Droplet in Atomizing Sprays

NASA Technical Reports Server (NTRS)

Balasubramanyam, M. S.; Chen, C. P.; Trinh, H. P.

2006-01-01

A new approach to account for finite thermal conductivity and turbulence effects within atomizing liquid sprays is presented in this paper. The model is an extension of the T-blob and T-TAB atomization/spray model of Trinh and Chen (2005). This finite conductivity model is based on the two-temperature film theory, where the turbulence characteristics of the droplet are used to estimate the effective thermal diffhsivity within the droplet phase. Both one-way and two-way coupled calculations were performed to investigate the performance of this model. The current evaporation model is incorporated into the T-blob atomization model of Trinh and Chen (2005) and implemented in an existing CFD Eulerian-Lagrangian two-way coupling numerical scheme. Validation studies were carried out by comparing with available evaporating atomization spray experimental data in terms of jet penetration, temperature field, and droplet SMD distribution within the spray. Validation results indicate the superiority of the finite-conductivity model in low speed parallel flow evaporating spray.

Incorporation of Copper Enhances the Anti-Ageing Property of Flame-Sprayed High-Density Polyethylene Coatings

NASA Astrophysics Data System (ADS)

Jia, Zhengmei; Huang, Jing; Gong, Yongfeng; Jin, Peipeng; Suo, Xinkun; Li, Hua

2017-02-01

High-density polyethylene (HDPE)-copper (Cu) composite coatings were prepared through depositing HDPE-Cu core-shell particles by flame spraying. The HDPE-Cu composite coatings and the HDPE coatings were aged in xenon lamp ageing testing chamber. The variations of chemical compositions and surface morphology of the coatings before and after the ageing testing were analyzed using infrared spectroscopy, scanning electron microscopy, thermogravimetric analysis, differential scanning calorimetry and ultraviolet-visible spectrophotometer. Results show that there is no chemical composition variation in the HDPE-Cu coatings. Cracks were found on the surfaces of the HDPE coatings, while the HDPE-Cu coating shows almost intact surface morphology. These results suggest that the HDPE-Cu coatings present better anti-ageing performances than the HDPE coatings. Further assessment of the function of Cu shells on the anti-ageing property reveals that Cu shells not only enhanced the absorption of the coatings to ultraviolet, but also increased their reflectivity to visible light. Additionally, the Cu shells enhanced the decomposition temperature and thermal stability of HDPE in the composite coatings. These results give bright insight into potential anti-ageing applications of the polymer-based structures.

JT9D ceramic outer air seal system refinement program

NASA Technical Reports Server (NTRS)

Gaffin, W. O.

1982-01-01

The abradability and durability characteristics of the plasma sprayed system were improved by refinement and optimization of the plasma spray process and the metal substrate design. The acceptability of the final seal system for engine testing was demonstrated by an extensive rig test program which included thermal shock tolerance, thermal gradient, thermal cycle, erosion, and abradability tests. An interim seal system design was also subjected to 2500 endurance test cycles in a JT9D-7 engine.

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

NASA Astrophysics Data System (ADS)

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

2014-01-01

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

Thermal Expansion of Polyurethane Foam

NASA Technical Reports Server (NTRS)

Lerch, Bradley A.; Sullivan, Roy M.

2006-01-01

Closed cell foams are often used for thermal insulation. In the case of the Space Shuttle, the External Tank uses several thermal protection systems to maintain the temperature of the cryogenic fuels. A few of these systems are polyurethane, closed cell foams. In an attempt to better understand the foam behavior on the tank, we are in the process of developing and improving thermal-mechanical models for the foams. These models will start at the microstructural level and progress to the overall structural behavior of the foams on the tank. One of the key properties for model characterization and verification is thermal expansion. Since the foam is not a material, but a structure, the modeling of the expansion is complex. It is also exacerbated by the anisoptropy of the material. During the spraying and foaming process, the cells become elongated in the rise direction and this imparts different properties in the rise direction than in the transverse directions. Our approach is to treat the foam as a two part structure consisting of the polymeric cell structure and the gas inside the cells. The polymeric skeleton has a thermal expansion of its own which is derived from the basic polymer chemistry. However, a major contributor to the thermal expansion is the volume change associated with the gas inside of the closed cells. As this gas expands it exerts pressure on the cell walls and changes the shape and size of the cells. The amount that this occurs depends on the elastic and viscoplastic properties of the polymer skeleton. The more compliant the polymeric skeleton, the more influence the gas pressure has on the expansion. An additional influence on the expansion process is that the polymeric skeleton begins to breakdown at elevated temperatures and releases additional gas species into the cell interiors, adding to the gas pressure. The fact that this is such a complex process makes thermal expansion ideal for testing the models. This report focuses on the thermal expansion tests and the response of the microstructure. A novel optical method is described which is appropriate for measuring thermal expansion at high temperatures without influencing the thermal expansion measurement. Detailed microstructural investigations will also be described which show cell expansion as a function of temperature. Finally, a phenomenological model on thermal expansion will be described.

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.

Prototype of low thermal expansion materials: fabrication of mesoporous silica/polymer composites with densely filled polymer inside mesopore space.

PubMed

Kiba, Shosuke; Suzuki, Norihiro; Okawauchi, Yoshinori; Yamauchi, Yusuke

2010-09-03

A prototype of novel low thermal expansion materials using mesoporous silica particles is demonstrated. Mesoporous silica/polymer composites with densely filled polymer inside the mesopore space are fabricated by mechanically mixing both organically modified mesoporous silica and epoxy polymer. The mesopores are easily penetrated by polymers as a result of the capillary force during the mechanical composite processing. Furthermore, we propose a new model of polymer mobility restriction using mesoporous silica with a large pore space. The robust inorganic frameworks covering the polymer effectively restrict the polymer mobility against thermal energy. As a result, the degree of total thermal expansion of the composites is drastically decreased. From the mass-normalized thermal mechanical analysis (TMA) charts of various composites with different amounts of mesoporous silica particles, it is observed that the coefficient of thermal expansion (CTE) values gradually increase with an increase of the polymer amount outside the mesopores. It is proven that the CTE values in the range over the glass-transition temperatures (T(g)) are perfectly proportional to the outside polymer amounts. Importantly, the Y-intercept of the relation equation obtained by a least-square method is the CTE value and is almost zero. This means that thermal expansion does not occur if no polymers are outside the mesopores. Through such a quantative discussion, we clarify that only the outside polymer affects the thermal expansion of the composites, that is, the embedded polymers inside the mesopores do not expand at all during the thermal treatment.

Practical Aspects of Suspension Plasma Spray for Thermal Barrier Coatings on Potential Gas Turbine Components

NASA Astrophysics Data System (ADS)

Ma, X.; Ruggiero, P.

2018-04-01

Suspension plasma spray (SPS) process has attracted extensive efforts and interests to produce fine-structured and functional coatings. In particular, thermal barrier coatings (TBCs) applied by SPS process gain increasing interest due to its potential for superior thermal protection of gas turbine hot sections as compared to conventional TBCs. Unique columnar architectures and nano- and submicrometric grains in the SPS-TBC demonstrated some advantages of thermal shock durability, low thermal conductivity, erosion resistance and strain-tolerant microstructure. This work aimed to look into some practical aspects of SPS processing for TBC applications before it becomes a reliable industry method. The spray capability and applicability of SPS process to achieve uniformity thickness and microstructure on curved substrates were emphasized in designed spray trials to simulate the coating fabrication onto industrial turbine parts with complex configurations. The performances of the SPS-TBCs were tested in erosion, falling ballistic impact and indentational loading tests as to evaluate SPS-TBC performances in simulated turbine service conditions. Finally, a turbine blade was coated and sectioned to verify SPS sprayability in multiple critical sections. The SPS trials and test results demonstrated that SPS process is promising for innovative TBCs, but some challenges need to be addressed and resolved before it becomes an economic and capable industrial process, especially for complex turbine components.

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.

Structural and oxidative stabilization of spray dried fish oil microencapsulates with gum arabic and sage polyphenols: Characterization and release kinetics.

PubMed

Binsi, P K; Nayak, Natasha; Sarkar, P C; Jeyakumari, A; Muhamed Ashraf, P; Ninan, George; Ravishankar, C N

2017-03-15

The synergistic efficacy of gum arabic and sage polyphenols in stabilising capsule wall and protecting fish oil encapsulates from heat induced disruption and oxidative deterioration during spray drying was assessed. The emulsions prepared with sodium caseinate as wall polymer, gum arabic as wall co-polymer and sage extract as wall stabiliser was spray dried using a single fluid nozzle. Fish oil encapsulates stabilised with gum arabic and sage extract (SOE) exhibited significantly higher encapsulation efficiency compared to encapsulates containing gum arabic alone (FOE). Scanning electron microscopic and atomic force microscopic images revealed uniform encapsulates with good sphericity and smooth surface for SOE, compared to FOE powder. In vitro oil release of microencapsulates indicated negligible oil release in buffered saline whereas more than 80% of the oil loaded in encapsulates were released in simulated GI fluids. The encapsulates containing sage extract showed a lower rate of lipid oxidation during storage. Copyright © 2016 Elsevier Ltd. All rights reserved.

Transparent superhydrophobic surfaces using a spray coating process

DOE PAGES

Polyzos, Georgios; Jang, Gyoung Gug; Smith, D. Barton; ...

2017-11-03

One significant maintenance problem and cost associated with solar energy conversion systems is the soiling due to the accumulation of dust and other pollutants. Here in this work, we describe a scalable approach for applying antisoiling coatings based on superhydrophobic (SH) silica particles using a spray coating process. A large water contact angle (WCA) is one of the characteristics of excellent SH surfaces and because of the low surface energy and low adhesion forces the soiling rate is reduced. Our findings indicate that the WCA depends strongly on the ratio of the polymer binder and the nanoparticles. The nanoparticle surfacemore » coverage of the spray coated samples was substantially improved after rinsing with solvent. This process tended to remove large aggregates and excess polymer binder and further increased the WCA by allowing exposure of the functionalized nanoparticles. The durability of the SH coatings was enhanced when the substrate was pretreated with polymer binder and an optimal curing time between 30 and 60 min. The abrasion tests of the SH coatings we report in this study showed that the WCA decreased from ~ 166° to ~ 157° after exposure to 2.6 g of sand. Such coatings will help reduce costs of periodic cleaning of solar energy conversion systems (photovoltaic panels and concentrated solar mirrors).« less

Transparent superhydrophobic surfaces using a spray coating process

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

Polyzos, Georgios; Jang, Gyoung Gug; Smith, D. Barton

One significant maintenance problem and cost associated with solar energy conversion systems is the soiling due to the accumulation of dust and other pollutants. Here in this work, we describe a scalable approach for applying antisoiling coatings based on superhydrophobic (SH) silica particles using a spray coating process. A large water contact angle (WCA) is one of the characteristics of excellent SH surfaces and because of the low surface energy and low adhesion forces the soiling rate is reduced. Our findings indicate that the WCA depends strongly on the ratio of the polymer binder and the nanoparticles. The nanoparticle surfacemore » coverage of the spray coated samples was substantially improved after rinsing with solvent. This process tended to remove large aggregates and excess polymer binder and further increased the WCA by allowing exposure of the functionalized nanoparticles. The durability of the SH coatings was enhanced when the substrate was pretreated with polymer binder and an optimal curing time between 30 and 60 min. The abrasion tests of the SH coatings we report in this study showed that the WCA decreased from ~ 166° to ~ 157° after exposure to 2.6 g of sand. Such coatings will help reduce costs of periodic cleaning of solar energy conversion systems (photovoltaic panels and concentrated solar mirrors).« less

High temperature polymers - A review of novel thermally stable hexafluoroisopropylidene-containing polymers

NASA Technical Reports Server (NTRS)

Kane, K. M.; Cassidy, P. E.; Tullos, G. L.; Reynolds, D. W.

1990-01-01

The synthesis and properties to date of several novel HFIP-containing polymers and copolymers are presented. Thermal analyses of polyether ketones (PEK), aromatic polyesters, and polymers from a novel 18F-diacid were performed on a thermal analyzer. All three polymer types exhibited enhanced solubility, thermal stability, and low dielectric constants that are predicted for polymers containing the HFIP moiety. The moderate thermal stability observed in the polymers derived from the 18F-diacid is attributed to the oxidatively weak methylene linkage between the HFIP groups and the phenyl rings. PEKs and polyarylates show potential as high emissivity coatings under conditions where atomic oxygen is present.

Dry-spray deposition of TiO2 for a flexible dye-sensitized solar cell (DSSC) using a nanoparticle deposition system (NPDS).

PubMed

Kim, Min-Saeng; Chun, Doo-Man; Choi, Jung-Oh; Lee, Jong-Cheon; Kim, Yang Hee; Kim, Kwang-Su; Lee, Caroline Sunyong; Ahn, Sung-Hoon

2012-04-01

TiO2 powders were deposited on indium tin oxide (ITO) coated polyethylene terephthalate (PET) substrates for application to the photoelectrode of a dye-sensitized solar cell (DSSC). In the conventional DSSC manufacturing process, a semiconductor oxide such as TiO2 powder requires a sintering process at higher temperature than the glass transition temperature (T(g)) of polymers, and thus utilization of flexible polymer substrates in DSSC research has been constrained. To overcome this restriction related to sintering, we used a nanoparticle deposition system (NPDS) that could produce a thin coating layer through a dry-spray method under atmospheric pressure at room temperature. The powder was sprayed through a slit-type nozzle having a 0.4 x 10 mm2 rectangular outlet. In order to determine the deposited TiO2 thickness, five kinds of TiO2 layered specimens were prepared, where the specimens have single and double layer structures. Deposited powders on the ITO coated PET substrates were observed using FE-SEM and a scan profiler The thicker TiO2 photoelectrode with a DSSC having a double layer structure showed higher energy efficiency than the single layer case. The highest fabricated flexible DSSC displayed a short circuit current density J(sc) = 1.99 mA cm(-2), open circuit voltage V(oc) = 0.71 V, and energy efficiency eta = 0.94%. These results demonstrate the possibility of utilizing the dry-spray method to fabricate a TiO2 layer on flexible polymer substrates at room temperature under atmospheric pressure.

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

NASA Technical Reports Server (NTRS)

Agapakis, John E.; Bolstad, Jon

1993-01-01

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

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.

Potential of thermally conductive polymers for the cooling of mechatronic parts

NASA Astrophysics Data System (ADS)

Heinle, C.; Drummer, D.

Adding thermally conductive fillers to polymers the thermal conductivity can be raised significantly. Thermal conductive polymers (TC-plastics) open up a vast range of options to set up novel concepts of polymer technological system solutions in the area of mechatronics. Heating experiment of cooling ribs show the potential in thermal management of mechatronic parts with TC-polymers in comparison with widely used reference materials copper and aluminum. The results demonstrate that especially for certain thermal boundary conditions comparable performance between these two material grades can be measured.

Analysis of the ceramic layer microstructure influence on plasma spray thermal barrier coating performance

NASA Astrophysics Data System (ADS)

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

2017-12-01

This paper outlines the results of analysis and describes the structure of the thermal protection coatings formed by atomic ion stream deposition in vacuum, and plasma thermal spraying method. Crystallite structure features are considered along with the crystallite dimensions, spatial orientation, and position of the boundaries between separate crystallites. Discontinuity, volume, and morphology of the pores has been evaluated. Experimental studies have been accomplished using various fractions of the powder-like material ZrO2 - 8%Y2O3. The influence of the coating microstructure on the coating performance has been analyzed, such as adhesive strength, thermal stability, and thermal conductivity.

Near-net-shape manufacturing: Spray-formed metal matrix composites and tooling

NASA Technical Reports Server (NTRS)

Mchugh, Kevin M.

1994-01-01

Spray forming is a materials processing technology in which a bulk liquid metal is converted to a spray of fine droplets and deposited onto a substrate or pattern to form a near-net-shape solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g. refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. The Idaho National Engineering Laboratory is developing a unique spray-forming method, the Controlled Aspiration Process (CAP), to produce near-net-shape solids and coatings of metals, polymers, and composite materials. Results from two spray-accompanying technical and economic benefits. These programs involved spray forming aluminum strip reinforced with SiC particulate, and the production of tooling, such as injection molds and dies, using low-melting-point metals.

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.

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

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.

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.

Physicochemical Characteristics of Dust Particles in HVOF Spraying and Occupational Hazards: Case Study in a Chinese Company

NASA Astrophysics Data System (ADS)

Huang, Haihong; Li, Haijun; Li, Xinyu

2016-06-01

Dust particles generated in thermal spray process can cause serious health problems to the workers. Dust particles generated in high velocity oxy-fuel (HVOF) spraying WC-Co coatings were characterized in terms of mass concentrations, particle size distribution, micro morphologies, and composition. Results show that the highest instantaneous exposure concentration of dust particles in the investigated thermal spray workshop is 140 mg/m3 and the time-weighted average concentration is 34.2 mg/m3, which are approximately 8 and 4 times higher than the occupational exposure limits in China, respectively. The large dust particles above 10 μm in size present a unique morphology of polygonal or irregular block of crushed powder, and smaller dust particles mainly exist in the form of irregular or flocculent agglomerates. Some heavy metals, such as chromium, cobalt, and nickel, are also found in the air of the workshop and their concentrations are higher than the limits. Potential occupational hazards of the dust particles in the thermal spray process are further analyzed based on their characteristics and the workers' exposure to the nanoparticles is assessed using a control banding tool.

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.

Variable Gravity Effects on the Cooling Performance of a Single Phase Confined Spray

NASA Technical Reports Server (NTRS)

Michalak, Travis; Yerkes, Kirk; Baysinger, Karri; McQuillen, John

2005-01-01

The objective of this paper is to discuss the testing of a spray cooling experiment designed to be flown on NASA's KC-135 Reduced Gravity Testing Platform. Spray cooling is an example of a thermal management technique that may be utilized in high flux heat acquisition and high thermal energy transport concepts. Many researchers have investigated the utility of spray cooling for the thermal management of devices generating high heat fluxes. However, there has been little research addressing the physics and ultimate performance of spray cooling in a variable gravity environment. An experimental package, consisting of a spray chamber coupled to a fluid delivery loop system, was fabricated for variable gravity flight tests. The spray chamber contains two opposing nozzles spraying on target Indium Tin Oxide (ITO) heaters. These heaters are mounted on glass pedestals, which are part of a sump system to remove unconstrained liquid from the test chamber. Liquid is collected in the sumps and returned to the fluid delivery loop. Thermocouples mounted in and around the pedestals are used to determine both the heat loss through the underside of the IT0 heater and the heat extracted by the spray. A series of flight tests were carried out aboard the KC-135, utilizing the ability of the aircraft to produce various gravity conditions. During the flight tests, for a fixed flow rate, heat input was varied at 20, 30, 50, and 80W with variable gravities of 0.01, 0.16, 0.36, and 1.8g. Flight test data was compared to terrestrial baseline data in addition to analytical and numerical solutions to evaluate the heat transfer in the heater and support structure . There were significant differences observed in the spray cooling performance as a result of variable gravity conditions and heat inputs. In general, the Nussult number at the heater surface was found to increase with decreasing gravity conditions for heat loads greater than 30W.

Obtaining Thickness-Limited Electrospray Deposition for 3D Coating.

PubMed

Lei, Lin; Kovacevich, Dylan A; Nitzsche, Michael P; Ryu, Jihyun; Al-Marzoki, Kutaiba; Rodriguez, Gabriela; Klein, Lisa C; Jitianu, Andrei; Singer, Jonathan P

2018-04-04

Electrospray processing utilizes the balance of electrostatic forces and surface tension within a charged spray to produce charged microdroplets with a narrow dispersion in size. In electrospray deposition, each droplet carries a small quantity of suspended material to a target substrate. Past electrospray deposition results fall into two major categories: (1) continuous spray of films onto conducting substrates and (2) spray of isolated droplets onto insulating substrates. A crossover regime, or a self-limited spray, has only been limitedly observed in the spray of insulating materials onto conductive substrates. In such sprays, a limiting thickness emerges, where the accumulation of charge repels further spray. In this study, we examined the parametric spray of several glassy polymers to both categorize past electrospray deposition results and uncover the critical parameters for thickness-limited sprays. The key parameters for determining the limiting thickness were (1) field strength and (2) spray temperature, related to (i) the necessary repulsive field and (ii) the ability for the deposited materials to swell in the carrier solvent vapor and redistribute charge. These control mechanisms can be applied to the uniform or controllably-varied microscale coating of complex three-dimensional objects.

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

DOEpatents

Subramanian, Ramesh

2001-01-01

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

Thermal Fatigue Behavior of Air-Plasma Sprayed Thermal Barrier Coating with Bond Coat Species in Cyclic Thermal Exposure

PubMed Central

Lu, Zhe; Myoung, Sang-Won; Jung, Yeon-Gil; Balakrishnan, Govindasamy; Lee, Jeongseung; Paik, Ungyu

2013-01-01

The effects of the bond coat species on the delamination or fracture behavior in thermal barrier coatings (TBCs) was investigated using the yclic thermal fatigue and thermal-shock tests. The interface microstructures of each TBC showed a good condition without cracking or delamination after flame thermal fatigue (FTF) for 1429 cycles. The TBC with the bond coat prepared by the air-plasma spray (APS) method showed a good condition at the interface between the top and bond coats after cyclic furnace thermal fatigue (CFTF) for 1429 cycles, whereas the TBCs with the bond coats prepared by the high-velocity oxygen fuel (HVOF) and low-pressure plasma spray (LPPS) methods showed a partial cracking (and/or delamination) and a delamination after 780 cycles, respectively. The TBCs with the bond coats prepared by the APS, HVOF and LPPS methods were fully delaminated (>50%) after 159, 36, and 46 cycles, respectively, during the thermal-shock tests. The TGO thickness in the TBCs was strongly dependent on the both exposure time and temperature difference tested. The hardness values were found to be increased only after the CFTF, and the TBC with the bond coat prepared by the APS showed the highest adhesive strength before and after the FTF. PMID:28811441

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.

Laser Processing of Multilayered Thermal Spray Coatings: Optimal Processing Parameters

NASA Astrophysics Data System (ADS)

Tewolde, Mahder; Zhang, Tao; Lee, Hwasoo; Sampath, Sanjay; Hwang, David; Longtin, Jon

2017-12-01

Laser processing offers an innovative approach for the fabrication and transformation of a wide range of materials. As a rapid, non-contact, and precision material removal technology, lasers are natural tools to process thermal spray coatings. Recently, a thermoelectric generator (TEG) was fabricated using thermal spray and laser processing. The TEG device represents a multilayer, multimaterial functional thermal spray structure, with laser processing serving an essential role in its fabrication. Several unique challenges are presented when processing such multilayer coatings, and the focus of this work is on the selection of laser processing parameters for optimal feature quality and device performance. A parametric study is carried out using three short-pulse lasers, where laser power, repetition rate and processing speed are varied to determine the laser parameters that result in high-quality features. The resulting laser patterns are characterized using optical and scanning electron microscopy, energy-dispersive x-ray spectroscopy, and electrical isolation tests between patterned regions. The underlying laser interaction and material removal mechanisms that affect the feature quality are discussed. Feature quality was found to improve both by using a multiscanning approach and an optional assist gas of air or nitrogen. Electrically isolated regions were also patterned in a cylindrical test specimen.

Load responsive multilayer insulation performance testing

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

Dye, S.; Kopelove, A.; Mills, G. L.

Cryogenic insulation designed to operate at various pressures from one atmosphere to vacuum, with high thermal performance and light weight, is needed for cryogenically fueled space launch vehicles and aircraft. Multilayer insulation (MLI) performs well in a high vacuum, but the required vacuum shell for use in the atmosphere is heavy. Spray-on foam insulation (SOFI) is often used in these systems because of its light weight, but can have a higher heat flux than desired. We report on the continued development of Load Responsive Multilayer Insulation (LRMLI), an advanced thermal insulation system that uses dynamic beam discrete spacers that providemore » high thermal performance both in atmosphere and vacuum. LRMLI consists of layers of thermal radiation barriers separated and supported by micromolded polymer spacers. The spacers have low thermal conductance, and self-support a thin, lightweight vacuum shell that provides internal high vacuum in the insulation. The dynamic load responsive spacers compress to support the external load of a vacuum shell in one atmosphere, and decompress under reduced atmospheric pressure for lower heat leak. Structural load testing was performed on the spacers with various configurations. LRMLI was installed on a 400 liter tank and boil off testing with liquid nitrogen performed at various chamber pressures from one atmosphere to high vacuum. Testing was also performed with an MLI blanket on the outside of the LRMLI.« less

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.

Microstructural characterization of Ni-based self-fluxing alloy after selective surface-engineering using diode laser

NASA Astrophysics Data System (ADS)

Chun, Eun-Joon; Park, Changkyoo; Nishikawa, Hiroshi; Kim, Min-Su

2018-06-01

The microstructural characterization of thermal-sprayed Ni-based self-fluxing alloy (Metco-16C®) after laser-assisted homogenization treatment was performed. To this end, a high-power diode laser system was used. This supported the real-time control of the target homogenization temperature at the substrate surface. Non-homogeneities of the macrosegregation of certain elements (C and Cu) and the local concentration of Cr-based carbides and borides in certain regions in the as-sprayed state could be enhanced with the application of homogenization. After homogenization at 1423 K, the hardness of the thermal-sprayed layer was found to have increased by 1280 HV from the as-sprayed state (750 HV). At this homogenization temperature, the microstructure of the thermal-sprayed layer consisted of a lamellar structuring of the matrix phase (austenite and Ni3Si) with fine (<5 μm) carbides and borides (the rod-like phase of Cr5B3, the lumpy phase of M23C6, and the extra-fine phase of M7C3). Despite the formation of several kinds of carbides and borides during homogenization at 1473 K, the lowest hardness level was found to be less than that of the as-sprayed state, because of the liquid-state homogenization treatment without formation of lamellar structuring between austenite and Ni3Si.

Improved Thermal Cycling Durability of Thermal Barrier Coatings Manufactured by PS-PVD

NASA Astrophysics Data System (ADS)

Rezanka, S.; Mauer, G.; Vaßen, R.

2014-01-01

The plasma spray-physical vapor deposition (PS-PVD) process is a promising method to manufacture thermal barrier coatings (TBCs). It fills the gap between traditional thermal spray processes and electron beam physical vapor deposition (EB-PVD). The durability of PS-PVD manufactured columnar TBCs is strongly influenced by the compatibility of the metallic bondcoat (BC) and the ceramic TBC. Earlier investigations have shown that a smooth BC surface is beneficial for the durability during thermal cycling. Further improvements of the bonding between BC and TBC could be achieved by optimizing the formation of the thermally grown oxide (TGO) layer. In the present study, the parameters of pre-heating and deposition of the first coating layer were investigated in order to adjust the growth of the TGO. Finally, the durability of the PS-PVD coatings was improved while the main advantage of PS-PVD, i.e., much higher deposition rate in comparison to EB-PVD, could be maintained. For such coatings, improved thermal cycling lifetimes more than two times higher than conventionally sprayed TBCs, were measured in burner rigs at ~1250 °C/1050 °C surface/substrate exposure temperatures.

Shock tube studies of thermal radiation of diesel-spray combustion under a range of spray conditions

NASA Astrophysics Data System (ADS)

Tsuboi, T.; Kurihara, Y.; Takasaki, M.; Katoh, R.; Ishii, K.

2007-05-01

A tailored interface shock tube and an over-tailored interface shock tube were used to measure the thermal energy radiated during diesel-spray combustion of light oil, α-methylnaphthalene and cetane by changing the injection pressure. The ignition delay of methanol and the thermal radiation were also measured. Experiments were performed in a steel shock tube with a 7 m low-pressure section filled with air and a 6 m high-pressure section. Pre-compressed fuel was injected through a throttle nozzle into air behind a reflected shock wave. Monochromatic emissive power and the power emitted across all infrared wavelengths were measured with IR-detectors set along the central axis of the tube. Time-dependent radii where soot particles radiated were also determined, and the results were as follows. For diesel spray combustion with high injection pressures (from 10 to 80 MPa), the thermal radiation energy of light oil per injection increased with injection pressure from 10 to 30 MPa. The energy was about 2% of the heat of combustion of light oil at P inj = about 30 MPa. At injection pressure above 30 MPa the thermal radiation decreased with increasing injection pressure. This profile agreed well with the combustion duration, the flame length, the maximum amount of soot in the flame, the time-integrated soot volume and the time-integrated flame volume. The ignition delay of light oil was observed to decrease monotonically with increasing fuel injection pressure. For diesel spray combustion of methanol, the thermal radiation including that due to the gas phase was 1% of the combustion heat at maximum, and usually lower than 1%. The thermal radiation due to soot was lower than 0.05% of the combustion heat. The ignition delays were larger (about 50%) than those of light oil. However, these differences were within experimental error.

Epitaxial Growth and Cracking Mechanisms of Thermally Sprayed Ceramic Splats

NASA Astrophysics Data System (ADS)

Chen, Lin; Yang, Guan-jun

2018-02-01

In the present study, the epitaxial growth and cracking mechanisms of thermally sprayed ceramic splats were explored. We report, for the first time, the epitaxial growth of various splat/substrate combinations at low substrate temperatures (100 °C) and large lattice mismatch (- 11.26%). Our results suggest that thermal spray deposition was essentially a liquid-phase epitaxy, readily forming chemical bonding. The interface temperature was also estimated. The results convincingly demonstrated that atoms only need to diffuse and rearrange over a sufficiently short range during extremely rapid solidification. Concurrently, severe cracking occurred in the epitaxial splat/substrate systems, which indicated high tensile stress was produced during splat deposition. The origin of the tensile stress was attributed to the strong constraint of the locally heated substrate by its cold surroundings.

High Thermal Conductivity Carbon Nanomaterials for Improved Thermal Management in Armament Composites

DTIC Science & Technology

2017-03-01

polymer matrices. In addition to improving mechanical and electrical properties, these forms of carbon typically demonstrate high intrinsic thermal...conductivities, a property that could be useful in improving the thermal dissipation performance of polymer matrix composites. In this study, carbon...nanotubes, carbon nanofibers and graphene have been added to polymers and polymer matrix composites in order to study the effect on the thermal

Spray forming polymer membranes, coatings and films

DOEpatents

McHugh, Kevin M.; Watson, Lloyd D.; McAtee, Richard E.; Ploger, Scott A.

1993-01-01

A method of forming a polymer film having controlled physical and chemical characteristics, wherein a plume of nebulized droplets of a polymer or polymer precursor is directed toward a substrate from a converging/diverging nozzle having a throat at which the polymer or a precursor thereof is introduced and an exit from which the nebulized droplets of the polymer or precursor thereof leave entrained in a carrier gas. Relative movement between the nozzle and the substrate is provided to form a polymer film. Physical and chemical characteristics can be controlled by varying the deposition parameters and the gas and liquid chemistries. Semipermeable membranes of polyphosphazene films are disclosed, as are a variety of other polymer systems, both porous and non-porous.

Conductive polymer and Si nanoparticles composite secondary particles and structured current collectors for high loading lithium ion negative electrode application

DOEpatents

Liu, Gao

2017-07-11

Embodiments of the present invention disclose a composition of matter comprising a silicon (Si) nanoparticle coated with a conductive polymer. Another embodiment discloses a method for preparing a composition of matter comprising a plurality of silicon (Si) nanoparticles coated with a conductive polymer comprising providing Si nanoparticles, providing a conductive polymer, preparing a Si nanoparticle, conductive polymer, and solvent slurry, spraying the slurry into a liquid medium that is a non-solvent of the conductive polymer, and precipitating the silicon (Si) nanoparticles coated with the conductive polymer. Another embodiment discloses an anode comprising a current collector, and a composition of matter comprising a silicon (Si) nanoparticle coated with a conductive polymer.

Spray forming polymer membranes, coatings and films

DOEpatents

McHugh, K.M.; Watson, L.D.; McAtee, R.E.; Ploger, S.A.

1993-10-12

A method is described for forming a polymer film having controlled physical and chemical characteristics, wherein a plume of nebulized droplets of a polymer or polymer precursor is directed toward a substrate from a converging/diverging nozzle having a throat at which the polymer or a precursor thereof is introduced and an exit from which the nebulized droplets of the polymer or precursor thereof leave entrained in a carrier gas. Relative movement between the nozzle and the substrate is provided to form a polymer film. Physical and chemical characteristics can be controlled by varying the deposition parameters and the gas and liquid chemistries. Semipermeable membranes of polyphosphazene films are disclosed, as are a variety of other polymer systems, both porous and non-porous. 4 figures.

Determination of residual acetone and acetone related impurities in drug product intermediates prepared as Spray Dried Dispersions (SDD) using gas chromatography with headspace autosampling (GCHS).

PubMed

Quirk, Emma; Doggett, Adrian; Bretnall, Alison

2014-08-05

Spray Dried Dispersions (SDD) are uniform mixtures of a specific ratio of amorphous active pharmaceutical ingredient (API) and polymer prepared via a spray drying process. Volatile solvents are employed during spray drying to facilitate the formation of the SDD material. Following manufacture, analytical methodology is required to determine residual levels of the spray drying solvent and its associated impurities. Due to the high level of polymer in the SDD samples, direct liquid injection with Gas Chromatography (GC) is not a viable option for analysis. This work describes the development and validation of an analytical approach to determine residual levels of acetone and acetone related impurities, mesityl oxide (MO) and diacetone alcohol (DAA), in drug product intermediates prepared as SDDs using GC with headspace (HS) autosampling. The method development for these analytes presented a number of analytical challenges which had to be overcome before the levels of the volatiles of interest could be accurately quantified. GCHS could be used after two critical factors were implemented; (1) calculation and application of conversion factors to 'correct' for the reactions occurring between acetone, MO and DAA during generation of the headspace volume for analysis, and the addition of an equivalent amount of polymer into all reference solutions used for quantitation to ensure comparability between the headspace volumes generated for both samples and external standards. This work describes the method development and optimisation of the standard preparation, the headspace autosampler operating parameters and the chromatographic conditions, together with a summary of the validation of the methodology. The approach has been demonstrated to be robust and suitable to accurately determine levels of acetone, MO and DAA in SDD materials over the linear concentration range 0.008-0.4μL/mL, with minimum quantitation limits of 20ppm for acetone and MO, and 80ppm for DAA. Copyright © 2014 Elsevier B.V. All rights reserved.

Impact of a heterogeneous liquid droplet on a dry surface: application to the pharmaceutical industry.

PubMed

Bolleddula, D A; Berchielli, A; Aliseda, A

2010-09-15

Droplet impact has been studied for over a hundred years dating back to the pioneering work of Worthington. In fact, much of his ingenuity contributed to modern day high speed photography. Over the past 40 years significant contributions in theoretical, numerical, and experimental work have been made. Droplet impact is a problem of fundamental importance due to the wealth of applications involved, namely, spray coating, spray painting, delivery of agricultural chemicals, spray cooling, inkjet printing, soil erosion due to rain drop impact, and turbine wear. Here we highlight one specific application, spray coating. Although most studies have focused their efforts on low viscosity Newtonian fluids, many industrial applications such as spray coating utilize more viscous and complex rheology liquids. Determining dominant effects and quantifying their behavior for colloidal suspensions and polymer solutions remains a challenge and thus has eluded much effort. In the last decade, it has been shown that introducing polymers to Newtonian solutions inhibits the rebounding of a drop upon impact, Bergeron et al. Furthermore Bartolo et al. concluded that the normal stress component of the elongational viscosity was responsible for the rebounding inhibition of polymer based non-Newtonian solutions. We aim to uncover the drop impact dynamics of highly viscous Newtonian and complex rheology liquids used in pharmaceutical coating processes. The generation and impact of drops of mm and microm size drops of coating liquids and glycerol/water mixtures on tablet surfaces are systematically studied over a range of We approximately O(1-300), Oh approximately O(10(-2)-1), and Re approximately O(1-700). We extend the range of Oh to values above 1, which are not available to previous studies of droplet impacts. Outcomes reveal that splashing and rebounding are completely inhibited and the role of wettability is negligible in the early stages of impact. The maximum spreading diameter of the drop is compared with three models demonstrating reasonable agreement. Copyright 2010 Elsevier B.V. All rights reserved.

A convective study of Al2O3-H2O and Cu- H2O nano-liquid films sprayed over a stretching cylinder with viscous dissipation

NASA Astrophysics Data System (ADS)

Alshomrani, Ali Saleh; Gul, Taza

2017-11-01

This study is related with the analysis of spray distribution considering a nanofluid thin layer over the slippery and stretching surface of a cylinder with thermal radiation. The distribution of the spray rate is designated as a function of the nanolayer thickness. The applied temperature used during spray phenomenon has been assumed as a reference temperature with the addition of the viscous dissipation term. The diverse behavior of the thermal radiation with magnetic and chemical reaction has been cautiously observed, which has consequences in causing variations in the spray distribution and heat transmission. Nanofluids have been used as water-based like Al2O3-H2O, Cu- H2O and have been examined under the consideration of momentum and thermal slip boundary conditions. The basic equations have been transformed into a set of nonlinear equations by using suitable variables for alteration. The approximate results of the problem have been achieved by using the optimal approach of the Homotopy Analysis Method (HAM). We demonstrate our results with the help of the numerical (ND-Solve) method. In addition, we found a close agreement of the two methods which is confirmed through graphs and tables. The rate of the spray pattern under the applied pressure term has also been obtained. The maximum cooling performance has been obtained by using the Cu water with the small values of the magnetic parameter and alumina for large values of the magnetic parameter. The outcomes of the Cu-water and Al2O3-H2O nanofluids have been linked to the published results in the literature. The impact of the physical parameters, like the skin friction coefficient, and the local Nusselt number have also been observed and compared with the published work. The momentum slip and thermal slip parameters, thermal radiation parameter, magnetic parameter and heat generation/absorption parameter effects on the spray rate have been calculated and 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.

Droplet-surface Impingement Dynamics for Intelligent Spray Design

NASA Technical Reports Server (NTRS)

VanderWal, Randy L.; Kizito, John P.; Tryggvason, Gretar; Berger, Gordon M.; Mozes, Steven D.

2004-01-01

Spray cooling has high potential in thermal management and life support systems by overcoming the deleterious effect of microgravity upon two-phase heat transfer. In particular spray cooling offers several advantages in heat flux removal that include the following: 1. By maintaining a wetted surface, spray droplets impinge upon a thin fluid film rather than a dry solid surface 2. Most heat transfer surfaces will not be smooth but rough. Roughness can enhance conductive cooling, aid liquid removal by flow channeling. 3. Spray momentum can be used to a) substitute for gravity delivering fluid to the surface, b) prevent local dryout and potential thermal runaway and c) facilitate liquid and vapor removal. Yet high momentum results in high We and Re numbers characterizing the individual spray droplets. Beyond an impingement threshold, droplets splash rather than spread. Heat flux declines and spray cooling efficiency can markedly decrease. Accordingly we are investigating droplet impingement upon a) dry solid surfaces, b) fluid films, c) rough surfaces and determining splashing thresholds and relationships for both dry surfaces and those covered by fluid films. We are presently developing engineering correlations delineating the boundary between splashing and non-splashing regions.

Polymer-based solar cells having an active area of 1.6 cm{sup 2} fabricated via spray coating

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

Scarratt, N. W.; Griffin, J.; Zhang, Y.

We demonstrate the fabrication of polymer solar cells in which both a PEDOT:PSS hole transport and a PCDTBT:PC{sub 71}BM photoactive layer are deposited by spray-casting. Two device geometries are explored, with devices having a pixel area of 165 mm{sup 2} attaining a power conversion efficiency of 3.7%. Surface metrology indicates that the PEDOT:PSS and PCDTBT:PC{sub 71}BM layers have a roughness of 2.57 nm and 1.18 nm over an area of 100 μm{sup 2}. Light beam induced current mapping reveals fluctuations in current generation efficiency over length-scales of ∼2 mm, with the average photocurrent being 75% of its maximum value.

Tuning the thermal conductivity of solar cell polymers through side chain engineering.

PubMed

Guo, Zhi; Lee, Doyun; Liu, Yi; Sun, Fangyuan; Sliwinski, Anna; Gao, Haifeng; Burns, Peter C; Huang, Libai; Luo, Tengfei

2014-05-07

Thermal transport is critical to the performance and reliability of polymer-based energy devices, ranging from solar cells to thermoelectrics. This work shows that the thermal conductivity of a low band gap conjugated polymer, poly(4,8-bis-alkyloxybenzo[1,2-b:4,5-b']dithiophene-2,6-diyl-alt-(alkylthieno[3,4-b]thiophene-2-carboxylate)-2,6-diyl) (PBDTTT), for photovoltaic applications can be actively tuned through side chain engineering. Compared to the original polymer modified with short branched side chains, the engineered polymer using all linear and long side chains shows a 160% increase in thermal conductivity. The thermal conductivity of the polymer exhibits a good correlation with the side chain lengths as well as the crystallinity of the polymer characterized using small-angle X-ray scattering (SAXS) experiments. Molecular dynamics simulations and atomic force microscopy are used to further probe the molecular level local order of different polymers. It is found that the linear side chain modified polymer can facilitate the formation of more ordered structures, as compared to the branched side chain modified ones. The effective medium theory modelling also reveals that the long linear side chain enables a larger heat carrier propagation length and the crystalline phase in the bulk polymer increases the overall thermal conductivity. It is concluded that both the length of the side chains and the induced polymer crystallization are important for thermal transport. These results offer important guidance for actively tuning the thermal conductivity of conjugated polymers through molecular level design.

Effect of methoprene treated polymer packaging on fecundity, egg hatchability, and egg-to-adult development of Tribolium castaneum and Trogoderma variabile

USDA-ARS?s Scientific Manuscript database

Methoprene is a commonly used insect growth regulator for aerosol sprays, residual surface treatments, and as a grain protectant. Methoprene has been impregnated into a polymer-based packing film to prevent insect infestations of packaged products. The objective of this study was to evaluate fecund...

In Vivo Laser Cartilage Reshaping with Carbon Dioxide Spray Cooling in a Rabbit Ear Model: A Pilot Study

PubMed Central

Kuan, Edward C.; Hamamoto, Ashley A.; Sun, Victor; Nguyen, Tony; Manuel, Cyrus T.; Protsenko, Dmitry E.; Wong, Brian J.F.; Nelson, J. Stuart; Jia, Wangcun

2014-01-01

BACKGROUND/OBJECTIVES Similar to conventional cryogen spray cooling, carbon dioxide (CO2) spray may be used in combination with laser cartilage reshaping (LCR) to produce cartilage shape change while minimizing cutaneous thermal injury. Recent ex vivo evaluation of LCR with CO2 cooling in a rabbit model has identified a promising initial parameter space for in vivo safety and efficacy evaluation. This pilot study aimed to evaluate shape change and cutaneous injury following LCR with CO2 cooling in 5 live rabbits. STUDY DESIGN/MATERIALS AND METHODS The midportion of live rabbit ears were irradiated with a 1.45 μm wavelength diode laser (12 J/cm2) with simultaneous CO2 spray cooling (85 ms duration, 4 alternating heating/cooling cycles per site, 5 to 6 irradiation sites per row for 3 rows per ear). Experimental and control ears (no LCR) were splinted in the flexed position for 30 days following exposure. A total of 5 ears each were allocated to the experimental and control groups. RESULTS Shape change was observed in all irradiated ears (mean 70 ± 3°), which was statistically different from control (mean 37 ± 11 °, p = 0.009). No significant thermal cutaneous injury was observed, with preservation of the full thickness of skin, microvasculature, and adnexal structures. Confocal microscopy and histology demonstrated an intact and viable chondrocyte population surrounding irradiated sites. CONCLUSIONS LCR with CO2 spray cooling can produce clinically significant shape change in the rabbit auricle while minimizing thermal cutaneous and cartilaginous injury and frostbite. This pilot study lends support for the potential use of CO2 spray as an adjunct to existing thermal-based cartilage reshaping modalities. An in vivo systematic evaluation of optimal laser dosimetry and cooling parameters is required. PMID:25557008

Method of altering the effective bulk density of solid material and the resulting product

DOEpatents

Kool, Lawrence B.; Nolen, Robert L.; Solomon, David E.

1983-01-01

A method of adjustably tailoring the effective bulk density of a solid material in which a mixture comprising the solid material, a film-forming polymer and a volatile solvent are sprayed into a drying chamber such that the solvent evaporates and the polymer dries into hollow shells having the solid material captured within the shell walls. Shell density may be varied as a function of solid/polymer concentration, droplet size and drying temperature.

Thermal transfer in extracted incisors during thermal pulp sensitivity testing.

PubMed

Linsuwanont, P; Palamara, J E; Messer, H H

2008-03-01

To measure the temperature distribution within tooth structure during and after application of thermal stimuli used during pulp sensitivity testing. Extracted intact human maxillary anterior teeth were investigated for temperature changes at the labial enamel, the dentino-enamel junction (DEJ) and pulpal surface during and after a 5-s application of six different thermal stimuli: hot water (80 degrees C), heated gutta-percha (140 degrees C), carbon dioxide dry ice (-72 degrees C), refrigerant spray (-50 degrees C), ice stick (0 degrees C) and cold water (2 degrees C). J-type thermocouples and heat conduction paste were used to detect temperature changes, together with a data acquisition system (Labview). Data were analysed using analysis of variance, with a confidence level of P < 0.05. Temperature change was detected more quickly at the DEJ and pulpal surface with the application of hot water, heated gutta-percha and refrigerant spray than with carbon dioxide dry ice and ice (P < 0.05). Cold water and refrigerant spray were in the same range in terms of time to detect temperature change at both the DEJ and pulpal surface. Thermal stimuli with greater temperature difference from tooth temperature created a greater thermal gradient initially, followed by a greater temperature change at the DEJ and the pulpal surface. In this regard, ice and cold water were weaker stimuli than others (P < 0.05). Thermal stimuli used in pulp testing are highly variable in terms of temperature of the stimulus, rate of thermal transfer to the tooth and extent of temperature change within tooth structure. Overall, dry ice and refrigerant spray provide the most consistent stimuli, whereas heated gutta-percha and hot water were highly variable. Ice was a weak stimulus.

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.

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

NASA Astrophysics Data System (ADS)

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

2015-01-01

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

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.

Impact of sea spray on the Yellow and East China Seas thermal structure during the passage of Typhoon Rammasun (2002)

NASA Astrophysics Data System (ADS)

Zhang, Lianxin; Zhang, Xuefeng; Chu, P. C.; Guan, Changlong; Fu, Hongli; Chao, Guofang; Han, Guijun; Li, Wei

2017-10-01

Strong winds lead to large amounts of sea spray in the lowest part of the atmospheric boundary layer. The spray droplets affect the air-sea heat fluxes due to their evaporation and the momentum due to the change of sea surface, and in turn change the upper ocean thermal structure. In this study, impact of sea spray on upper ocean temperatures in the Yellow and East China Seas (YES) during typhoon Rammasun's passage is investigated using the POMgcs ocean model with a sea spray parameterization scheme, in which the sea spray-induced heat fluxes are based on an improved Fairall's sea spray heat fluxes algorithm, and the sea spray-induced momentum fluxes are derived from an improved COARE version 2.6 bulk model. The distribution of the sea spray mediated turbulent fluxes was primarily located at Rammasun eye-wall region, in accord with the maximal wind speeds regions. When Rammasun enters the Yellow sea, the sea spray mediated latent (sensible) heat flux maximum is enhanced by 26% (13.5%) compared to that of the interfacial latent (sensible) heat flux. The maximum of the total air-sea momentum fluxes is enhanced by 43% compared to the counterpart of the interfacial momentum flux. Furthermore, the sea spray plays a key role in enhancing the intensity of the typhoon-induced "cold suction" and "heat pump" processes. When the effect of sea spray is considered, the maximum of the sea surface cooling in the right side of Rammasun's track is increased by 0.5°C, which is closer to the available satellite observations.

Investigation of Spray Cooling Schemes for Dynamic Thermal Management

NASA Astrophysics Data System (ADS)

Yata, Vishnu Vardhan Reddy

This study aims to investigate variable flow and intermittent flow spray cooling characteristics for efficiency improvement in active two-phase thermal management systems. Variable flow spray cooling scheme requires control of pump input voltage (or speed), while intermittent flow spray cooling scheme requires control of solenoid valve duty cycle and frequency. Several testing scenarios representing dynamic heat load conditions are implemented to characterize the overall performance of variable flow and intermittent flow spray cooling cases in comparison with the reference, steady flow spray cooling case with constant flowrate, continuous spray cooling. Tests are conducted on a small-scale, closed loop spray cooling system featuring a pressure atomized spray nozzle. HFE-7100 dielectric liquid is selected as the working fluid. Two types of test samples are prepared on 10 mm x 10 mm x 2 mm copper substrates with matching size thick film resistors attached onto the opposite side, to generate heat and simulate high heat flux electronic devices. The test samples include: (i) plain, smooth surface, and (ii) microporous surface featuring 100 ?m thick copper-based coating prepared by dual stage electroplating technique. Experimental conditions involve HFE-7100 at atmospheric pressure and 30°C and 10°C subcooling. Steady flow spray cooling tests are conducted at flow rates of 2-5 ml/cm2.s, by controlling the heat flux in increasing steps, and recording the corresponding steady-state temperatures to obtain cooling curves in the form of surface superheat vs. heat flux. Variable flow and intermittent flow spray cooling tests are done at selected flowrate and subcooling conditions to investigate the effects of dynamic flow conditions on maintaining the target surface temperatures defined based on reference steady flow spray cooling performance.

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.

High thermal conductivity in electrostatically engineered amorphous polymers

PubMed Central

Shanker, Apoorv; Li, Chen; Kim, Gun-Ho; Gidley, David; Pipe, Kevin P.; Kim, Jinsang

2017-01-01

High thermal conductivity is critical for many applications of polymers (for example, packaging of light-emitting diodes), in which heat must be dissipated efficiently to maintain the functionality and reliability of a system. Whereas uniaxially extended chain morphology has been shown to significantly enhance thermal conductivity in individual polymer chains and fibers, bulk polymers with coiled and entangled chains have low thermal conductivities (0.1 to 0.4 W m−1 K−1). We demonstrate that systematic ionization of a weak anionic polyelectrolyte, polyacrylic acid (PAA), resulting in extended and stiffened polymer chains with superior packing, can significantly enhance its thermal conductivity. Cross-plane thermal conductivity in spin-cast amorphous films steadily grows with PAA degree of ionization, reaching up to ~1.2 W m−1 K−1, which is on par with that of glass and about six times higher than that of most amorphous polymers, suggesting a new unexplored molecular engineering strategy to achieve high thermal conductivities in amorphous bulk polymers. PMID:28782022

Influence of Bondcoat Spray Process on Lifetime of Suspension Plasma-Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Gupta, M.; Markocsan, N.; Li, X.-H.; Östergren, L.

2017-12-01

Development of thermal barrier coatings (TBCs) manufactured by suspension plasma spraying (SPS) is of high commercial interest as SPS has been shown capable of producing highly porous columnar microstructures similar to the conventionally used electron beam-physical vapor deposition. However, lifetime of SPS coatings needs to be improved further to be used in commercial applications. The bondcoat microstructure as well as topcoat-bondcoat interface topography affects the TBC lifetime significantly. The objective of this work was to investigate the influence of different bondcoat deposition processes for SPS topcoats. In this work, a NiCoCrAlY bondcoat deposited by high velocity air fuel (HVAF) was compared to commercial vacuum plasma-sprayed NiCoCrAlY and PtAl diffusion bondcoats. All bondcoat variations were prepared with and without grit blasting the bondcoat surface. SPS was used to deposit the topcoats on all samples using the same spray parameters. Lifetime of these samples was examined by thermal cyclic fatigue testing. Isothermal heat treatment was performed to study bondcoat oxidation over time. The effect of bondcoat deposition process and interface topography on lifetime in each case has been discussed. The results show that HVAF could be a suitable process for bondcoat deposition in SPS TBCs.

Influence of Bondcoat Spray Process on Lifetime of Suspension Plasma-Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Gupta, M.; Markocsan, N.; Li, X.-H.; Östergren, L.

2018-01-01

Development of thermal barrier coatings (TBCs) manufactured by suspension plasma spraying (SPS) is of high commercial interest as SPS has been shown capable of producing highly porous columnar microstructures similar to the conventionally used electron beam-physical vapor deposition. However, lifetime of SPS coatings needs to be improved further to be used in commercial applications. The bondcoat microstructure as well as topcoat-bondcoat interface topography affects the TBC lifetime significantly. The objective of this work was to investigate the influence of different bondcoat deposition processes for SPS topcoats. In this work, a NiCoCrAlY bondcoat deposited by high velocity air fuel (HVAF) was compared to commercial vacuum plasma-sprayed NiCoCrAlY and PtAl diffusion bondcoats. All bondcoat variations were prepared with and without grit blasting the bondcoat surface. SPS was used to deposit the topcoats on all samples using the same spray parameters. Lifetime of these samples was examined by thermal cyclic fatigue testing. Isothermal heat treatment was performed to study bondcoat oxidation over time. The effect of bondcoat deposition process and interface topography on lifetime in each case has been discussed. The results show that HVAF could be a suitable process for bondcoat deposition in SPS TBCs.

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.

Porosity and wear resistance of flame sprayed tungsten carbide coatings

NASA Astrophysics Data System (ADS)

Winarto, Winarto; Sofyan, Nofrijon; Rooscote, Didi

2017-06-01

Thermal-sprayed coatings offer practical and economical solutions for corrosion and wear protection of components or tools. To improve the coating properties, heat treatment such as preheat is applied. The selection of coating and substrate materials is a key factor in improving the quality of the coating morphology after the heat treatment. This paper presents the experimental results regarding the effect of preheat temperatures, i.e. 200°C, 300°C and 400°C, on porosity and wear resistance of tungsten carbide (WC) coating sprayed by flame thermal coating. The powders and coatings morphology were analyzed by a Field Emission Scanning Electron Microscope equipped with Energy Dispersive Spectrometry (FE-SEM/EDS), whereas the phase identification was performed by X-Ray diffraction technique (XRD). In order to evaluate the quality of the flame spray obtained coatings, the porosity, micro-hardness and wear rate of the specimens was determined. The results showed that WC coating gives a higher surface hardness from 1391 HVN up to 1541 HVN compared to that of the non-coating. Moreover, the wear rate increased from 0.072 mm3/min. to 0.082 mm3/min. when preheat temperature was increased. Preheat on H13 steel substrate can reduce the percentage of porosity level from 10.24 % to 3.94% on the thermal spray coatings.

Evaporative cooling by a pulsed jet spray of binary ethanol-water mixture

NASA Astrophysics Data System (ADS)

Karpov, P. N.; Nazarov, A. D.; Serov, A. F.; Terekhov, V. I.

2015-07-01

We have experimentally studied the heat transfer under conditions of pulsed multinozzle jet spray impact onto a vertical surface. The working coolant fluid was aqueous ethanol solution in a range of concentrations K 1 = 0-96%. The duration of spray pulses was τ = 2, 4, and 10 ms at a repetition frequency of 10 Hz. The maximum heat transfer coefficient was achieved at an ethanol solution concentration within 50-60%. The thermal efficiency of pulsed spray cooling grows with increasing ethanol concentration and decreasing jet spray pulse duration.

Evaluation of thermal cooling mechanisms for laser application to teeth.

PubMed

Miserendino, L J; Abt, E; Wigdor, H; Miserendino, C A

1993-01-01

Experimental cooling methods for the prevention of thermal damage to dental pulp during laser application to teeth were compared to conventional treatment in vitro. Pulp temperature measurements were made via electrical thermistors implanted within the pulp chambers of extracted human third molar teeth. Experimental treatments consisted of lasing without cooling, lasing with cooling, laser pulsing, and high-speed dental rotary drilling. Comparisons of pulp temperature elevation measurements for each group demonstrated that cooling by an air and water spray during lasing significantly reduced heat transfer to dental pulp. Laser exposures followed by an air and water spray resulted in pulp temperature changes comparable to conventional treatment by drilling. Cooling by an air water spray with evacuation appears to be an effective method for the prevention of thermal damage to vital teeth following laser exposure.

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.

Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings

DOE PAGES

Wang, Hsin; Muralidharan, Govindarajan; Leonard, Donovan N.; ...

2018-01-04

In this paper, 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.more » 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. Finally, the microstructure of the multilayer coating was examined using scanning electron microscope and electron probe microanalysis.« less

Microstructural Analysis and Transport Properties of Thermally Sprayed Multiple-Layer Ceramic Coatings

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

Wang, Hsin; Muralidharan, Govindarajan; Leonard, Donovan N.

In this paper, 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.more » 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. Finally, the microstructure of the multilayer coating was examined using scanning electron microscope and electron probe microanalysis.« less

Response of female Ceratitis capitata (Diptera: Tephritidae) to a spinosad bait and polymer matrix mixture with extended residual effect in Hawaii.

PubMed

Piñero, Jaime C; Souder, Steven K; Gomez, Luis E; Mau, Ronald F L; Vargas, Roger I

2011-12-01

The effectiveness of foliar applications of protein baits against pestiferous fruit flies (Tephritidae) can be adversely affected by a rapid loss of attractive volatile compounds and by rainfall due to the high water solubility of the baits. In a large coffee, Coffea arabica L., plantation in Hawaii with high and low populations of Mediterranean fruit fly, Ceratitis capitata (Wiedemann) (Diptera: Tephritidae), the relative attractiveness of GF-120 NF Naturalyte Fruit Fly Bait as either a 40% (vol:vol) spray solution (= GF-120 NF) or as a formulated proprietary amorphous polymer matrix (= GF-120 APM) was compared. The GF-120 APM formulations contained either, 25, 50, or 75% of GF-120 NF (wt:wt). All baits were tested in association with visually attractive yellow bait stations as a way of standardizing the evaluations. With both high and low C. capitata populations, significantly more females were attracted to the fresh sprayed GF-120 NF than to any of the three fresh GF-120 APM formulations. The attractiveness of GF-120 sprayed decreased significantly after 1 wk, whereas 1-wk-old GF-120 APM formulations were as attractive as similar fresh formulations. GF-120 APM 75% aged for 3 wk outperformed similarly-aged sprayed GF-120 NF with comparatively high C. capitata populations. With low populations, both GF-120 APM 75% and GF-120 APM 50% aged for 2 wk outperformed the similarly aged sprayed GF-120 NF. Combined findings indicate that APM mixed with either 50 or 75% GF-120 applied to bait stations can be attractive to female C. capitata for up to 3 wk longer than the standard sprayed GF-120 NF.

Microencapsulation of superoxide dismutase into biodegradable microparticles by spray-drying.

PubMed

Youan, Bi-Botti Célestin

2004-01-01

The aim of this work was to encapsulate superoxide dismutase (SOD) into biodegradable microparticles by spray-drying technique. The nature of the organic solvent to dissolve the polymer, the method of incorporation of the drug in the organic phase (with or without a surfactant, namely sucrose ester of HLB = 6), the surfactant/polymer ratio, and the nature of the biodegradable polyesters were investigated as formulation variables. The polyesters investigated as matrix were poly(epsilon-caprolactone) (PCL), poly(d, l, lactide-co-glycolide) (PLG-RG756), and poly(d, l-lactide) (PLA-R207) of respective molecular weight 78.2 kDa, 84.8 kDa, and 199.8 kDa. At surfactant/polymer ratio of 1/10, the SOD-retained enzymatic activities were higher (> 95%) for PLG-RG756 and PLA-R207 but relatively lower for the PCL (approximately 85%) probably due to the PCL relatively higher hydrophobicity. The obtained microparticles exhibited average volume mean diameter of 4-10 microm, the smaller for PCL and the larger for PLG-RG756 polymeric matrix. The in vitro release profile showed that SOD was completely (100%) released from PLA-R207 in 48 hr and from PLG-RG756 and PCL within 72 hr. These results showed that spray-drying with incorporation of surfactant such as sucrose ester may efficiently encapsulate SOD into biodegradable microparticles. Such formulations may improve the bioavailability of SOD and similar biopharmaceuticals.

Spray Drying as a Reliable Route to Produce Metastable Carbamazepine Form IV.

PubMed

Halliwell, Rebecca A; Bhardwaj, Rajni M; Brown, Cameron J; Briggs, Naomi E B; Dunn, Jaclyn; Robertson, John; Nordon, Alison; Florence, Alastair J

2017-07-01

Carbamazepine (CBZ) is an active pharmaceutical ingredient used in the treatment of epilepsy that can form at least 5 polymorphic forms. Metastable form IV was originally discovered from crystallization with polymer additives; however, it has not been observed from subsequent solvent-only crystallization efforts. This work reports the reproducible formation of phase pure crystalline form IV by spray drying of methanolic CBZ solution. Characterization of the material was carried out using diffraction, scanning electron microscopy, and differential scanning calorimetry. In situ Raman spectroscopy was used to monitor the spray-dried product during the spray drying process. This work demonstrates that spray drying provides a robust method for the production of form IV CBZ, and the combination of high supersaturation and rapid solid isolation from solution overcomes the apparent limitation of more traditional solution crystallization approaches to produce metastable crystalline forms. Copyright © 2017 The Authors. Published by Elsevier Inc. All rights reserved.

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.

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

Colour Matching in Decorative Thermally Sprayed Glass Coatings

NASA Astrophysics Data System (ADS)

Poirier, Thierry; Bertrand, Pierre; Coddet, Christian

2013-02-01

Coloured coatings were obtained on steel by plasma spraying without severe in-flight alteration of pigments, taking profit of the low thermal conductivity of the glassy matrix of glaze particles. Colour matching was studied by mixing 3 different glazes, comparing Grassmann and Kubelka-Munk based algorithms. Results suggest that the latter method should be preferred upon Grassmann method, particularly when the light absorption/dispersion ratios of coloured feedstocks are very different.

Thermoelectric Device Fabrication Using Thermal Spray and Laser Micromachining

NASA Astrophysics Data System (ADS)

Tewolde, Mahder; Fu, Gaosheng; Hwang, David J.; Zuo, Lei; Sampath, Sanjay; Longtin, Jon P.

2016-02-01

Thermoelectric generators (TEGs) are solid-state devices that convert heat directly into electricity. They are used in many engineering applications such as vehicle and industrial waste-heat recovery systems to provide electrical power, improve operating efficiency and reduce costs. State-of-art TEG manufacturing is based on prefabricated materials and a labor-intensive process involving soldering, epoxy bonding, and mechanical clamping for assembly. This reduces their durability and raises costs. Additive manufacturing technologies, such as thermal spray, present opportunities to overcome these challenges. In this work, TEGs have been fabricated for the first time using thermal spray technology and laser micromachining. The TEGs are fabricated directly onto engineering component surfaces. First, current fabrication techniques of TEGs are presented. Next, the steps required to fabricate a thermal spray-based TEG module, including the formation of the metallic interconnect layers and the thermoelectric legs are presented. A technique for bridging the air gap between two adjacent thermoelectric elements for the top layer using a sacrificial filler material is also demonstrated. A flat 50.8 mm × 50.8 mm TEG module is fabricated using this method and its performance is experimentally characterized and found to be in agreement with expected values of open-circuit voltage based on the materials used.

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.

Sporicidal efficacy of thermal-sprayed copper alloy coating.

PubMed

Shafaghi, Romina; Mostaghimi, Javad; Pershin, Valerian; Ringuette, Maurice

2017-05-01

Approximately 200 000 Canadians acquire healthcare-associated bacterial infections each year and several-fold more acquire food-borne bacterial illnesses. Bacterial spores are particularly problematic because they can survive on surfaces for several months. Owing to its sporicidal activity, copper alloy sheet metal is sometimes used in hospital settings, but its widespread use is limited by cost and incompatibility with complex furniture and instrument designs and topographies. A potential alternative is the use of thermal spray technology to coat surfaces with copper alloys. We compared the sporicidal activity of thermally sprayed copper alloy on stainless steel with that of copper alloy sheet metal against Bacillus subtilis spores. Spores remained intact for at least 1 week on uncoated stainless steel, whereas spore fragmentation was initiated within 2 h of exposure to either copper surface. Less than 15% of spores were viable 2 h after exposure to either copper surface, as compared with stainless steel. By day 7, only degraded spores and petal-like nanoflowers were present on the copper surfaces. Nanoflowers, which are laminar arrangements of thin crystal sheets composed of carbon - copper phosphate, appeared to be derived from the degraded spores. Altogether, these results indicate that a thermal-sprayed copper alloy coating on stainless steel provides sporicidal activity similar to that afforded by copper alloy sheet metal.

Fabrication of polymer/cadmium sulfide hybrid solar cells [P3HT:CdS and PCPDTBT:CdS] by spray deposition.

PubMed

Kumar, Neetesh; Dutta, Viresh

2014-11-15

This paper investigates fabrication of surfactant free CdS nanoparticles (NPs) and application in the fabrication of P3HT:CdS and PCPDTBT:CdS bulk-heterojunction hybrid solar cells using high-throughput, large-area, low cost spray deposition technique. Both the hybrid active layers and hole transport layers are deposited by spray technique. The CdS/Poly(3-hexylthiophene-2,5-diyl) (P3HT) and CdS/Poly[2,6-(4,4-bis-(2-ethylhexyl)-4H-cyclopenta[2,1-b;3,4-b']dithiophene)-alt-4,7(2,1,3-benzothiadiazole)] (PCPDTBT) hybrid devices are fabricated by spray deposition process at optimized conditions (i.e. film thickness, spray solution volume, distance between sample and spray nozzle, substrate temperature, etc.). The power conversion efficiency of η=0.6% and 1.02% is obtained for P3HT:CdS and PCPDTBT:CdS hybrid devices, respectively. Spray coating holds significant promise as a technique capable of fabricating large-area, high performance hybrid solar cells. Copyright © 2014 Elsevier Inc. All rights reserved.

Preparation and Analysis of Co-precipitated, Biodegradable Poly-(Lactide-co-Glycolide) and Polyethylene Glycol Microspheres Prepared by Spray Drying

NASA Astrophysics Data System (ADS)

Javiya, Curie

Biodegradable poly-(d,l-lactide-co-glycolide) (PLGA) based microspheres are commonly used for numerous clinical applications. PEG is a widely used polymer due to its hydrophilic, biocompatible, and nontoxic nature. In this study, different blends of PLGA/PEG microspheres were prepared using a spray drying technique. The microspheres were spherical with maximum yield found to be 60.3% and average particle size in the range of 2.4 to 3.1 microm. Under the spray drying processing conditions, the polymers showed full miscibility slightly below 15% w/w and partial miscibility up to 20% w/w of PEG in the blended microspheres. At higher temperatures, PLGA and PEG were miscible in all proportions used for the blended microspheres. Blending 10% w/w PEG in PLGA membranes showed significant reduction in attachment of macrophages compared to PLGA membranes. The in-vitro response of macrophage towards the miscible blends of PLGA/PEG microspheres was further characterized. Results showed some reduction in macrophage viability and activation, however, significant effects with PLGA/PEG microspheres were not observed.

A demonstration of the antimicrobial effectiveness of various copper surfaces

PubMed Central

2013-01-01

Background Bacterial contamination on touch surfaces results in increased risk of infection. In the last few decades, work has been done on the antimicrobial properties of copper and its alloys against a range of micro-organisms threatening public health in food processing, healthcare and air conditioning applications; however, an optimum copper method of surface deposition and mass structure has not been identified. Results A proof-of-concept study of the disinfection effectiveness of three copper surfaces was performed. The surfaces were produced by the deposition of copper using three methods of thermal spray, namely, plasma spray, wire arc spray and cold spray The surfaces were then inoculated with meticillin-resistant Staphylococcus aureus (MRSA). After a two hour exposure to the surfaces, the surviving MRSA were assayed and the results compared. The differences in the copper depositions produced by the three thermal spray methods were examined in order to explain the mechanism that causes the observed differences in MRSA killing efficiencies. The cold spray deposition method was significantly more effective than the other methods. It was determined that work hardening caused by the high velocity particle impacts created by the cold spray technique results in a copper microstructure that enhances ionic diffusion, and copper ions are principally responsible for antimicrobial activity. Conclusions This test showed significant microbiologic differences between coatings produced by different spray techniques and demonstrates the importance of the copper application technique. The cold spray technique shows superior anti-microbial effectiveness caused by the high impact velocity imparted to the sprayed particles which results in high dislocation density and high ionic diffusivity. PMID:23537176

Toxic alveolitis after inhalation of a water repellent.

PubMed

Epping, Guido; Van Baarlen, Joop; Van Der Valk, Paul D L P M

2011-12-01

Inhalation of fluorocarbon polymers can cause pulmonary toxicity. Although multiple cases of lung injury have been reported, cellular characterization of the associated alveolitis occurring acutely after inhalation is limited. We report the case of a previously healthy woman who presented at our Emergency Department with an acute pneumonitis following inhalation of a fluorocarbon polymer-based rain-proofing spray. Bronchoalveolar lavage (BAL) performed shortly after the presentation showed an elevated total cell count, with a high proportion of neutrophils (58%) and eosinophils (9%). In addition, a lipid stain (Oil-Red-O-stain) showed a high level of lipid laden macrophages, a marker that could reflect a direct toxic effect of the spray on alveolar cells. The patient made a full recovery after four days of in-hospital observation with supportive care.

Improved the microstructures and properties of M3:2 high-speed steel by spray forming and niobium alloying

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

Lu, L.; Hou, L.G., E-mail: lghou@skl.ustb.edu.cn; Zhang, J.X.

The microstructures and properties of spray formed (SF) high-speed steels (HSSs) with or without niobium (Nb) addition were studied. Particular emphasis was placed on the effect of Nb on the solidification microstructures, decomposition of M{sub 2}C carbides, thermal stability and mechanical properties. The results show that spray forming can refine the cell size of eutectic carbides due to the rapid cooling effect during atomization. With Nb addition, further refinement of the eutectic carbides and primary austenite grains are obtained. Moreover, the Nb addition can accelerate the decomposition of M{sub 2}C carbides and increase the thermal stability of high-speed steel, andmore » also can improve the hardness and bending strength with slightly decrease the impact toughness. The high-speed steel made by spray forming and Nb alloying can give a better tool performance compared with powder metallurgy M3:2 and commercial AISI M2 high-speed steels. - Highlights: • Spray forming can effectively refine the microstructure of M3:2 steel. • Niobium accelerates the decomposition of M{sub 2}C carbides. • Niobium increases the hardness and bending strength of spray formed M3:2 steel. • Spray-formed niobium-containing M3:2 steel has the best tool performance.« less

High-volume use of self-cementing spray dry absorber material for structural applications

NASA Astrophysics Data System (ADS)

Riley, Charles E.

Spray dry absorber (SDA) material, or spray dryer ash, is a byproduct of energy generation by coal combustion and sulfur emissions controls. Like any resource, it ought to be used to its fullest potential offsetting as many of the negative environmental impacts of coal combustion as possible throughout its lifecycle. Its cementitious and pozzolanic properties suggest it be used to augment or replace another energy and emissions intensive product: Portland cement. There is excellent potential for spray dryer ash to be used beneficially in structural applications, which will offset CO2 emissions due to Portland cement production, divert landfill waste by further utilizing a plentiful coal combustion by-product, and create more durable and sustainable structures. The research into beneficial use applications for SDA material is relatively undeveloped and the material is highly underutilized. This dissertation explored a specific self-cementing spray dryer ash for use as a binder in structural materials. Strength and stiffness properties of hydrated spray dryer ash mortars were improved by chemical activation with Portland cement and reinforcement with polymer fibers from automobile tire recycling. Portland cement at additions of five percent of the cementitious material was found to function effectively as an activating agent for spray dryer ash and had a significant impact on the hardened properties. The recycled polymer fibers improved the ductility and toughness of the material in all cases and increased the compressive strength of weak matrix materials like the pure hydrated ash. The resulting hardened materials exhibited useful properties that were sufficient to suggest that they be used in structural applications such as concrete, masonry block, or as a hydraulic cement binder. While the long-term performance characteristics remain to be investigated, from an embodied-energy and carbon emissions standpoint the material investigated here is far superior to Portland cement.

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.

Atypical effects of incorporated surfactants on stability and dissolution properties of amorphous polymeric dispersions.

PubMed

Al-Obaidi, Hisham; Lawrence, M Jayne; Buckton, Graham

2016-11-01

To understand the impact of ionic and non-ionic surfactants on the dissolution and stability properties of amorphous polymeric dispersions using griseofulvin (GF) as a model for poorly soluble drugs. Solid dispersions of the poorly water-soluble drug, griseofulvin (GF) and the polymers, poly(vinylpyrrolidone) (PVP) and poly(2-hydroxypropyl methacrylate) (PHPMA), have been prepared by spray drying and bead milling and the effect of the ionic and non-ionic surfactants, namely sodium dodecyl sulphate (SDS) and Tween-80, on the physico-chemical properties of the solid dispersions studied. The X-ray powder diffraction data and hot-stage microscopy showed a fast re-crystallisation of GF. While dynamic vapour sorption (DVS) measurements indicated an increased water uptake, slow dissolution rates were observed for the solid dispersions incorporating surfactants. The order by which surfactants free dispersions were prepared seemed critical as indicated by DVS and thermal analysis. Dispersions prepared by milling with SDS showed significantly better stability than spray-dried dispersions (drug remained amorphous for more than 6 months) as well as improved dissolution profile. We suggest that surfactants can hinder the dissolution by promoting aggregation of polymeric chains, however that effect depends mainly on how the particles were prepared. © 2016 Royal Pharmaceutical Society.

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.

Optimizing Compliance and Thermal Conductivity of Plasma Sprayed Thermal Barrier Coatings via Controlled Powders and Processing Strategies

NASA Astrophysics Data System (ADS)

Tan, Yang; Srinivasan, Vasudevan; Nakamura, Toshio; Sampath, Sanjay; Bertrand, Pierre; Bertrand, Ghislaine

2012-09-01

The properties and performance of plasma-sprayed thermal barrier coatings (TBCs) are strongly dependent on the microstructural defects, which are affected by starting powder morphology and processing conditions. Of particular interest is the use of hollow powders which not only allow for efficient melting of zirconia ceramics but also produce lower conductivity and more compliant coatings. Typical industrial hollow spray powders have an assortment of densities resulting in masking potential advantages of the hollow morphology. In this study, we have conducted process mapping strategies using a novel uniform shell thickness hollow powder to control the defect microstructure and properties. Correlations among coating properties, microstructure, and processing reveal feasibility to produce highly compliant and low conductivity TBC through a combination of optimized feedstock and processing conditions. The results are presented through the framework of process maps establishing correlations among process, microstructure, and properties and providing opportunities for optimization of TBCs.

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.

Significantly High Thermal Rectification in an Asymmetric Polymer Molecule Driven by Diffusive versus Ballistic Transport.

PubMed

Ma, Hao; Tian, Zhiting

2018-01-10

Tapered bottlebrush polymers have novel nanoscale polymer architecture. Using nonequilibrium molecular dynamics simulations, we showed that these polymers have the unique ability to generate thermal rectification in a single polymer molecule and offer an exceptional platform for unveiling different heat conduction regimes. In sharp contrast to all other reported asymmetric nanostructures, we observed that the heat current from the wide end to the narrow end (the forward direction) in tapered bottlebrush polymers is smaller than that in the opposite direction (the backward direction). We found that a more disordered to less disordered structural transition within tapered bottlebrush polymers is essential for generating nonlinearity in heat conduction for thermal rectification. Moreover, the thermal rectification ratio increased with device length, reaching as high as ∼70% with a device length of 28.5 nm. This large thermal rectification with strong length dependence uncovered an unprecedented phenomenon-diffusive thermal transport in the forward direction and ballistic thermal transport in the backward direction. This is the first observation of radically different transport mechanisms when heat flow direction changes in the same system. The fundamentally new knowledge gained from this study can guide exciting research into nanoscale organic thermal diodes.

Tailoring Thermal Conductivity of Single-stranded Carbon-chain Polymers through Atomic Mass Modification

PubMed Central

Liao, Quanwen; Zeng, Lingping; Liu, Zhichun; Liu, Wei

2016-01-01

Tailoring the thermal conductivity of polymers is central to enlarge their applications in the thermal management of flexible integrated circuits. Progress has been made over the past decade by fabricating materials with various nanostructures, but a clear relationship between various functional groups and thermal properties of polymers remains to be established. Here, we numerically study the thermal conductivity of single-stranded carbon-chain polymers with multiple substituents of hydrogen atoms through atomic mass modification. We find that their thermal conductivity can be tuned by atomic mass modifications as revealed through molecular dynamics simulations. The simulation results suggest that heavy homogeneous substituents do not assist heat transport and trace amounts of heavy substituents can in fact hinder heat transport substantially. Our analysis indicates that carbon chain has the biggest contribution (over 80%) to the thermal conduction in single-stranded carbon-chain polymers. We further demonstrate that atomic mass modifications influence the phonon bands of bonding carbon atoms, and the discrepancies of phonon bands between carbon atoms are responsible for the remarkable drops in thermal conductivity and large thermal resistances in carbon chains. Our study provides fundamental insight into how to tailor the thermal conductivity of polymers through variable substituents. PMID:27713563

Effects of arc current on the life in burner rig thermal cycling of plasma sprayed ZrOsub2-Ysub2Osub3

NASA Technical Reports Server (NTRS)

Hendricks, R. C.; Mcdonald, G.

1982-01-01

An analysis of thermal cycle life data for four sets of eight thermal barrier coated specimens representing arc currents (plasma gun power) of 525, 600, 800, or 950 amps is presented. The ZrO2-8Y2O3/NiCrAlY plasma spray coated Rene 41 rods were thermal cycled to 1040 C in a Mach 0.3-Jet A/air burner flame. The experimental results indicate the existance of a minimum or threshold power level which coating life expectancy is less than 500 cycles. Above the threshold power level, coating life expectancy more than doubles and increases with arc current.

Effects of arc current on the life in burner rig thermal cycling of plasma sprayed ZrOsub2-Ysub2Osub3

NASA Astrophysics Data System (ADS)

Hendricks, R. C.; McDonald, G.

1982-02-01

An analysis of thermal cycle life data for four sets of eight thermal barrier coated specimens representing arc currents (plasma gun power) of 525, 600, 800, or 950 amps is presented. The ZrO2-8Y2O3/NiCrAlY plasma spray coated Rene 41 rods were thermal cycled to 1040 C in a Mach 0.3-Jet A/air burner flame. The experimental results indicate the existance of a minimum or threshold power level which coating life expectancy is less than 500 cycles. Above the threshold power level, coating life expectancy more than doubles and increases with arc current.

Development of Detonation Flame Sprayed Cu-Base Coatings Containing Large Ceramic Particles

NASA Astrophysics Data System (ADS)

Tillmann, Wolfgang; Vogli, Evelina; Nebel, Jan

2007-12-01

Metal-matrix composites (MMCs) containing large ceramic particles as superabrasives are typically used for grinding stone, minerals, and concrete. Sintering and brazing are the key manufacturing technologies for grinding tool production. However, restricted geometry flexibility and the absence of repair possibilities for damaged tool surfaces, as well as difficulties of controlling material interfaces, are the main weaknesses of these production processes. Thermal spraying offers the possibility to avoid these restrictions. The research for this paper investigated a fabrication method based on the use of detonation flame spraying technology to bond large superabrasive particles (150-600 μm, needed for grinding minerals and stones) in a metallic matrix. Layer morphology and bonding quality are evaluated with respect to superabrasive material, geometry, spraying, and powder-injection parameters. The influence of process temperature and the possibilities of thermal treatment of MMC layers are analyzed.

Heat, Mass and Aerosol Transfers in Spray Conditions for Containment Application

NASA Astrophysics Data System (ADS)

Porcheron, Emmanuel; Lemaitre, Pascal; Nuboer, Amandine; Vendel, Jacques

TOSQAN is an experimental program undertaken by the Institut de Radioprotection et de Surété Nucleaire (IRSN) in order to perform thermal hydraulic containment studies. The TOSQAN facility is a large enclosure devoted to simulating typical accidental thermal hydraulic flow conditions in nuclear Pressurized Water Reactor (PWR) containment. The TOSQAN facility, which is highly instrumented with non-intrusive optical diagnostics, is particularly adapted to nuclear safety CFD code validation. The present work is devoted to studying the interaction of a water spray injection used as a mitigation means in order to reduce the gas pressure and temperature in the containment, to produce gases mixing and washout of fission products. In order to have a better understanding of heat and mass transfers between spray droplets and the gas mixture, and to analyze mixing effects due to spray activation, we performed detailed characterization of the two-phase flow.

Composite foam structures

NASA Technical Reports Server (NTRS)

Williams, Brian E. (Inventor); Brockmeyer, Jerry (Inventor); Tuffias, Robert H. (Inventor)

2005-01-01

A composite rigid foam structure that has a skin or coating on at least one of its surfaces. The skin is formed in situ by thermal spray techniques. The skin is bonded substantially throughout the surface of the porous substrate to the peripheries of the pores. The skin on the average does not penetrate the surface of the substrate by more than the depth of about 2 to 5 pores. Thus, thermal spraying the skin onto the rigid foam produces a composite that is tightly and uniformly bonded together without unduly increasing the weight of the composite structure. Both thermal conductivity and bonding are excellent.

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.

Prediction of Phase Behavior of Spray-Dried Amorphous Solid Dispersions: Assessment of Thermodynamic Models, Standard Screening Methods and a Novel Atomization Screening Device with Regard to Prediction Accuracy

PubMed Central

Chavez, Pierre-François; Meeus, Joke; Robin, Florent; Schubert, Martin Alexander; Somville, Pascal

2018-01-01

The evaluation of drug–polymer miscibility in the early phase of drug development is essential to ensure successful amorphous solid dispersion (ASD) manufacturing. This work investigates the comparison of thermodynamic models, conventional experimental screening methods (solvent casting, quench cooling), and a novel atomization screening device based on their ability to predict drug–polymer miscibility, solid state properties (Tg value and width), and adequate polymer selection during the development of spray-dried amorphous solid dispersions (SDASDs). Binary ASDs of four drugs and seven polymers were produced at 20:80, 40:60, 60:40, and 80:20 (w/w). Samples were systematically analyzed using modulated differential scanning calorimetry (mDSC) and X-ray powder diffraction (XRPD). Principal component analysis (PCA) was used to qualitatively assess the predictability of screening methods with regards to SDASD development. Poor correlation was found between theoretical models and experimentally-obtained results. Additionally, the limited ability of usual screening methods to predict the miscibility of SDASDs did not guarantee the appropriate selection of lead excipient for the manufacturing of robust SDASDs. Contrary to standard approaches, our novel screening device allowed the selection of optimal polymer and drug loading and established insight into the final properties and performance of SDASDs at an early stage, therefore enabling the optimization of the scaled-up late-stage development. PMID:29518936

Modelling drug degradation in a spray dried polymer dispersion using a modified Arrhenius equation.

PubMed

Patterson, Adele; Ferreira, Ana P; Banks, Elizabeth; Skeene, Kirsty; Clarke, Graham; Nicholson, Sarah; Rawlinson-Malone, Clare

2015-01-15

The Pharmaceutical industry is increasingly utilizing amorphous technologies to overcome solubility challenges. A common approach is the use of drug in polymer dispersions to prevent recrystallization of the amorphous drug. Understanding the factors affecting chemical and physical degradation of the drug within these complex systems, e.g., temperature and relative humidity, is an important step in the selection of a lead formulation, and development of appropriate packaging/storage control strategies. The Arrhenius equation has been used as the basis of a number of models to predict the chemical stability of formulated product. In this work, we investigate the increase in chemical degradation seen for one particular spray dried dispersion formulation using hydroxypropyl methylcellulose acetate succinate (HPMC-AS). Samples, prepared using polymers with different substitution levels, were placed on storage for 6 months under a range of different temperature and relative humidity conditions and the degradant level monitored using high-performance liquid chromatography (HPLC). While the data clearly illustrates the impact of temperature and relative humidity on the degradant levels detected, it also highlighted that these terms do not account for all the variability in the data. An extension of the Arrhenius equation to include a term for the polymer chemistry, specifically the degree of succinoyl substitution on the polymer backbone, was shown to improve the fit of the model to the data. Copyright © 2014 Elsevier B.V. All rights reserved.

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.

Substrate system for spray forming

DOEpatents

Chu, Men G.; Chernicoff, William P.

2000-01-01

A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

Substrate system for spray forming

DOEpatents

Chu, Men G.; Chernicoff, William P.

2002-01-01

A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

Arc spray process for the aircraft and stationary gas turbine industry

NASA Astrophysics Data System (ADS)

Sampson, E. R.; Zwetsloot, M. P.

1997-06-01

Technological advances in arc spray have produced a system that competes favorably with other thermal spray processes. In the past, arc spray was thought of as a process for very large parts that need thick buildups. However, an attachment device known as the arc jet system has been developed that focuses the pattern and accelerates the particles. This attachment device, coupled with the in-troduction of metal-cored wires that provide the same chemistries as plasma-sprayed powders, pro-vides application engineers with a viable economic alternative to existing spray methods. A comparative evaluation of a standard production plasma spray system was conducted with the arc spray process using the attachment device. This evaluation was conducted by an airline company on four major parts coated with nickel-aluminum. Results show that, for these applications, the arc spray process offers several benefits.

Processing, structure, property and performance relationships for the thermal spray of the internal surface of aluminum cylinders

NASA Astrophysics Data System (ADS)

Cook, David James

The increased need for automotive weight reduction has necessitated the use of aluminum for engine blocks. Conventional aluminum alloys cannot survive the constant wear from a piston ring reciprocating on the surface. However, a wear resistant thermal spray coating can be applied on the internal surface of the cylinder bore, which has significant advantages over other available options. Thermal spray is a well-established process for depositing molten, semi-molten, or solid particles onto a substrate to form a protective coating. For this application, the two main challenges were obtaining good wear resistance, and achieving good adhesion. To design a system capable of producing a well-adhered, wear resistant coating for this high volume application it is necessary to identify the overall processing, structure, properties, and performance relationships. The results will demonstrate that very important relationships exist among particle characteristics, substrate conditions, and the properties of the final coating. However, it is the scientific studies to understand some of the process physics in these relationships that allow recognition of the critical processing conditions that need to be controlled to ensure a consistent, reliable thermal spray coating. In this investigation, it will be shown that the critical microstructural aspect of the coating that produced the required tribological properties was the presence of wuestite (FeO). It was found that by using a low carbon steel material with compressed air atomizing gas, it was possible to create an Fe/FeO structure that exhibited excellent tribological properties. This study will also show that traditional thermal spray surface preparation techniques were not ideal for this application, therefore a novel alternative approach was developed. The application of a flux to the aluminum surface prior to thermal spray promotes excellent bond strengths to non-roughened aluminum. Analysis will show that this flux strips the oxide from the aluminum and allows for chemical bonding of the NiAl coating to the aluminum via the formation of intermetallics. By developing processing, structure, property, and performance relationships for the full process, it was possible to design a complete coating process to succeed in this application. The determination of these relationships and the underlying process physics improves reliability and instills confidence in the process.

Failure modes of vacuum plasma spray tungsten coating created on carbon fibre composites under thermal loads

NASA Astrophysics Data System (ADS)

Hirai, T.; Bekris, N.; Coad, J. P.; Grisolia, C.; Linke, J.; Maier, H.; Matthews, G. F.; Philipps, V.; Wessel, E.

2009-07-01

Vacuum plasma spray tungsten (VPS-W) coating created on a carbon fibre reinforced composite (CFC) was tested under two thermal load schemes in the electron beam facility to examine the operation limits and failure modes. In cyclic ELM-like short transient thermal loads, the VPS-W coating was destroyed sub-layer by sub-layer at 0.33 GW/m 2 for 1 ms pulse duration. At longer single pulses, simulating steady-state thermal loads, the coating was destroyed at surface temperatures above 2700 °C by melting of the rhenium containing multilayer at the interface between VPS-W and CFC. The operation limits and failure modes of the VPS-W coating in the thermal load schemes are discussed in detail.

Physicochemical characterization and water vapor sorption of organic solution advanced spray-dried inhalable trehalose microparticles and nanoparticles for targeted dry powder pulmonary inhalation delivery.

PubMed

Li, Xiaojian; Mansour, Heidi M

2011-12-01

Novel advanced spray-dried inhalable trehalose microparticulate/nanoparticulate powders with low water content were successfully produced by organic solution advanced spray drying from dilute solution under various spray-drying conditions. Laser diffraction was used to determine the volumetric particle size and size distribution. Particle morphology and surface morphology was imaged and examined by scanning electron microscopy. Hot-stage microscopy was used to visualize the presence/absence of birefringency before and following particle engineering design pharmaceutical processing, as well as phase transition behavior upon heating. Water content in the solid state was quantified by Karl Fisher (KF) coulometric titration. Solid-state phase transitions and degree of molecular order were examined by differential scanning calorimetry (DSC) and powder X-ray diffraction, respectively. Scanning electron microscopy showed a correlation between particle morphology, surface morphology, and spray drying pump rate. All advanced spray-dried microparticulate/nanoparticulate trehalose powders were in the respirable size range and exhibited a unimodal distribution. All spray-dried powders had very low water content, as quantified by KF. The absence of crystallinity in spray-dried particles was reflected in the powder X-ray diffractograms and confirmed by thermal analysis. DSC thermal analysis indicated that the novel advanced spray-dried inhalable trehalose microparticles and nanoparticles exhibited a clear glass transition (T(g)). This is consistent with the formation of the amorphous glassy state. Spray-dried amorphous glassy trehalose inhalable microparticles and nanoparticles exhibited vapor-induced (lyotropic) phase transitions with varying levels of relative humidity as measured by gravimetric vapor sorption at 25°C and 37°C.

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,

Evaluation of thermal sprayed metallic coatings for use on the structures at Launch Complex 39

NASA Technical Reports Server (NTRS)

Welch, Peter J.

1990-01-01

The current status of the evaluation program is presented. The objective was to evaluate the applicability of Thermal Sprayed Coatings (TSC) to protect the structures in the high temperature acid environment produced by exhaust of the Solid Rocket Boosters during the launches of the Shuttle Transportation System. Only the relatively low cost aluminum TSC which provides some cathodic protection for steel appears to be a practical candidate for further investigation.

Effect of whey protein isolate and β-cyclodextrin wall systems on stability of microencapsulated vanillin by spray-freeze drying method.

PubMed

Hundre, Swetank Y; Karthik, P; Anandharamakrishnan, C

2015-05-01

Vanillin flavour is highly volatile in nature and due to that application in food incorporation is limited; hence microencapsulation of vanillin is an ideal technique to increase its stability and functionality. In this study, vanillin was microencapsulated for the first time by non-thermal spray-freeze-drying (SFD) technique and its stability was compared with other conventional techniques such as spray drying (SD) and freeze-drying (FD). Different wall materials like β-cyclodextrin (β-cyd), whey protein isolate (WPI) and combinations of these wall materials (β-cyd + WPI) were used to encapsulate vanillin. SFD microencapsulated vanillin with WPI showed spherical shape with numerous fine pores on the surface, which in turn exhibited good rehydration ability. On the other hand, SD powder depicted spherical shape without pores and FD encapsulated powder yielded larger particle sizes with flaky structure. FTIR analysis confirmed that there was no interaction between vanillin and wall materials. Moreover, spray-freeze-dried vanillin + WPI sample exhibited better thermal stability than spray dried and freeze-dried microencapsulated samples. Copyright © 2014 Elsevier Ltd. All rights reserved.

Improved Single-Source Precursors for Solar-Cell Absorbers

NASA Technical Reports Server (NTRS)

Banger, Kulbinder K.; Harris, Jerry; Hepp, Aloysius

2007-01-01

Improved single-source precursor compounds have been invented for use in spray chemical vapor deposition (spray CVD) of chalcopyrite semiconductor absorber layers of thin-film cells. A "single-source precursor compound" is a single molecular compound that contains all the required elements, which when used under the spray CVD conditions, thermally decomposes to form CuIn(x)Ga(1-x)S(y)Se(2-y).

Electrical Characteristics and Preparation of (Ba0.5Sr0.5)TiO3 Films by Spray Pyrolysis and Rapid Thermal Annealing

NASA Astrophysics Data System (ADS)

Koo, Horng-Show; Chen, Mi; Ku, Hong-Kou; Kawai, Tomoji

2007-04-01

Functional films of (Ba0.5Sr0.5)TiO3 on Pt (1000 Å)/Ti (100 Å)/SiO2 (2000 Å)/Si substrates are prepared by spray pyrolysis and subsequently rapid thermal annealing. Barium nitrate, strontium nitrate and titanium isopropoxide are used as starting materials with ethylene glycol as solvent. For (Ba0.5Sr0.5)TiO3 functional thin film, thermal characteristics of the precursor powder scratched from as-sprayed films show a remarkable peak around 300-400 °C and 57.7% weight loss up to 1000 °C. The as-sprayed precursor film with coffee-like color and amorphous-like phase is transformed into the resultant film with white, crystalline perovskite phase and characteristic peaks (110) and (100). The resultant films show correspondent increases of dielectric constant, leakage current and dissipation factor with increasing annealing temperatures. The dielectric constant is 264 and tangent loss is 0.21 in the resultant films annealed at 750 °C for 5 min while leakage current density is 1.5× 10-6 A/cm2 in the film annealed at 550 °C for 5 min.

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.

Visualization of Flow in Pressurizer Spray Line Piping and Estimation of Thermal Stress Fluctuation Caused by Swaying of Water Surface

NASA Astrophysics Data System (ADS)

Oumaya, Toru; Nakamura, Akira; Onojima, Daisuke; Takenaka, Nobuyuki

The pressurizer spray line of PWR plants cools reactor coolant by injecting water into pressurizer. Since the continuous spray flow rate during commercial operation of the plant is considered insufficient to fill the pipe completely, there is a concern that a water surface exists in the pipe and may periodically sway. In order to identify the flow regimes in spray line piping and assess their impact on pipe structure, a flow visualization experiment was conducted. In the experiment, air was used substituted for steam to simulate the gas phase of the pressurizer, and the flow instability causing swaying without condensation was investigated. With a full-scale mock-up made of acrylic, flow under room temperature and atmospheric pressure conditions was visualized, and possible flow regimes were identified based on the results of the experiment. Three representative patterns of swaying of water surface were assumed, and the range of thermal stress fluctuation, when the surface swayed instantaneously, was calculated. With the three patterns of swaying assumed based on the visualization experiment, it was confirmed that the thermal stress amplitude would not exceed the fatigue endurance limit prescribed in the Japanese Design and Construction Code.

Degradation of a two-layer thermal barrier coating under thermal cycling. [for superalloys of aircraft turbine engine blades

NASA Technical Reports Server (NTRS)

Maier, R. D.; Scheuermann, C. M.; Andrews, C. W.

1981-01-01

A two-layer plasma-sprayed thermal barrier coating on a directionally solidified nickel-base eutectic alloy substrate was characterized prior to and after thermal cycling to 1095 C in an accelerated furnace test. The coating was comprised of an inner layer of Ni-16.4Cr-5.1Al-0.15Y (wt%) bond coat and an outer layer of ZrO2-7.9Y2O3 (wt%) thermal barrier. Characterization of the bond coat revealed that substantial amounts of yttrium and aluminum were oxidized during plasma-spraying in air. The oxidation of these elements reduced the protective capacity of the bond coat so that, on thermal exposure, severe degradation of the bond coat resulted and large amounts of nickel oxide formed. This nickel oxide was demonstrated to grow outward into the thermal barrier, which appears to have increased the stresses in the thermal barrier and contributed to its failure near the thermal barrier-bond coat interface.

Effect of electron beam irradiation on thermal and mechanical properties of epoxy polymer

NASA Astrophysics Data System (ADS)

Nguyen, A. T.; Visakh, P. M.; Nazarenko, O. B.; Chandran, C. S.; Melnikova, T. V.

2017-01-01

This study investigates the thermal and mechanical properties of epoxy polymer after exposure to different doses of electron beam irradiation. The epoxy polymer was prepared using epoxy-diane resin ED-20 cured by polyethylenepolyamine. The irradiation of the samples was carried out with doses of 30, 100 and 300 kGy. The effects of doses on thermal and mechanical properties of the epoxy polymer were investigated by the methods of thermal gravimetric analysis, tensile test, and dynamic mechanical analysis. The thermal properties of the epoxy polymer slightly increased after irradiation at the heating in air. The tensile strength and Young’s modulus of the epoxy polymer increased by the action of electron beam up to dose of 100 kGy and then decreased. The elongation at break decreased with increasing the irradiation dose.

Evaporating Spray in Supersonic Streams Including Turbulence Effects

NASA Technical Reports Server (NTRS)

Balasubramanyam, M. S.; Chen, C. P.

2006-01-01

Evaporating spray plays an important role in spray combustion processes. This paper describes the development of a new finite-conductivity evaporation model, based on the two-temperature film theory, for two-phase numerical simulation using Eulerian-Lagrangian method. The model is a natural extension of the T-blob/T-TAB atomization/spray model which supplies the turbulence characteristics for estimating effective thermal diffusivity within the droplet phase. Both one-way and two-way coupled calculations were performed to investigate the performance of this model. Validation results indicate the superiority of the finite-conductivity model in low speed parallel flow evaporating sprays. High speed cross flow spray results indicate the effectiveness of the T-blob/T-TAB model and point to the needed improvements in high speed evaporating spray modeling.

Trehalose limits BSA aggregation in spray-dried formulations at high temperatures: implications in preparing polymer implants for long-term protein delivery.

PubMed

Rajagopal, Karthikan; Wood, Joseph; Tran, Benjamin; Patapoff, Thomas W; Nivaggioli, Thierry

2013-08-01

Polymer implants are promising systems for sustained release applications but their utility for protein delivery has been hindered because of concerns over drug stability at elevated temperatures required for processing. Using bovine serum albumin (BSA) as a model, we have assessed whether proteins can be formulated for processing at elevated temperatures. Specifically, the effect of trehalose and histidine-HCl buffer on BSA stability in a spray-dried formulation has been investigated at temperatures ranging from 80°C to 110°C. When both the sugar and buffer are present, aggregation is suppressed even when exposed to 100°C, the extrusion temperature of poly(lactide-co-glycolide) (PLGA), a bioresorbable polymer. Estimation of aggregation rate constants (k) indicate that though both trehalose and histidine-HCl buffer contribute to BSA stability, the effect because of trehalose alone is more pronounced. BSA-loaded PLGA implants were prepared using hot-melt extrusion process and in vitro release was conducted in phosphate buffered saline at 37°C. Comparison of drug released from implants prepared using four different formulations confirmed that maximal release was achieved from the formulation in which BSA was least aggregated. These studies demonstrate that when trehalose and histidine-HCl buffer are included in spray-dried formulations, BSA stability is maintained both during processing at 100°C and long-term residence within implants. Copyright © 2013 Wiley Periodicals, Inc.

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.

Gas-phase synthesis of magnetic metal/polymer nanocomposites.

PubMed

Starsich, Fabian H L; Hirt, Ann M; Stark, Wendelin J; Grass, Robert N

2014-12-19

Highly magnetic metal Co nanoparticles were produced via reducing flame spray pyrolysis, and directly coated with an epoxy polymer in flight. The polymer content in the samples varied between 14 and 56 wt% of nominal content. A homogenous dispersion of Co nanoparticles in the resulting nanocomposites was visualized by electron microscopy. The size and crystallinity of the metallic fillers was not affected by the polymer, as shown by XRD and magnetic hysteresis measurements. The good control of the polymer content in the product nanocomposite was shown by elemental analysis. Further, the successful polymerization in the gas phase was demonstrated by electron microscopy and size measurements. The presented effective, dry and scalable one-step synthesis method for highly magnetic metal nanoparticle/polymer composites presented here may drastically decrease production costs and increase industrial yields.

Gas-phase synthesis of magnetic metal/polymer nanocomposites

NASA Astrophysics Data System (ADS)

Starsich, Fabian H. L.; Hirt, Ann M.; Stark, Wendelin J.; Grass, Robert N.

2014-12-01

Highly magnetic metal Co nanoparticles were produced via reducing flame spray pyrolysis, and directly coated with an epoxy polymer in flight. The polymer content in the samples varied between 14 and 56 wt% of nominal content. A homogenous dispersion of Co nanoparticles in the resulting nanocomposites was visualized by electron microscopy. The size and crystallinity of the metallic fillers was not affected by the polymer, as shown by XRD and magnetic hysteresis measurements. The good control of the polymer content in the product nanocomposite was shown by elemental analysis. Further, the successful polymerization in the gas phase was demonstrated by electron microscopy and size measurements. The presented effective, dry and scalable one-step synthesis method for highly magnetic metal nanoparticle/polymer composites presented here may drastically decrease production costs and increase industrial yields.

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.

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%.

Molecular engineered conjugated polymer with high thermal conductivity

PubMed Central

Song, Bai; Lee, Elizabeth M. Y.; Gleason, Karen K.

2018-01-01

Traditional polymers are both electrically and thermally insulating. The development of electrically conductive polymers has led to novel applications such as flexible displays, solar cells, and wearable biosensors. As in the case of electrically conductive polymers, the development of polymers with high thermal conductivity would open up a range of applications in next-generation electronic, optoelectronic, and energy devices. Current research has so far been limited to engineering polymers either by strong intramolecular interactions, which enable efficient phonon transport along the polymer chains, or by strong intermolecular interactions, which enable efficient phonon transport between the polymer chains. However, it has not been possible until now to engineer both interactions simultaneously. We report the first realization of high thermal conductivity in the thin film of a conjugated polymer, poly(3-hexylthiophene), via bottom-up oxidative chemical vapor deposition (oCVD), taking advantage of both strong C=C covalent bonding along the extended polymer chain and strong π-π stacking noncovalent interactions between chains. We confirm the presence of both types of interactions by systematic structural characterization, achieving a near–room temperature thermal conductivity of 2.2 W/m·K, which is 10 times higher than that of conventional polymers. With the solvent-free oCVD technique, it is now possible to grow polymer films conformally on a variety of substrates as lightweight, flexible heat conductors that are also electrically insulating and resistant to corrosion. PMID:29670943

Formation of low charge state ions of synthetic polymers using quaternary ammonium compounds.

PubMed

Nasioudis, Andreas; Joyce, William F; van Velde, Jan W; Heeren, Ron M A; van den Brink, Oscar F

2010-07-01

Factors such as high polymer dispersity and variation in elemental composition (of copolymers) often complicate the electrospray ionization mass spectrometry (ESI-MS) analysis of synthetic polymers with high molar mass. In the experiments described in this study, quaternary ammonium compounds were observed to facilitate the production of low charge state pseudomolecular ions when added to the spray solution for ESI-MS. This approach was then used for the ESI time-of-flight mass spectrometry (TOF-MS) analysis of synthetic polymers. Hexadecyltrimethylammonium chloride permitted the successful analysis of poly(ethylene glycol) of 2-40 kDa, poly(propylene glycol) and poly(tetramethylene glycol) oligomers. Increasing the quaternary ammonium compounds' concentration results in the production of low charge state pseudomolecular ions. A comparison of structurally different quaternary ammonium compounds showed that the best performance is expected from large molecules with specific charge localization, which leaves the charge available for interactions. The applicability of the method for the MS analysis of other polymeric systems was also studied. In the case of poly(tetramethylene glycol), the method not only shifted the distributions to higher m/z values but also allowed the detection of high molecular weight material that was not observed without addition of the modifier to the spray solution.

Determination of Selection Criteria for Spray Drift Reduction from Atomization Data

DTIC Science & Technology

2012-01-01

Solutions Testing was conducted using glyphosate (Roundup PowerMAX, EPA Reg. No. 524–549, Monsanto Company, St. Louis, MO) as the active ingredient...This po- tassium glyphosate contains 540 g acid equivalent glyphosate per liter and is sprayed at 1.6 l/hectare (22 oz/acre), yielding a 1.7 % v/v...Table 1) were tested in water only and in water plus the glyphosate . The specific polymers were chosen so as to cre- ate a range of solutions with and

Spray forming process for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.; Key, James F.

1998-01-01

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

Ultrafast Fabrication of Flexible Dye-Sensitized Solar Cells by Ultrasonic Spray-Coating Technology

PubMed Central

Han, Hyun-Gyu; Weerasinghe, Hashitha C.; Min Kim, Kwang; Soo Kim, Jeong; Cheng, Yi-Bing; Jones, David J.; Holmes, Andrew B.; Kwon, Tae-Hyuk

2015-01-01

This study investigates novel deposition techniques for the preparation of TiO2 electrodes for use in flexible dye-sensitized solar cells. These proposed new methods, namely pre-dye-coating and codeposition ultrasonic spraying, eliminate the conventional need for time-consuming processes such as dye soaking and high-temperature sintering. Power conversion efficiencies of over 4.0% were achieved with electrodes prepared on flexible polymer substrates using this new deposition technology and N719 dye as a sensitizer. PMID:26420466

Spray forming system for producing molds, dies and related tooling

DOEpatents

McHugh, Kevin M.

2000-01-01

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

Spray forming process for producing molds, dies and related tooling

DOEpatents

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

1998-02-17

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

Liquid immersion thermal crosslinking of 3D polymer nanopatterns for direct carbonisation with high structural integrity

NASA Astrophysics Data System (ADS)

Kang, Da-Young; Kim, Cheolho; Park, Gyurim; Moon, Jun Hyuk

2015-12-01

The direct pyrolytic carbonisation of polymer patterns has attracted interest for its use in obtaining carbon materials. In the case of carbonisation of nanopatterned polymers, the polymer flow and subsequent pattern change may occur in order to relieve their high surface energies. Here, we demonstrated that liquid immersion thermal crosslinking of polymer nanopatterns effectively enhanced the thermal resistance and maintained the structure integrity during the heat treatment. We employed the liquid immersion thermal crosslinking for 3D porous SU8 photoresist nanopatterns and successfully converted them to carbon nanopatterns while maintaining their porous features. The thermal crosslinking reaction and carbonisation of SU8 nanopatterns were characterised. The micro-crystallinity of the SU8-derived carbon nanopatterns was also characterised. The liquid immersion heat treatment can be extended to the carbonisation of various polymer or photoresist nanopatterns and also provide a facile way to control the surface energy of polymer nanopatterns for various purposes, for example, to block copolymer or surfactant self-assemblies.

Liquid immersion thermal crosslinking of 3D polymer nanopatterns for direct carbonisation with high structural integrity

PubMed Central

Kang, Da-Young; Kim, Cheolho; Park, Gyurim; Moon, Jun Hyuk

2015-01-01

The direct pyrolytic carbonisation of polymer patterns has attracted interest for its use in obtaining carbon materials. In the case of carbonisation of nanopatterned polymers, the polymer flow and subsequent pattern change may occur in order to relieve their high surface energies. Here, we demonstrated that liquid immersion thermal crosslinking of polymer nanopatterns effectively enhanced the thermal resistance and maintained the structure integrity during the heat treatment. We employed the liquid immersion thermal crosslinking for 3D porous SU8 photoresist nanopatterns and successfully converted them to carbon nanopatterns while maintaining their porous features. The thermal crosslinking reaction and carbonisation of SU8 nanopatterns were characterised. The micro-crystallinity of the SU8-derived carbon nanopatterns was also characterised. The liquid immersion heat treatment can be extended to the carbonisation of various polymer or photoresist nanopatterns and also provide a facile way to control the surface energy of polymer nanopatterns for various purposes, for example, to block copolymer or surfactant self-assemblies. PMID:26677949

Liquid immersion thermal crosslinking of 3D polymer nanopatterns for direct carbonisation with high structural integrity.

PubMed

Kang, Da-Young; Kim, Cheolho; Park, Gyurim; Moon, Jun Hyuk

2015-12-18

The direct pyrolytic carbonisation of polymer patterns has attracted interest for its use in obtaining carbon materials. In the case of carbonisation of nanopatterned polymers, the polymer flow and subsequent pattern change may occur in order to relieve their high surface energies. Here, we demonstrated that liquid immersion thermal crosslinking of polymer nanopatterns effectively enhanced the thermal resistance and maintained the structure integrity during the heat treatment. We employed the liquid immersion thermal crosslinking for 3D porous SU8 photoresist nanopatterns and successfully converted them to carbon nanopatterns while maintaining their porous features. The thermal crosslinking reaction and carbonisation of SU8 nanopatterns were characterised. The micro-crystallinity of the SU8-derived carbon nanopatterns was also characterised. The liquid immersion heat treatment can be extended to the carbonisation of various polymer or photoresist nanopatterns and also provide a facile way to control the surface energy of polymer nanopatterns for various purposes, for example, to block copolymer or surfactant self-assemblies.

Thermally crosslinked polymeric compositions and methods of making the same

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

Koros, William John; Kratochvil, Adam Michal

2014-03-04

The various embodiments of the present disclosure relate generally to thermally crosslinked polymeric compositions and methods of making thermally crosslinked polymeric compositions. An embodiment of the present invention comprises a composition comprising: a first polymer comprising a first repeat unit, the first repeat unit comprising a carboxyl group, wherein the first polymer crosslinks to a second polymer formed from a second repeat unit, and wherein the first polymer crosslinks to the second polymer without formation of an ester group.

Method for fabricating beryllium structures

DOEpatents

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

1977-01-01

Thin-walled beryllium structures are prepared by plasma spraying a mixture of beryllium powder and about 2500 to 4000 ppm silicon powder onto a suitable substrate, removing the plasma-sprayed body from the substrate and placing it in a sizing die having a coefficient of thermal expansion similar to that of the beryllium, exposing the plasma-sprayed body to a moist atmosphere, outgassing the plasma-sprayed body, and then sintering the plasma-sprayed body in an inert atmosphere to form a dense, low-porosity beryllium structure of the desired thin-wall configuration. The addition of the silicon and the exposure of the plasma-sprayed body to the moist atmosphere greatly facilitate the preparation of the beryllium structure while minimizing the heretofore deleterious problems due to grain growth and grain orientation.

Vacuum plasma spray applications on liquid fuel rocket engines

NASA Technical Reports Server (NTRS)

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

1992-01-01

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

Method for forming an abrasive surface on a tool

DOEpatents

Seals, Roland D.; White, Rickey L.; Swindeman, Catherine J.; Kahl, W. Keith

1999-01-01

A method for fabricating a tool used in cutting, grinding and machining operations, is provided. The method is used to deposit a mixture comprising an abrasive material and a bonding material on a tool surface. The materials are propelled toward the receiving surface of the tool substrate using a thermal spray process. The thermal spray process melts the bonding material portion of the mixture, but not the abrasive material. Upon impacting the tool surface, the mixture or composition solidifies to form a hard abrasive tool coating.

Thermal Shock Damage and Microstructure Evolution of Thermal Barrier Coatings on Mar-M247 Superalloy in a Combustion Gas Environment

NASA Astrophysics Data System (ADS)

Mei, Hui

2012-06-01

The effect of preoxidation on the thermal shock of air plasma sprayed thermal barrier coatings (TBCs) was completely investigated in a combustion gas environment by burning jet fuel with high speed air. Results show that with increasing cycles, the as-oxidized TBCs lost more weight and enlarged larger spallation area than the as-sprayed ones. Thermally grown oxide (TGO) growth and thermal mismatch stress were proven to play critical roles on the as-oxidized TBC failure. Two types of significant cracks were identified: the type I crack was vertical to the TGO interface and the type II crack was parallel to the TGO interface. The former accelerated the TGO growth to develop the latter as long as the oxidizing gas continuously diffused inward and then oxidized the more bond coat (BC). The preoxidation treatment directly increased the TGO thickness, formed the parallel cracks earlier in the TGO during the thermal shocks, and eventually resulted in the worse thermal shock resistance.

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.

Replacing thermal sprayed zinc anodes on cathodically protected steel reinforced concrete bridges.

DOT National Transportation Integrated Search

2011-09-01

This research aimed to address questions underlying the replacement of arc-sprayed zinc anodes on cathodically protected steel reinforced concrete bridges and to develop a protocol to prepare the concrete surface for the new anode, through a combinat...

Replacing thermal sprayed zinc anodes on cathodically protected steel reinforced concrete bridges.

DOT National Transportation Integrated Search

2011-08-01

"This research aimed to address questions underlying the replacement of arc-sprayed zinc anodes on cathodically protected steel reinforced concrete bridges and to develop a protocol to prepare the concrete surface for the new anode, through a combina...

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.

Carboranylmethylene-substituted phosphazenes and polymers thereof

NASA Technical Reports Server (NTRS)

Allcock, H. R.; Scopelianos, A. G. (Inventor)

1984-01-01

Carboranylmethylene-substituted cyclophosphazenes are described which can be thermally polymerized into carboranylmethylene-substituted phosphazene polymers. The polymers are useful as thermally stable coatings. Also, due to the characteristics of these polymers in acting as a ligand for transition metals, metalocarboranylmethylene phosphazene polymers are described which can act as immobilized catalyst systems, and are electrically conductive and superconductive.

LSPRAY: Lagrangian Spray Solver for Applications With Parallel Computing and Unstructured Gas-Phase Flow Solvers

NASA Technical Reports Server (NTRS)

Raju, Manthena S.

1998-01-01

Sprays occur in a wide variety of industrial and power applications and in the processing of materials. A liquid spray is a phase flow with a gas as the continuous phase and a liquid as the dispersed phase (in the form of droplets or ligaments). Interactions between the two phases, which are coupled through exchanges of mass, momentum, and energy, can occur in different ways at different times and locations involving various thermal, mass, and fluid dynamic factors. An understanding of the flow, combustion, and thermal properties of a rapidly vaporizing spray requires careful modeling of the rate-controlling processes associated with the spray's turbulent transport, mixing, chemical kinetics, evaporation, and spreading rates, as well as other phenomena. In an attempt to advance the state-of-the-art in multidimensional numerical methods, we at the NASA Lewis Research Center extended our previous work on sprays to unstructured grids and parallel computing. LSPRAY, which was developed by M.S. Raju of Nyma, Inc., is designed to be massively parallel and could easily be coupled with any existing gas-phase flow and/or Monte Carlo probability density function (PDF) solver. The LSPRAY solver accommodates the use of an unstructured mesh with mixed triangular, quadrilateral, and/or tetrahedral elements in the gas-phase solvers. It is used specifically for fuel sprays within gas turbine combustors, but it has many other uses. The spray model used in LSPRAY provided favorable results when applied to stratified-charge rotary combustion (Wankel) engines and several other confined and unconfined spray flames. The source code will be available with the National Combustion Code (NCC) as a complete package.

Properties of Polymer-Infiltrated Carbon Foams

NASA Astrophysics Data System (ADS)

Adams, W. A.; Bunning, T. J.; Farmer, B. L.; Kearns, K. M.; Anderson, D. A.; Roy, A. K.; Banerjee, T.; Jeon, H. G.

2001-03-01

There is considerable interest in extending the use-temperatures of both commodity and high performance polymers. There is also interest in improving the mechanical strength of carbon foams. Composites prepared by infiltrating carbon foam with polymers may offer significant improvements in both, the polymer helping to rigidize the foam and the foam providing thermal protection by virtue of its high thermal conductivity. The mechanical properties and thermal stability of carbon foams of various densities infiltrated with polyurethane have been studied. When used with a heat sink, the composite is able to maintain a substantial thermal gradient which provides stability of the polymer nominally above its decomposition temperature. The composite also has much improved strength properties without sacrificing tensile modulus. The composites may be very well suited for thermal management applications.

Temperature changes in the pulp chamber during dentin ablation with Er:YAG laser

NASA Astrophysics Data System (ADS)

Zhang, Xianzeng; Zhao, Haibin; Zhan, Zhenlin; Guo, Wenqing; Xie, Shusen

2012-12-01

To examine the temperature changes in the pulp chamber during cavity preparation in dentin with the Er:YAG laser (2940 nm), a total 20 intact premolars teeth were divided into 4 groups for dentin ablation with different radiant exposures at 4Hz and 8Hz with and without water spray. A K-type thermocouple was used to monitor the temperature changes in pulp chamber during laser treatment. The total time of irradiation was 70 sec. the water spray rate was 3 mL/min. It showed that maximum temperature rise increases with the increasing of radiant exposure and pulse repetition rate and the additional water cooling during laser ablation can significantly reduce the temperature rise in pulp chamber which will benefit to avoid or reduce thermal damage to tooth structure and dental pulp. The highest rise of temperature in the pulp was achieved with 20 J/cm2 and 8 Hz (19.83°C ). For all sample without water spray, the rise of temperature was exceed 5 °C . In contrast, with water spray, the temperature rise in the pulp can be firmly controlled under 1°C. The results also indicated that ablation rate and efficiency can be enhanced by increasing the incident radiant exposure and pulse repetition rate, which simultaneously producing more heat accumulation in dental tissue and causing thermal damage to dental tissue. By applying an additional water spray, thermal damage can be significantly reduced in clinical application.

Design of an inhalable dry powder formulation of DOTAP-modified PLGA nanoparticles loaded with siRNA.

PubMed

Jensen, Ditte Krohn; Jensen, Linda Boye; Koocheki, Saeid; Bengtson, Lasse; Cun, Dongmei; Nielsen, Hanne Mørck; Foged, Camilla

2012-01-10

Matrix systems based on biocompatible and biodegradable polymers like the United States Food and Drug Administration (FDA)-approved polymer poly(DL-lactide-co-glycolide acid) (PLGA) are promising for the delivery of small interfering RNA (siRNA) due to favorable safety profiles, sustained release properties and improved colloidal stability, as compared to polyplexes. The purpose of this study was to design a dry powder formulation based on cationic lipid-modified PLGA nanoparticles intended for treatment of severe lung diseases by pulmonary delivery of siRNA. The cationic lipid dioleoyltrimethylammoniumpropane (DOTAP) was incorporated into the PLGA matrix to potentiate the gene silencing efficiency. The gene knock-down level in vitro was positively correlated to the weight ratio of DOTAP in the particles, and 73% silencing was achieved in the presence of 10% (v/v) serum at 25% (w/w) DOTAP. Optimal properties were found for nanoparticles modified with 15% (w/w) DOTAP, which reduced the gene expression with 54%. This formulation was spray-dried with mannitol into nanocomposite microparticles of an aerodynamic size appropriate for lung deposition. The spray-drying process did not affect the physicochemical properties of the readily re-dispersible nanoparticles, and most importantly, the in vitro gene silencing activity was preserved during spray-drying. The siRNA content in the powder was similar to the theoretical loading and the siRNA was intact, suggesting that the siRNA is preserved during the spray-drying process. Finally, X-ray powder diffraction analysis demonstrated that mannitol remained in a crystalline state upon spray-drying with PLGA nanoparticles suggesting that the sugar excipient might exert its stabilizing effect by sterical inhibition of the interactions between adjacent nanoparticles. This study demonstrates that spray-drying is an excellent technique for engineering dry powder formulations of siRNA nanoparticles, which might enable the local delivery of biologically active siRNA directly to the lung tissue. Copyright © 2011 Elsevier B.V. All rights reserved.

Thermophysical Properties of Polymer Materials with High Thermal Conductivity

NASA Astrophysics Data System (ADS)

Lebedev, S. M.; Gefle, O. S.; Dneprovskii, S. N.; Amitov, E. T.

2015-06-01

Results of studies on the main thermophysical properties of new thermally conductive polymer materials are presented. It is shown that modification of polymer dielectrics by micron-sized fillers allows thermally conductive materials with thermal conductivity not less than 2 W/(m K) to be produced, which makes it possible to use such materials as cooling elements of various electrical engineering and semiconductor equipment and devices.

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.

Designing energy dissipation properties via thermal spray coatings

DOE PAGES

Brake, Matthew R. W.; Hall, Aaron Christopher; Madison, Jonathan D.

2016-12-14

The coefficient of restitution is a measure of energy dissipation in a system across impact events. Often, the dissipative qualities of a pair of impacting components are neglected during the design phase. This research looks at the effect of applying a thin layer of metallic coating, using thermal spray technologies, to significantly alter the dissipative properties of a system. We studied the dissipative properties across multiple impacts in order to assess the effects of work hardening, the change in microstructure, and the change in surface topography. The results of the experiments indicate that any work hardening-like effects are likely attributablemore » to the crushing of asperities, and the permanent changes in the dissipative properties of the system, as measured by the coefficient of restitution, are attributable to the microstructure formed by the thermal spray coating. Furthermore, the microstructure appears to be robust across impact events of moderate energy levels, exhibiting negligible changes across multiple impact events.« less

Laser-assisted selective fusing of thermal sprayed Ni-based self-fluxing alloys by using high-power diode lasers

NASA Astrophysics Data System (ADS)

Chun, Eun-Joon; Kim, Min-Su; Nishikawa, Hiroshi; Park, Changkyoo; Suh, Jeong

2018-03-01

Fusing treatment of Ni-based self-fluxing alloys (Metco-16C and 1276F) was performed using high-power diode lasers to control the temperature of the substrate's surface in real time. The effects of the fusing treatment temperature on the microstructural change and hardness distribution were also investigated. For Metco-16C and 1276F, the macrostructural inhomogeneity (voids) within the thermal sprayed layer decreased considerably as the fusing temperature increased. For both self-fluxing alloys, the optimal temperature for fusing was approximately 1423 K (for Metco-16C) and 1373 K (for 1276F), both of which are within the solid state temperature range; these temperatures maximize the alloy hardness together with the macrostructural homogeneity. In this temperature range, the microstructure consists of a lamellar-structured matrix phase with fine (<5 μm) carbides and borides. Selective fusing for a thermal sprayed layer 0.2-0.5 mm in thickness could be successfully achieved in a high-power diode laser system.

Impact Response of Thermally Sprayed Metal Deposits

NASA Astrophysics Data System (ADS)

Wise, J. L.; Hall, A. C.; Moore, N. W.; Pautz, S. D.; Franke, B. C.; Scherzinger, W. M.; Brown, D. W.

2017-06-01

Gas-gun experiments have probed the impact response of tantalum specimens that were additively manufactured using a controlled thermal spray deposition process. Velocity interferometer (VISAR) diagnostics provided time-resolved measurements of sample response under one-dimensional (i . e . , uniaxial strain) shock compression to peak stresses ranging between 1 and 4 GPa. The acquired wave-profile data have been analyzed to determine the Hugoniot Elastic Limit (HEL), Hugoniot equation of state, and high-pressure yield strength of the thermally deposited samples for comparison to published baseline results for conventionally wrought tantalum. The effects of composition, porosity, and microstructure (e . g . , grain/splat size and morphology) are assessed to explain differences in the dynamic mechanical behavior of spray-deposited versus conventional material. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under contract DE-AC04-94AL85000.

Designing energy dissipation properties via thermal spray coatings

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

Brake, Matthew R. W.; Hall, Aaron Christopher; Madison, Jonathan D.

The coefficient of restitution is a measure of energy dissipation in a system across impact events. Often, the dissipative qualities of a pair of impacting components are neglected during the design phase. This research looks at the effect of applying a thin layer of metallic coating, using thermal spray technologies, to significantly alter the dissipative properties of a system. We studied the dissipative properties across multiple impacts in order to assess the effects of work hardening, the change in microstructure, and the change in surface topography. The results of the experiments indicate that any work hardening-like effects are likely attributablemore » to the crushing of asperities, and the permanent changes in the dissipative properties of the system, as measured by the coefficient of restitution, are attributable to the microstructure formed by the thermal spray coating. Furthermore, the microstructure appears to be robust across impact events of moderate energy levels, exhibiting negligible changes across multiple impact events.« less

[Preparation of citrulline microspheres by spray drying technique for colonic targeting].

PubMed

Bahri, S; Zerrouk, N; Lassoued, M-A; Tsapis, N; Chaumeil, J-C; Sfar, S

2014-03-01

Citrulline is an amino acid that becomes essential in situations of intestinal insufficiency such as short bowel syndrome. It is therefore interesting to provide the patients with dosage forms for routing citrulline to the colon. The aim of this work is to formulate microspheres of citrulline for colonic targeting by the technique of spray drying. Eudragit(®) FS 30D was selected as polymer to encapsulate citrulline using the spray drying technique. Citrulline and Eudragit(®) FS 30D were dissolved in water and ethanol, respectively. The aqueous and the ethanolic solutions were then mixed in 1:2 (v/v) ratio. Microspheres were obtained by nebulizing the citrulline-Eudragit(®) FS 30D solution using a Mini spray dryer equipped with a 0.7mm nozzle. The microspheres have been formulated using citrulline and Eudragit(®) FS 30D. The size distribution of microspheres was determined by light diffraction. The morphology of the microspheres was studied by electron microscopy. Manufacturing yields, encapsulation rate and dissolution profiles were also studied. The microspheres obtained had a spherical shape with a smooth surface and a homogeneous size except for the microspheres containing the highest concentration of polymer (90 %). The formulation showed that the size and morphology of the microspheres are influenced by the polymer concentration. Manufacturing yields were about 51 % but encapsulation rate were always very high (above 90 %). The in vitro dissolution study showed that the use of the Eudragit(®) FS 30D under these conditions is not appropriate to change the dissolution profile of the citrulline. This technique has led to the formulation of microspheres with good physical properties in terms of morphology and size. The compression of the microspheres should help to control citrulline release for colonic targeting. Copyright © 2013 Elsevier Masson SAS. All rights reserved.

Design of Experiment Analysis of the Sulzer Metco DJ High Velocity Oxy-Fuel Coating of Hydroxyapatite for Orthopedic Applications

NASA Astrophysics Data System (ADS)

Hasan, S.; Stokes, J.

2011-01-01

High Velocity Oxy-Fuel (HVOF) has the potential to produce hydroxyapatite (HA; Bio-ceramic) coatings based on its experience with other sprayed ceramic materials. This technique should offer mechanical and biological results comparable to other thermal spraying processes, such as atmospheric plasma thermal spray, currently FDA approved for HA deposition. Deposition of HA via HVOF is a new venture especially using the Sulzer Metco Diamond Jet (DJ) process, and the aim of this article was to establish this technique's potential in providing superior HA coating results compared to the FDA-approved plasma spray technique. In this research, a Design of Experiment (DOE) model was developed to optimize the Sulzer Metco DJ HVOF process for the deposition of HA. In order to select suitable ranges for the production of HA coatings, the parameters were first investigated. Five parameters (factors) were researched over two levels namely: oxygen flow rate, propylene flow rate, air flow rate, spray distance, and powder flow rate. Coating crystallinity and purity were measured at the surface of each sample as the responses to the factors used. The research showed that propylene, air flow rate, spray distance, and powder feed rate had the largest effect on the responses, and the study aimed to find the preferred optimized settings to achieve high crystallinity and purity of percentages of up to 95%. This research found crystallinity and purity values of 93.8 and 99.8%, respectively, for a set of HVOF parameters which showed improvement compared to the crystallinity and purity values of 87.6 and 99.4%, respectively, found using the FDA-approved Sulzer Metco Atmospheric Plasma thermal spray process. Hence, a new technique for HA deposition now exists using the DJ HVOF facility; however, other mechanical and biorelated properties must also be assessed.

A study on thermal properties of biodegradable polymers using photothermal methods

NASA Astrophysics Data System (ADS)

Siqueira, A. P. L.; Poley, L. H.; Sanchez, R.; da Silva, M. G.; Vargas, H.

2005-06-01

In this work is reported the use of photothermal techniques applied to the thermal characterization of biodegradable polymers of Polyhydroxyalkanoates (PHAs) family. This is a family of polymer produced by bacteria using renewable resources. It exhibits thermoplastic properties and therefore it can be an alternative product for engineering plastics, being also applied as packages for food industry and fruits. Thermal diffusivities were determined using the open photoacoustic cell (OPC) configuration. Specific heat capacity measurements were performed monitoring temperature of the samples under white light illumination against time. Typical values obtained for the thermal properties are in good agreement with those found in the literature for other polymers. Due to the incorporation of hydroxyvalerate in the monomer structure, the thermal diffusivity and thermal conductivity increase reaching a saturation value, otherwise the specific thermal capacity decreases as the concentration of the hydroxyvalerate (HV) increases. These results can be explained by polymers internal structure and are allowing new applications of these materials.

Thermal Aging Behavior of Axial Suspension Plasma-Sprayed Yttria-Stabilized Zirconia (YSZ) Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Zhao, Yuexing; Wang, Liang; Yang, Jiasheng; Li, Dachuan; Zhong, Xinghua; Zhao, Huayu; Shao, Fang; Tao, Shunyan

2015-02-01

7.5YSZ thermal barrier coatings (TBCs) were deposited onto the stainless steel substrates using axial suspension plasma spraying (ASPS). Free-standing coatings were isothermally aged in air from 1200 to 1600 °C for 24 h and at 1550 °C for 20 to 100 h, respectively. Thermal aging behavior such as phase composition, microstructure evolutions, grain growth, and mechanical properties for thermal-aged coatings were investigated. Results show that the as-sprayed metastable tetragonal (t'-ZrO2) phase decomposes into equilibrium tetragonal (t-ZrO2) and cubic (c-ZrO2) phases during high-temperature exposures. Upon further cooling, the c-ZrO2 may be retained or transform into another metastable tetragonal (t″-ZrO2) phase, and tetragonal → monoclinic phase transformation occurred after 1550 °C/40 h aging treatment. The coating exhibits a unique structure with segmentation cracks and micro/nano-size grains, and the grains grow gradually with increasing aging temperature and time. In addition, the hardness ( H) and Young's modulus ( E) significantly increased as a function of temperature due to healing of pores or cracks and grain growth of the coating. And a nonmonotonic variation is found in the coatings thermal aged at a constant temperature (1550 °C) with prolonged time, this is a synergetic effect of coating sintering and m-ZrO2 phase formation.

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.

Open cell fire-resistant foam

NASA Technical Reports Server (NTRS)

Thompson, J. E.; Wittman, J. W.; Reynard, K. A.

1976-01-01

Candidate polyphosphazene polymers were investigated to develop a fire-resistant, thermally stable and flexible open cell foam. The copolymers were prepared in several mole ratios of the substituent side chains and a (nominal) 40:60 derivative was selected for formulation studies. Synthesis of the polymers involved solution by polymerization of hexachlorophosphazene to soluble high molecular weight poly(dichlorophosphazene), followed by derivatization of the resultant polymer in a normal fashion to give polymers in high yield and high molecular weight. Small amounts of a cure site were incorporated into the polymer for vulcanization purposes. The poly(aryloxyphosphazenes) exhibited good thermal stability and the first polymer mentioned above exhibited the best thermal behavior of all the candidate polymers studied.

Spatially-resolved velocities of thermally-produced spray droplets using a velocity-divided Abel inversion of photographed streaks

NASA Astrophysics Data System (ADS)

Kawaguchi, Y.; Kobayashi, N.; Yamagata, Y.; Miyazaki, F.; Yamasaki, M.; Muraoka, K.

2017-10-01

Droplet velocities of thermal spray are known to have profound effects on important coating qualities, such as adhesive strength, porosity, and hardness, for various applications. For obtaining the droplet velocities, therefore, the TOF (time-of-flight) technique has been widely used, which relies on observations of emitted radiation from the droplets, where all droplets along the line-of-sight contribute to signals. Because droplets at and near the flow axis mostly contribute coating layers, it has been hoped to get spatially resolved velocities. For this purpose, a velocity-divided Abel inversion was devised from CMOS photographic data. From this result, it has turned out that the central velocity is about 25% higher than that obtained from the TOF technique for the case studied (at the position 150 mm downstream of the plasma spray gun, where substrates for spray coatings are usually placed). Further implications of the obtained results are discussed.

Thermal Protection System Application to Composite Cryotank Technology Demonstrator

NASA Technical Reports Server (NTRS)

Protz, Alison; Nettles, Mindy

2015-01-01

The EM41 Thermal Protection System (TPS) team contributed to the success of the Composite Cryotank Technology Demonstrator (CCTD) manufacturing by developing and implementing a low-cost solution to apply cryoinsulation foam on the exterior surface of the tank in the NASA Marshall Space Flight Center (MSFC) TPS Development Facility, Bldg. 4765. The TPS team used techniques developed for the smallscale composite cryotank to apply Stepanfoam S-180 polyurethane foam to the 5.5-meter CCTD using a manual spray process. Manual spray foam technicians utilized lifts and scaffolding to access the barrel and dome sections of the large-scale tank in the horizontal orientation. During manufacturing, the tank was then oriented vertically, allowing access to the final barrel section for manual spray foam application. The CCTD was the largest application of manual spray foam performed to date with the S-180 polyurethane foam and required the TPS team to employ best practices for process controls on the development article.

Apparatus and method to control atmospheric water vapor composition and concentration during dynamic cooling of biological tissues in conjunction with laser irradiations

DOEpatents

Nelson, J. Stuart; Anvari, Bahman; Tanenbaum, B. Samuel; Milner, Thomas E.

1999-01-01

Cryogen spray cooling of skin surface with millisecond cryogen spurts is an effective method for establishing a controlled temperature distribution in tissue and protecting the epidermis from nonspecific thermal injury during laser mediated dermatological procedures. Control of humidity level, spraying distance and cryogen boiling point is material to the resulting surface temperature. Decreasing the ambient humidity level results in less ice formation on the skin surface without altering the surface temperature during the cryogen spurt. For a particular delivery nozzle, increasing the spraying distance to 85 millimeters lowers the surface temperature. The methodology comprises establishing a controlled humidity level in the theater of operation of the irradiation site of the biological tissues before and/or during the cryogenic spray cooling of the biological tissue. At cold temperatures calibration was achieved by mounting a thermistor on a thermoelectric cooler. The thermal electric cooler was cooled from from 20.degree. C. to about -20.degree. C. while measuring its infrared emission.

Process-based quality for thermal spray via feedback control

NASA Astrophysics Data System (ADS)

Dykhuizen, R. C.; Neiser, R. A.

2006-09-01

Quality control of a thermal spray system manufacturing process is difficult due to the many input variables that need to be controlled. Great care must be taken to ensure that the process remains constant to obtain a consistent quality of the parts. Control is greatly complicated by the fact that measurement of particle velocities and temperatures is a noisy stochastic process. This article illustrates the application of quality control concepts to a wire flame spray process. A central feature of the real-time control system is an automatic feedback control scheme that provides fine adjustments to ensure that uncontrolled variations are accommodated. It is shown how the control vectors can be constructed from simple process maps to independently control particle velocity and temperature. This control scheme is shown to perform well in a real production environment. We also demonstrate that slight variations in the feed wire curvature can greatly influence the process. Finally, the geometry of the spray system and sensor must remain constant for the best reproducibility.

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.

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

DOE PAGES

Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay; ...

2014-06-09

Fracture toughness has become one of the dominant design parameters that dictates the selection of materials and their microstructure to obtain durable thermal barrier coatings (TBCs). Much progress has been made in characterizing the fracture toughness of relevant TBC compositions in bulk form, and it has become apparent that this property is significantly affected by process-induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma sprayed (APS) TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different spray process conditions inducing different levelsmore » of porosity and interfacial defects. Fracture toughness was measured on free standing coatings in as-processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative TBC composition, Gd 2Zr 2O 7 (GDZ), which as anticipated shows significantly lower fracture toughness compared to YSZ. Furthermore, the results from these studies not only point towards a need for process and microstructure optimization for enhanced TBC performance but also a framework for establishing performance metrics for promising new TBC compositions.« less

Precipitation of lamellar gold nanocrystals in molten polymers

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

Palomba, M.; Carotenuto, G., E-mail: giancaro@unina.it

Non-aggregated lamellar gold crystals with regular shape (triangles, squares, pentagons, etc.) have been produced by thermal decomposition of gold chloride (AuCl) molecules in molten amorphous polymers (polystyrene and poly(methyl methacrylate)). Such covalent inorganic gold salt is high soluble into non-polar polymers and it thermally decomposes at temperatures compatible with the polymer thermal stability, producing gold atoms and chlorine radicals. At the end of the gold precipitation process, the polymer matrix resulted chemically modified because of the partial cross-linking process due to the gold atom formation reaction.

Formation of Fiber Materials by Pneumatic Spraying of Polymers in Viscous-Flow States

NASA Astrophysics Data System (ADS)

Lysak, I. A.; Malinovskaya, T. D.; Lysak, G. V.; Potekaev, A. I.; Kulagina, V. V.; Tazin, D. I.

2017-02-01

Using a novel ejection spraying unit and relying on new approaches, fibers are formed by the method of pneumatic melt blowing of polycarbonate, polypropylene, and polyethylene terephthalate. The proposed approach is based on the concepts of atomization of the polymer melt flow as a preferential regime for fibermaterial formation. From the analysis of the values of numerical characteristics in the zone of atomization and the physical background of the criteria under study a conclusion is drawn that the essential role in destruction of the jet belongs to the formation of a boundary layer in the melt under the action of friction forces, followed by its separation. An assumption is made on the prevailing action of the separating destruction of the melt jet via the mechanism of `skinning' of the boundary layer of the melt due to a shorter time of its persistence compared to the development of the Kelvin-Helmholtz instability.

Spray-Deposited Superconductor/Polymer Coatings

NASA Technical Reports Server (NTRS)

Wise, Stephanie A.; Tran, Sang Q.; Hooker, Matthew W.

1993-01-01

Coatings that exhibit the Meissner effect formed at relatively low temperature. High-temperature-superconductor/polymer coatings that exhibit Meissner effect deposited onto components in variety of shapes and materials. Simple, readily available equipment needed in coating process, mean coatings produced economically. Coatings used to keep magnetic fields away from electronic circuits in such cryogenic applications as magnetic resonance imaging and detection of infrared, and in magnetic suspensions to provide levitation and/or damping of vibrations.

Heat transfer and thermal management studies of lithium polymer batteries for electric vehicle applications

NASA Astrophysics Data System (ADS)

Song, Li

The thermal conductivities of the polymer electrolyte and composite cathode are important parameters characterizing heat transport in lithium polymer batteries. The thermal conductivities of lithium polymer electrolytes, including poly-ethylene oxide (PEO), PEO-LiClO4, PEO-LiCF3SO 3, PEO-LiN(CF3SO2)2, PEO-LiC(CF 3SO2)3, and the thermal conductivities of TiS 2 and V6O13 composite cathodes, were measured over the temperature range from 25°C to 150°C by a guarded heat flow meter. The thermal conductivities of the electrolytes were found to be relatively constant for the temperature and for electrolytes with various concentrations of the lithium salt. The thermal conductivities of the composite cathodes were found to increase with the temperature below the melting temperature of the polymer electrolyte and only slightly increase above the melting temperature. Three different lithium polymer cells, including Li/PEO-LiCF3 S O3/TiS2, Li/PEO-LiC(CF3 S O2)3/V6 O13, and Li/PEO-LiN(CF3 S O2)2/ Li1+x Mn2 O4 were prepared and their discharge curves, along with heat generation rates, were measured at various galvanostatic discharge current densities, and at different temperature (70°C, 80°C and 90°C), by a potentiostat/galvanostat and an isothermal microcalorimeter. The thermal stability of a lithium polymer battery was examined by a linear perturbation analysis. In contrast to the thermal conductivity, the ionic conductivity of polymer electrolytes for lithium-polymer cell increases greatly with increasing temperature, an instability could arise from this temperature dependence. The numerical calculations, using a two dimensional thermal model, were carried out for constant potential drop across the electrolyte, for constant mean current density and for constant mean cell output power. The numerical calculations were approximately in agreement with the linear perturbation analysis. A coupled mathematical model, including electrochemical and thermal components, was developed to study the heat transfer and thermal management of lithium polymer batteries. The results calculated from the model, including temperature distributions, and temperatures at different stages of discharge are significantly different from those calculated from the thermal model. The discharge curves and heat generation rates calculated by the electrochemical-thermal model were in agreement with the experimental results. Different thermal management approaches, including a variable conductance insulation enclosure were studied.

Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review

NASA Astrophysics Data System (ADS)

Toma, Filofteia-Laura; Potthoff, Annegret; Berger, Lutz-Michael; Leyens, Christoph

2015-10-01

Research and development work for about one decade have demonstrated many unique thermal spray coating properties, particularly for oxide ceramic coatings by using suspensions of fine powders as feedstock in APS and HVOF processes. Some particular advantages are direct feeding of fine nano- and submicron-scale particles avoiding special feedstock powder preparation, ability to produce coating thicknesses ranging from 10 to 50 µm, homogeneous microstructure with less anisotropy and lower surface roughness compared to conventional coatings, possibility of retention of the initial crystalline phases, and others. This paper discusses the main aspects of thermal spraying with suspensions which have been taken into account in order to produce these coatings on an economical way. The economic efficiency of the process depends on the availability of suitable additional system components (suspension feeder, injectors), on the development and handling of stable suspensions, as well as on the high process stability for acceptance at industrial scale. Special focus is made on the development and processability of highly concentrated water-based suspensions. While costs and operational safety clearly speak for use of water as a liquid media for preparing suspensions on an industrial scale, its use is often critically discussed due to the required higher heat input during spraying compared to alcoholic suspensions.

Microstructure and properties of thermally sprayed Al-Sn-based alloys for plain bearing applications

NASA Astrophysics Data System (ADS)

Marrocco, T.; Driver, L. C.; Harris, S. J.; McCartney, D. G.

2006-12-01

Al-Sn plain bearings for automotive applications traditionally comprise a multilayer structure. Conventionally, bearing manufacturing involves casting the Al-Sn alloy and roll-bonding to a steel backing strip. Recently, high-velocity oxyfuel (HVOF) thermal spraying has been used as a novel alternative manufacturing route. The present project extends previous work on ternary Al-Sn-Cu alloys to quaternary systems, which contain specific additions for potentially enhanced properties. Two alloys were studied in detail, namely, Al-20wt.%Sn-1wt.%Cu-2wt.%Ni and Al-20wt.%Sn-1wt.%Cu-7wt.%Si. This article will describe the microstructural evolution of these alloys following HVOF spraying onto steel substrates and subsequent heat treatment. The microstructures of powders and coatings were investigated by scanning electron microscopy, and the phases were identified by x-ray diffraction. Coating microhardnesses were determined under both as-sprayed and heat-treated conditions, and by the differences related to the microstructures that developed. Finally, the wear behavior of the sprayed and heat-treated coatings in hot engine oil was measured using an industry standard test and was compared with that of previous work on a ternary alloy.

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.

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

NASA Astrophysics Data System (ADS)

Lindner, T.; Bonebeau, S.; Drehmann, R.; Grund, T.; Pawlowski, L.; Lampke, T.

2016-03-01

In wire arc spraying, the raw material needs to exhibit sufficient formability and ductility in order to be processed. By using an electrically conductive, metallic sheath, it is also possible to handle non-conductive and/or brittle materials such as ceramics. In comparison to massive wire, a cored wire has a heterogeneous material distribution. Due to this fact and the complex thermodynamic processes during wire arc spraying, it is very difficult to predict the resulting chemical composition in the coating with sufficient accuracy. An Inconel 625 cored wire was used to investigate this issue. In a comparative study, the analytical results of the raw material were compared to arc sprayed coatings and droplets, which were remelted in an arc furnace under argon atmosphere. Energy-dispersive X-ray spectroscopy (EDX) and X-ray fluorescence (XRF) analysis were used to determine the chemical composition. The phase determination was performed by X-ray diffraction (XRD). The results were related to the manufacturer specifications and evaluated in respect to differences in the chemical composition. The comparison between the feedstock powder, the remelted droplets and the thermally sprayed coatings allows to evaluate the influence of the processing methods on the resulting chemical and phase composition.

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.

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.

Method of producing thermally sprayed metallic coating

DOEpatents

Byrnes, Larry Edward [Rochester Hills, MI; Kramer, Martin Stephen [Clarkston, MI; Neiser, Richard A [Albuquerque, NM

2003-08-26

The cylinder walls of light metal engine blocks are thermally spray coated with a ferrous-based coating using an HVOF device. A ferrous-based wire is fed to the HVOF device to locate a tip end of the wire in a high temperature zone of the device. Jet flows of oxygen and gaseous fuel are fed to the high temperature zone and are combusted to generate heat to melt the tip end. The oxygen is oversupplied in relation to the gaseous fuel. The excess oxygen reacts with and burns a fraction of the ferrous-based feed wire in an exothermic reaction to generate substantial supplemental heat to the HVOF device. The molten/combusted metal is sprayed by the device onto the walls of the cylinder by the jet flow of gases.

Wear and corrosion behaviour of Al2O3-TiO2 coatings produced by flame thermal projection

NASA Astrophysics Data System (ADS)

Forero-Duran, M.; Dulce-Moreno, H. J.; Ferrer-Pacheco, M.; Vargas-Galvis, F.

2017-12-01

Evaluated the wear resistance and the coatings corrosion behaviour of Al2O3-TiO2 prepared by thermal spraying by flame on AISI 1020 carbon steel substrates, previously coated with an alloy base Ni. For this purpose, were controlled parameters of thermal spraying and the use of powders of similar but different chemical composition is taken as a variable commercial reference for ceramic coating. SEM images allowed to know the morphology of the powders and coatings. Electrochemical techniques (Tafel) were applied to evaluate the protection against corrosion. Coatings were tested for wear with a tribometer configuration bola-disco. It was determined that the phases present in coatings are directly relate to the behaviour against corrosion and wear them. Keywords: wear, corrosion, thermal imaging.

A Review of Single Source Precursors for the Deposition of Ternary Chalcopyrite Materials

NASA Technical Reports Server (NTRS)

Banger, K. K.; Cowen, J.; Harris, J.; McClarnon, R.; Hehemann, D. G.; Duraj, S. A.; Scheiman, D.; Hepp, A. F.

2002-01-01

The development of thin-film solar cells on flexible, lightweight, space-qualified durable substrates (i.e. Kapton) provides an attractive solution to fabricating solar arrays with high specific power, (W/kg). The syntheses and thermal modulation of ternary single source precursors, based on the [{LR}2Cu(SR')2In(SR')2] architecture in good yields are described. Thermogravimetric analyses (TGA) and Low temperature Differential Scanning Caloriometry, (DSC) demonstrate that controlled manipulation of the steric and electronic properties of either the group five-donor and/or chalcogenide moiety permits directed adjustment of the thermal stability and physical properties of the precursors. TGA-Evolved Gas Analysis, confirms that single precursors decompose by the initial extrusion of the sulphide moiety, followed by the loss of the neutral donor group, (L) to release the ternary chalcopyrite matrix. X-ray diffraction studies, EDS and SEM on the non-volatile pyrolized material demonstrate that these derivatives afford single-phase CuInS2/CuInSe2 materials at low temperature. Thin-film fabrication studies demonstrate that these single source precursors can be used in a spray chemical vapor deposition process, for depositing CuInS2 onto flexible polymer substrates at temperatures less than 400 C.

Time constants for the evolution of sea spray droplets

NASA Astrophysics Data System (ADS)

Andreas, Edgar L.

1990-11-01

Sea spray droplets start with the same temperature as the ocean surface from which they form. In high-latitude, polar-low conditions, they therefore cool and evaporate in a relatively cold wind and may alter the air sea exchange of heat and moisture. This paper presents equations that model the thermal and size (moisture) evolution of a spray droplet from the time it forms until it reaches equilibrium with its environment. The model does well when tested against some of the scanty data available on the evolution of saline droplets. We parameterize the thermal and size evolution of spray droplets with the time constants τT and τr, which are, respectively, the times required for a droplet to come to within e1 of its equilibrium temperature and within e1 of its equilibrium radius. τr is always about three orders of magnitude larger than τT; the thermal exchange is thus complete before the moisture exchange even starts. Consequently, the ambient humidity has little effect on the thermal exchange rate, and the initial droplet temperature has negligible effect on the moisture exchange rate. We also parameterize the gravitational settling of droplets and their potential for turbulent suspension with the time scales τf and τw, respectively. Comparing the four time scales, we see that spray droplets with initial radii less than 10μm reach both thermal and size equilibrium with the ambient air. Droplets with initial radii greater than 300μm, on the other hand, fall back into the sea before exchanging appreciable heat or moisture; they thus have little impact on air sea exchange. In the mid-range, droplets with initial radii between 10 and 300μm, the physics is more complex. Even after comparing τT and τr with τf and τw, we still cannot say unequivocally which process is fastest because of the rudimentary nature of the τw estimates. Future work must thus focus on the generation and turbulent transport of droplets of this size if we are to understand how sea spray affects air sea exchange.

Recyclable thermosetting thermal pad using silicone-based polyurethane crosslinked by Diels-Alder adduct

NASA Astrophysics Data System (ADS)

Kim, Jong-Woong; Lee, Da Hee; Jeon, Hee-Jeong; Jang, Sung Il; Cho, Hyun Min; Kim, Youngmin

2018-01-01

The recyclable silicone-based thermoset was successfully synthesized by making use of a Diels-Alder (DA) adduct as a cross-linker. The incorporation of the furan-tethered diol 1 into the polymer backbones realized the crosslinking of polymers via the DA reaction. The thermosetting polymer was dissolved in DMF after the retro DA reaction which was monitored by 1H NMR spectroscopy. Due to the retro DA reaction, polymer showed the mendable behavior when it was scratched followed by being heated. This polymer was mixed with alumina powders to fabricate the thermal pad. The thermal resistance of this pad was measured to be 0.48 K/W by a thermal transient test. The thermosetting composite was recycled via the retro DA reaction. The thermal resistance of the recycled one was similar to that of the original one.

Gas Dynamic Spray Technology Demonstration

NASA Technical Reports Server (NTRS)

Burford, Pattie Lewis

2011-01-01

Zinc primer systems are currently used across NASA and AFSPC for corrosion protection of steel. AFSPC and NASA have approved the use of Thermal Spray Coatings (TSCs) as an environmentally preferable alternative. TSCs are approved in NASA-STD-5008 and AFSPC and KSC is currently looking for additional applications in which TSC can be used. Gas Dynamic Spray (GDS, also known as Cold Spray) is being evaluated as a means of repairing TSCs and for areas such as corners and edges where TSCs do not work as well. Other applications could include spot repair/maintenance of steel on structures, facilities, and ground support equipment.

Protection of alodine coatings from thermal aging by removable polymer coatings.

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

Wagstaff, Brett R.; Bradshaw, Robert W.; Whinnery, LeRoy L., Jr.

2006-12-01

Removable polymer coatings were evaluated as a means to suppress dehydration of Alodine chromate conversion coatings during thermal aging and thereby retain the corrosion protection afforded by Alodine. Two types of polymer coatings were applied to Alodine-treated panels of aluminum alloys 7075-T73 and 6061-T6 that were subsequently aged for 15 to 50 hours at temperatures between 135 F to 200 F. The corrosion resistance of the thermally aged panels was evaluated, after stripping the polymer coatings, by exposure to a standard salt-fog corrosion test and the extent of pitting of the polymer-coated and untreated panels compared. Removable polymer coatings mitigatedmore » the loss of corrosion resistance due to thermal aging experienced by the untreated alloys. An epoxide coating was more effective than a fluorosilicone coating as a dehydration barrier.« less

Polyphosphazine-based polymer materials

DOEpatents

Fox, Robert V.; Avci, Recep; Groenewold, Gary S.

2010-05-25

Methods of removing contaminant matter from porous materials include applying a polymer material to a contaminated surface, irradiating the contaminated surface to cause redistribution of contaminant matter, and removing at least a portion of the polymer material from the surface. Systems for decontaminating a contaminated structure comprising porous material include a radiation device configured to emit electromagnetic radiation toward a surface of a structure, and at least one spray device configured to apply a capture material onto the surface of the structure. Polymer materials that can be used in such methods and systems include polyphosphazine-based polymer materials having polyphosphazine backbone segments and side chain groups that include selected functional groups. The selected functional groups may include iminos, oximes, carboxylates, sulfonates, .beta.-diketones, phosphine sulfides, phosphates, phosphites, phosphonates, phosphinates, phosphine oxides, monothio phosphinic acids, and dithio phosphinic acids.

Position Paper External Tank Thermal Protection System (TPS) Manually Sprayed fly-as-is Foam Certification

NASA Technical Reports Server (NTRS)

Stadler, John H.

2009-01-01

During manufacture of the existing External Tanks (ETs), the Thermal Protection System (TPS) foam manual spray application processes lacked the enhanced controls/procedures to ensure that defects produced were less than the critical size. Therefore the only remaining option to certify the "fly-as-is" foam is to verify ET120 tank hardware meets the new foam debris requirements. The ET project has undertaken a significant effort studying the existing "fly-as-is" TPS foam. This paper contains the findings of the study.

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.

Macro controlling of copper oxide deposition processes and spray mode by using home-made fully computerized spray pyrolysis system

NASA Astrophysics Data System (ADS)

Essa, Mohammed Sh.; Chiad, Bahaa T.; Shafeeq, Omer Sh.

2017-09-01

Thin Films of Copper Oxide (CuO) absorption layer have been deposited using home-made Fully Computerized Spray Pyrolysis Deposition system FCSPD on glass substrates, at the nozzle to substrate distance equal to 20,35 cm, and computerized spray mode (continues spray, macro-control spray). The substrate temperature has been kept at 450 °c with the optional user can enter temperature tolerance values ± 5 °C. Also that fixed molar concentration of 0.1 M, and 2D platform speed or deposition platform speed of 4mm/s. more than 1000 instruction program code, and specific design of graphical user interface GUI to fully control the deposition process and real-time monitoring and controlling the deposition temperature at every 200 ms. The changing in the temperature has been recorded during deposition processes, in addition to all deposition parameters. The films have been characterized to evaluate the thermal distribution over the X, Y movable hot plate, the structure and optical energy gap, thermal and temperature distribution exhibited a good and uniform distribution over 20 cm2 hot plate area, X-ray diffraction (XRD) measurement revealed that the films are polycrystalline in nature and can be assigned to monoclinic CuO structure. Optical band gap varies from 1.5-1.66 eV depending on deposition parameter.

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

Method for Forming Fiber Reinforced Composite Bodies with Graded Composition and Stress Zones

NASA Technical Reports Server (NTRS)

Singh, Mrityunjay (Inventor); Levine, Stanley R. (Inventor); Smialek, James A. (Inventor)

1999-01-01

A near-net, complex shaped ceramic fiber reinforced silicon carbide based composite bodies with graded compositions and stress zones is disclosed. To provide the composite a fiber preform is first fabricated and an interphase is applied by chemical vapor infiltration, sol-gel or polymer processes. This first body is further infiltrated with a polymer mixture containing carbon, and/or silicon carbide, and additional oxide, carbide, or nitride phases forming a second body. One side of the second body is spray coated or infiltrated with slurries containing high thermal expansion and oxidation resistant. crack sealant phases and the other side of this second body is coated with low expansion phase materials to form a third body. This third body consisting of porous carbonaceous matrix surrounding the previously applied interphase materials, is then infiltrated with molten silicon or molten silicon-refractory metal alloys to form a fourth body. The resulting fourth body comprises dense composites consisting of fibers with the desired interphase which are surrounded by silicon carbide and other second phases materials at the outer and inner surfaces comprising material of silicon, germanium, refractory metal suicides, borides, carbides, oxides, and combinations thereof The resulting composite fourth body has different compositional patterns from one side to the other.

Pressurized feed-injection spray-forming apparatus

DOEpatents

Berry, R.A.; Fincke, J.R.; McHugh, K.M.

1995-08-29

A spray apparatus and method are disclosed for injecting a heated, pressurized liquid in a first predetermined direction into a pressurized gas flow that is flowing in a second predetermined direction, to provide for atomizing and admixing the liquid with the gas to form a two-phase mixture. A valve is also disposed within the injected liquid conduit to provide for a pulsed injection of the liquid and timed deposit of the atomized gas phase. Preferred embodiments include multiple liquid feed ports and reservoirs to provide for multiphase mixtures of metals, ceramics, and polymers. 22 figs.

Pressurized feed-injection spray-forming apparatus

DOEpatents

Berry, Ray A.; Fincke, James R.; McHugh, Kevin M.

1995-01-01

A spray apparatus and method for injecting a heated, pressurized liquid in a first predetermined direction into a pressurized gas flow that is flowing in a second predetermined direction, to provide for atomizing and admixing the liquid with the gas to form a two-phase mixture. A valve is also disposed within the injected liquid conduit to provide for a pulsed injection of the liquid and timed deposit of the atomized gas phase. Preferred embodiments include multiple liquid feed ports and reservoirs to provide for multiphase mixtures of metals, ceramics, and polymers.

Multi-Layer Coating of Ultrathin Polymer Films on Nanoparticles of Alumina by a Plasma Treatment

DTIC Science & Technology

2001-01-01

Proc. Vol. 635 © 2001 Materials Research Society Multi-Layer Coating of Ultrathin Polymer Films on Nanoparticles of Alumina by a Plasma Treatment Donglu...interconnected organic and inorganic networks results in coatings with a very low permeability for gases and liquids. Hybrid materials are very suitable for... materials consist of a clear alcoholic solution that can easily be processed by classical application techniques such as dipping, spraying, or spin coating

Ex vivo investigations of laser auricular cartilage reshaping with carbon dioxide spray cooling in a rabbit model

PubMed Central

Wu, Edward C.; Sun, Victor; Manuel, Cyrus T.; Protsenko, Dmitriy E.; Jia, Wangcun; Nelson, J. Stuart; Wong, Brian J. F.

2014-01-01

Laser cartilage reshaping (LCR) with cryogen spray cooling is a promising modality for producing cartilage shape change while reducing cutaneous thermal injury. However, LCR in thicker tissues, such as auricular cartilage, requires higher laser power, thus increasing cooling requirements. To eliminate the risks of freeze injury characteristic of high cryogen spray pulse rates, a carbon dioxide (CO2) spray, which evaporates rapidly from the skin, has been proposed as the cooling medium. This study aims to identify parameter sets which produce clinically significant reshaping while producing minimal skin thermal injury in LCR with CO2 spray cooling in ex vivo rabbit auricular cartilage. Excised whole rabbit ears were mechanically deformed around a cylindrical jig and irradiated with a 1.45-μm wavelength diode laser (fluence 12–14 J/cm2 per pulse, four to six pulse cycles per irradiation site, five to six irradiation sites per row for four rows on each sample) with concomitant application of CO2 spray (pulse duration 33–85 ms) to the skin surface. Bend angle measurements were performed before and after irradiation, and the change quantified. Surface temperature distributions were measured during irradiation/cooling. Maximum skin surface temperature ranged between 49.0 to 97.6 °C following four heating/cooling cycles. Significant reshaping was achieved with all laser dosimetry values with a 50–70 °C difference noted between controls (no cooling) and irradiated ears. Increasing cooling pulse duration yielded progressively improved gross skin protection during irradiation. CO2 spray cooling may potentially serve as an alternative to traditional cryogen spray cooling in LCR and may be the preferred cooling medium for thicker tissues. Future studies evaluating preclinical efficacy in an in vivo rabbit model are in progress. PMID:23307439

Ex vivo investigations of laser auricular cartilage reshaping with carbon dioxide spray cooling in a rabbit model.

PubMed

Wu, Edward C; Sun, Victor; Manuel, Cyrus T; Protsenko, Dmitriy E; Jia, Wangcun; Nelson, J Stuart; Wong, Brian J F

2013-11-01

Laser cartilage reshaping (LCR) with cryogen spray cooling is a promising modality for producing cartilage shape change while reducing cutaneous thermal injury. However, LCR in thicker tissues, such as auricular cartilage, requires higher laser power, thus increasing cooling requirements. To eliminate the risks of freeze injury characteristic of high cryogen spray pulse rates, a carbon dioxide (CO2) spray, which evaporates rapidly from the skin, has been proposed as the cooling medium. This study aims to identify parameter sets which produce clinically significant reshaping while producing minimal skin thermal injury in LCR with CO2 spray cooling in ex vivo rabbit auricular cartilage. Excised whole rabbit ears were mechanically deformed around a cylindrical jig and irradiated with a 1.45-μm wavelength diode laser (fluence 12-14 J/cm(2) per pulse, four to six pulse cycles per irradiation site, five to six irradiation sites per row for four rows on each sample) with concomitant application of CO2 spray (pulse duration 33-85 ms) to the skin surface. Bend angle measurements were performed before and after irradiation, and the change quantified. Surface temperature distributions were measured during irradiation/cooling. Maximum skin surface temperature ranged between 49.0 to 97.6 °C following four heating/cooling cycles. Significant reshaping was achieved with all laser dosimetry values with a 50-70 °C difference noted between controls (no cooling) and irradiated ears. Increasing cooling pulse duration yielded progressively improved gross skin protection during irradiation. CO2 spray cooling may potentially serve as an alternative to traditional cryogen spray cooling in LCR and may be the preferred cooling medium for thicker tissues. Future studies evaluating preclinical efficacy in an in vivo rabbit model are in progress.

Enhanced thermal conductance of polymer composites through embedding aligned carbon nanofibers

DOE PAGES

Nicholas, Roberts; Hensley, Dale K.; Wood, David

2016-07-08

The focus of this work is to find a more efficient method of enhancing the thermal conductance of polymer thin films. This work compares polymer thin films embedded with randomly oriented carbon nanotubes to those with vertically aligned carbon nanofibers. Thin films embedded with carbon nanofibers demonstrated a similar thermal conductance between 40–60 μm and a higher thermal conductance between 25–40 μm than films embedded with carbon nanotubes with similar volume fractions even though carbon nanotubes have a higher thermal conductivity than carbon nanofibers

Enhanced thermal conductance of polymer composites through embedding aligned carbon nanofibers

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

Nicholas, Roberts; Hensley, Dale K.; Wood, David

The focus of this work is to find a more efficient method of enhancing the thermal conductance of polymer thin films. This work compares polymer thin films embedded with randomly oriented carbon nanotubes to those with vertically aligned carbon nanofibers. Thin films embedded with carbon nanofibers demonstrated a similar thermal conductance between 40–60 μm and a higher thermal conductance between 25–40 μm than films embedded with carbon nanotubes with similar volume fractions even though carbon nanotubes have a higher thermal conductivity than carbon nanofibers

Effect of spray-drying with organic solvents on the encapsulation, release and stability of fish oil.

PubMed

Encina, Cristian; Márquez-Ruiz, Gloria; Holgado, Francisca; Giménez, Begoña; Vergara, Cristina; Robert, Paz

2018-10-15

Fish-oil (FO) was encapsulated with hydroxypropylcelullose (HPC) by conventional spray-drying with water (FO-water) and solvent spray-drying with ethanol (FO-EtOH), methanol (FO-MeOH) and acetone (FO-Acet) in order to study the effect of the solvent on the encapsulation efficiency (EE), microparticle properties and stability of FO during storage at 40 °C. Results showed that FO-Acet presented the highest EE of FO (92.0%), followed by FO-EtOH (80.4%), FO-MeOH (75.0%) and FO-water (71.1%). A decrease of the dielectric constant increased the EE of FO, promoting triglyceride-polymer interactions instead of oil-in-water emulsion retention. FO release profile in aqueous model was similar for all FO-microparticles, releasing only the surface FO, according to Higuchi model. Oxidative stability of FO significantly improved by spray-drying with MeOH, both in surface and encapsulated oil fractions. In conclusion, encapsulation of FO by solvent spray-drying can be proposed as an alternative technology for encapsulation of hydrophobic molecules. Copyright © 2018 Elsevier Ltd. All rights reserved.

Reliability and effective thermal conductivity of three metallic-ceramic composite insulating coatings on cooled hydrogen-oxygen rockets

NASA Technical Reports Server (NTRS)

Price, H. G., Jr.; Schacht, R. L.; Quentmeyer, R. J.

1973-01-01

An experimental investigation of the structural integrity and effective thermal conductivity of three metallic-ceramic composite coatings was conducted. These coatings were plasma sprayed onto the combustion side of water-cooled, 12.7-centimeter throat diameter, hydrogen-oxygen rocket thrust chambers operating at 2.07 to 4.14 meganewtons per square meter chamber pressure. The metallic-ceramic composites functioned for six to 17 cycles and for as long as 213 seconds of rocket operations and could have probably provided their insulating properties for many additional cycles. The effective thermal conductivity of all the coatings was in the range of 0.7472 to 4.483 w/(m)(K), which makes the coatings a very effective thermal barrier. Photomicrographic studies of cross-sectioned coolant tubes seem to indicate that the effective thermal conductivity of the coatings is controlled by contact resistance between the particles, as a result of the spraying process, and not the thermal conductivity of the bulk materials.

Fuel thermal stability effects on spray characteristics

NASA Technical Reports Server (NTRS)

Lefebvre, A. H.; Nickolaus, D.

1987-01-01

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

LSPRAY-V: A Lagrangian Spray Module

NASA Technical Reports Server (NTRS)

Raju, M. S.

2015-01-01

LSPRAY-V is a Lagrangian spray solver developed for application with unstructured grids and massively parallel computers. It is mainly designed to predict the flow, thermal and transport properties of a rapidly vaporizing spray encountered over a wide range of operating conditions in modern aircraft engine development. It could easily be coupled with any existing gas-phase flow and/or Monte Carlo Probability Density Function (PDF) solvers. The manual provides the user with an understanding of various models involved in the spray formulation, its code structure and solution algorithm, and various other issues related to parallelization and its coupling with other solvers. With the development of LSPRAY-V, we have advanced the state-of-the-art in spray computations in several important ways.

Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

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

2001-01-01

Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.

Thermal Diffusivity Measurement for Thermal Spray Coating Attached to Substrate Using Laser Flash Method

NASA Astrophysics Data System (ADS)

Akoshima, Megumi; Tanaka, Takashi; Endo, Satoshi; Baba, Tetsuya; Harada, Yoshio; Kojima, Yoshitaka; Kawasaki, Akira; Ono, Fumio

2011-11-01

Ceramic-based thermal barrier coatings are used as heat and wear shields of gas turbine blades. There is a strong need to evaluate the thermal conductivity of coating for thermal design and use. The thermal conductivity of a bulk material is obtained as the product of thermal diffusivity, specific heat capacity, and density above room temperature in many cases. Thermal diffusivity and thermal conductivity are unique for a given material because they are sensitive to the structure of the material. Therefore, it is important to measure them in each sample. However it is difficult to measure the thermal diffusivity and thermal conductivity of coatings because coatings are attached to substrates. In order to evaluate the thermal diffusivity of a coating attached to the substrate, we have examined the laser flash method with the multilayer model on the basis of the response function method. We carried out laser flash measurements in layered samples composed of a CoNiCrAlY bond coating and a 8YSZ top coating by thermal spraying on a Ni-based superalloy substrate. It was found that the procedure using laser flash method with the multilayer model is useful for the thermal diffusivity evaluation of a coating attached to a substrate.

Synthesis and characterization of thermally stable and/or conductive polymers

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

Gajiwala, H.M.

1992-01-01

Eight new thermally stable polyimides were synthesized from two tricyclic heterocyclic diamines: thionine which has a phenothiazine moiety and proflavine which has an acridine unit. The polymerization reactions were optimized with respect to solvents, reaction time, reaction temperature, solid contents, etc., and their structure property relationships were studied. All these soluble polyimides have nice film forming properties. One of the polyimides containing the acridine moiety, appears to have a tendency to form a liquid crystalline state when its solution is passed through a fine capillary. All of these polyimides were thermally stable in air up to 500-550[degrees]C and up tomore » 600[degrees]C in a nitrogen atmosphere. They have refractive indices in the range of 1.65 to 1.85 and have relatively low value of permittivity. Two other thermally stable polymers, viz., polybenzimidazole and the ladder polymer having the phenazine moiety in the backbone were also synthesized. For these polymerization reactions, tetraamino derivative of phenazine was synthesized from the commercially available diamino, dinitro derivative of benzene. The polybenzimidazole was prepared via the azomethine pathway. This polymer had an intrinsic viscosity of 0.94 in methanesulfonic acid. The nice film forming polybenzimidazole polymer was found to be thermally stable up to 400[degrees]C. The ladder type of a polymer was synthesized by condensation polymerization between tetraaminophenazine and dihydroxybenzophenone in polyphosphoric acid at an elevated temperature. The completely conjugated ladder polymer was found to be semiconducting on doping with iodine. This polymer was highly crystalline as demonstrated by its X-ray diffraction pattern. A morphology study of the polymer indicated that the material has a tendency to form dendritic crystals. The polymer was thermally stable up to about 400[degrees]C in air.« less

Self-Cleaning Anticondensing Glass via Supersonic Spraying of Silver Nanowires, Silica, and Polystyrene Nanoparticles.

PubMed

Lee, Jong-Gun; An, Seongpil; Kim, Tae-Gun; Kim, Min-Woo; Jo, Hong-Seok; Swihart, Mark T; Yarin, Alexander L; Yoon, Sam S

2017-10-11

We have sequentially deposited layers of silver nanowires (AgNWs), silicon dioxide (SiO 2 ) nanoparticles, and polystyrene (PS) nanoparticles on uncoated glass by a rapid low-cost supersonic spraying method to create antifrosting, anticondensation, and self-cleaning glass. The conductive silver nanowire network embedded in the coating allows electrical heating of the glass surface. Supersonic spraying is a single-step coating technique that does not require vacuum. The fabricated multifunctional glass was characterized by X-ray diffraction analysis (XRD), scanning electron microscopy (SEM), atomic force microscopy (AFM), ultraviolet-visible spectroscopy, and transmission electron microscopy (TEM). The thermal insulation and antifrosting performance were demonstrated using infrared thermal imaging. The reliability of the electrical heating function was tested through extensive cycling. This transparent multifunctional coating holds great promise for use in various smart window designs.

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.

Sequential cryogen spraying for heat flux control at the skin surface

NASA Astrophysics Data System (ADS)

Majaron, Boris; Aguilar, Guillermo; Basinger, Brooke; Randeberg, Lise L.; Svaasand, Lars O.; Lavernia, Enrique J.; Nelson, J. Stuart

2001-05-01

Heat transfer rate at the skin-air interface is of critical importance for the benefits of cryogen spray cooling in combination with laser therapy of shallow subsurface skin lesions, such as port-wine stain birthmarks. With some cryogen spray devices, a layer of liquid cryogen builds up on the skin surface during the spurt, which may impair heat transfer across the skin surface due to relatively low thermal conductivity and potentially higher temperature of the liquid cryogen layer as compared to the spray droplets. While the mass flux of cryogen delivery can be adjusted by varying the atomizing nozzle geometry, this may strongly affect other spray properties, such as lateral spread (cone), droplet size, velocity, and temperature distribution. We present here first experiments with sequential cryogen spraying, which may enable accurate mass flux control through variation of spray duty cycle, while minimally affecting other spray characteristics. The observed increase of cooling rate and efficiency at moderate duty cycle levels supports the above described hypothesis of isolating liquid layer, and demonstrates a novel approach to optimization of cryogen spray devices for individual laser dermatological applications.

Bond Coat Engineering Influence on the Evolution of the Microstructure, Bond Strength, and Failure of TBCs Subjected to Thermal Cycling

NASA Astrophysics Data System (ADS)

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

2015-01-01

Different types of thermal spray systems, including HVOF (JP5000 and DJ2600-hybrid), APS (F4-MB and Axial III), and LPPS (Oerlikon Metco system) were employed to spray CoNiCrAlY bond coats (BCs) onto Inconel 625 substrates. The chemical composition of the BC powder was the same in all cases; however, the particle size distribution of the powder employed with each torch was that specifically recommended for the torch. For optimization purposes, these BCs were screened based on initial evaluations of roughness, porosity, residual stress, relative oxidation, and isothermal TGO growth. A single type of standard YSZ top coat was deposited via APS (F4MB) on all the optimized BCs. The TBCs were thermally cycled by employing a furnace cycle test (FCT) (1080 °C-1 h—followed by forced air cooling). Samples were submitted to 10, 100, 400, and 1400 cycles as well as being cycled to failure. The behavior of the microstructures, bond strength values (ASTM 633), and the TGO evolution of these TBCs, were investigated for the as-sprayed and thermally cycled samples. During FCT, the TBCs found to be both the best and poorest performing and had their BCs deposited via HVOF. The results showed that engineering low-oxidized BCs does not necessarily lead to an optimal TBC performance. Moreover, the bond strength values decrease significantly only when the TBC is about to fail (top coat spall off) and the as-sprayed bond strength values cannot be used as an indicator of TBC performance.

Vacuum application of thermal barrier plasma coatings

NASA Technical Reports Server (NTRS)

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

1988-01-01

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

Single droplet drying step characterization in microsphere preparation.

PubMed

Al Zaitone, Belal; Lamprecht, Alf

2013-05-01

Spray drying processes are difficult to characterize since process parameters are not directly accessible. Acoustic levitation was used to investigate microencapsulation by spray drying on one single droplet facilitating the analyses of droplet behavior upon drying. Process parameters were simulated on a poly(lactide-co-glycolide)/ethyl acetate combination for microencapsulation. The results allowed quantifying the influence of process parameters such as temperature (0-40°C), polymer concentration (5-400 mg/ml), and droplet size (0.5-1.37 μl) on the drying time and drying kinetics as well as the particle morphology. The drying of polymer solutions at temperature of 21°C and concentration of 5 mg/ml, shows that the dimensionless particle diameter (Dp/D0) approaches 0.25 and the particle needs 350 s to dry. At 400 mg/ml, Dp/D0=0.8 and the drying time increases to one order of magnitude and a hollow particle is formed. The study demonstrates the benefit of using the acoustic levitator as a lab scale method to characterize and study the microparticle formation. This method can be considered as a helpful tool to mimic the full scale spray drying process by providing identical operational parameters such as air velocity, temperature, and variable droplet sizes. Copyright © 2013 Elsevier B.V. All rights reserved.

Surface characteristic of chemically converted graphene coated low carbon steel by electro spray coating method for polymer electrolyte membrane fuel cell bipolar plate.

PubMed

Kim, Jungsoo; Kim, Yang Do; Nam, Dae Geun

2013-05-01

Graphene was coated on low carbon steel (SS400) by electro spray coating method to improve its properties of corrosion resistance and contact resistance. Exfoliated graphite was made of the graphite by chemical treatment (Chemically Converted Graphene, CCG). CCG is distributed using dispersing agent, and low carbon steel was coated with diffuse graphene solution by electro spray coating method. The structure of the CCG was analyzed using XRD and the coating layer of surface was analyzed using SEM. Analysis showed that multi-layered graphite structure was destroyed and it was transformed in to fine layers graphene structure. And the result of SEM analysis on the surface and the cross section, graphene layer was uniformly formed with 3-5 microm thickness on the surface of substrate. Corrosion resistance test was applied in the corrosive solution which is similar to the polymer electrolyte membrane fuel cell (PEMFC) stack inside. And interfacial contact resistance (ICR) test was measured to simulate the internal operating conditions of PEMFC stack. As a result of measuring corrosion resistance and contact resistance, it could be confirmed that low carbon steel coated with CCG was revealed to be more effective in terms of its applicability as PEMFC bipolar plate.

Erosion Performance of Gadolinium Zirconate-Based Thermal Barrier Coatings Processed by Suspension Plasma Spray

NASA Astrophysics Data System (ADS)

Mahade, Satyapal; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per; Vaßen, Robert

2017-01-01

7-8 wt.% Yttria-stabilized zirconia (YSZ) is the standard thermal barrier coating (TBC) material used by the gas turbines industry due to its excellent thermal and thermo-mechanical properties up to 1200 °C. The need for improvement in gas turbine efficiency has led to an increase in the turbine inlet gas temperature. However, above 1200 °C, YSZ has issues such as poor sintering resistance, poor phase stability and susceptibility to calcium magnesium alumino silicates (CMAS) degradation. Gadolinium zirconate (GZ) is considered as one of the promising top coat candidates for TBC applications at high temperatures (>1200 °C) due to its low thermal conductivity, good sintering resistance and CMAS attack resistance. Single-layer 8YSZ, double-layer GZ/YSZ and triple-layer GZdense/GZ/YSZ TBCs were deposited by suspension plasma spray (SPS) process. Microstructural analysis was carried out by scanning electron microscopy (SEM). A columnar microstructure was observed in the single-, double- and triple-layer TBCs. Phase analysis of the as-sprayed TBCs was carried out using XRD (x-ray diffraction) where a tetragonal prime phase of zirconia in the single-layer YSZ TBC and a cubic defect fluorite phase of GZ in the double and triple-layer TBCs was observed. Porosity measurements of the as-sprayed TBCs were made by water intrusion method and image analysis method. The as-sprayed GZ-based multi-layered TBCs were subjected to erosion test at room temperature, and their erosion resistance was compared with single-layer 8YSZ. It was shown that the erosion resistance of 8YSZ single-layer TBC was higher than GZ-based multi-layered TBCs. Among the multi-layered TBCs, triple-layer TBC was slightly better than double layer in terms of erosion resistance. The eroded TBCs were cold-mounted and analyzed by SEM.

Effects of Processing on Structure and Thermal Properties of Powdered Preterm Infant Formula.

PubMed

Sun, Xiaomeng; Wang, Cuina; Wang, Hao; Guo, Mingruo

2018-06-01

Powdered infant formula is usually manufactured by ingredients mixing, homogenization, pasteurization, evaporation and spray drying. Effects of unit operations on the microstructure, thermal properties and other characteristics of preterm infant formula, fat (F), serum (S), and pellet (P) fractions on centrifugation were investigated using Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), Differential Scanning Calorimetry (DSC), and Fourier Transform Infrared (FTIR) spectroscopy. After homogenization, particles which may be casein and denatured whey proteins were observed on the surface of F fraction in microstructure images. DSC results showed that the onset temperature of the second endothermic peak of F fraction shifted to higher temperature, and an endothermic transition appeared at 173.3 °C in P fraction. The -CH 2 group corresponding to F fraction showed less intensity in FTIR spectrum after homogenization. Microstructure images for S and P fractions showed larger aggregates due to the pasteurization processing. Apparent exothermic transition in DSC curve occurred at 101.6 °C indicated whey protein aggregation. Spray drying resulted in some open areas in F fraction and lager aggregates in S fraction revealed by microstructure pictures. A new exothermic transition appeared at 93.6 °C in DSC curve of S fraction. Changes in amide I and amide II regions in FTIR spectra of samples resulted from pasteurization and spray drying indicated the changes in secondary structure of casein and whey proteins. All results indicated that homogenization, pasteurization, and spray drying exhibited pronounced impacts on the microstructure, thermal properties and structural characteristics of samples. Preterm infant formula is an important dairy food for preborn infants. Our results indicate that unit operations especially homogenization, pasteurization, and spray drying during the processing have the most impacts on the microstructure, thermal properties and other characteristics of infant formula. This work provides further understanding of component interactions during the processing of infant formula and theoretical basis for the production of dairy food. © 2018 Institute of Food Technologists®.

A scalable ultrasonic-assisted and foaming combination method preparation polyvinyl alcohol/phytic acid polymer sponge with thermal stability and conductive capability.

PubMed

Li, Yongshen; Song, Yunna; Li, Jihui; Li, Yuehai; Li, Ning; Niu, Shuai

2018-04-01

In this article, polyvinyl alcohol/phytic acid polymer (PVA/PA polymer) is synthesized from PVA and PA via the esterification reaction of PVA and PA in the case of acidity and ultrasound irradiation, and PVA/PA polymer sponge is prepared via foaming PVA/PA polymer in the presence of n-pentane and ammonium bicarbonate, and the structure of PVA/PA polymer and the structure, morphology and crystallinity of PVA/PA polymer sponge are characterized, and the thermal stability and surface resistivity of PVA/PA polymer sponge are investigated. Based on these, it has been attested that PVA/PA polymer synthesized under the acidity and ultrasound irradiation and PVA/PA polymer sponge are structured by the chain of PVA and the cricoid PA connected in the form of ether bonds and phosphonate bonds, and the thermal stability of PVA/PA polymer sponge attains 416.5 °C, and the surface resistivity of PVA/PA polymer sponge reaches 5.76 × 10 4  ohms/sq. Copyright © 2017 Elsevier B.V. All rights reserved.

Coating Bores of Light Metal Engine Blocks with a Nanocomposite Material using the Plasma Transferred Wire Arc Thermal Spray Process

NASA Astrophysics Data System (ADS)

Bobzin, K.; Ernst, F.; Zwick, J.; Schlaefer, T.; Cook, D.; Nassenstein, K.; Schwenk, A.; Schreiber, F.; Wenz, T.; Flores, G.; Hahn, M.

2008-09-01

Engine blocks of modern passenger car engines are generally made of light metal alloys, mostly hypoeutectic AlSi-alloys. Due to their low hardness, these alloys do not meet the tribological requirements of the system cylinder running surface—piston rings—lubricating oil. In order to provide a suitable cylinder running surface, nowadays cylinder liners made of gray cast iron are pressed in or cast into the engine block. A newer approach is to apply thermal spray coatings onto the cylinder bore walls. Due to the geometric conditions, the coatings are applied with specifically designed internal diameter thermal spray systems. With these processes a broad variety of feedstock can be applied, whereas mostly low-alloyed carbon steel feedstock is being used for this application. In the context of this work, an iron-based wire feedstock has been developed, which leads to a nanocrystalline coating. The application of this material was carried out with the Plasma Transferred Wire Arc system. AlMgSi0.5 liners were used as substrates. The coating microstructure and the properties of the coatings were analyzed.

A Robot Trajectory Optimization Approach for Thermal Barrier Coatings Used for Free-Form Components

NASA Astrophysics Data System (ADS)

Cai, Zhenhua; Qi, Beichun; Tao, Chongyuan; Luo, Jie; Chen, Yuepeng; Xie, Changjun

2017-10-01

This paper is concerned with a robot trajectory optimization approach for thermal barrier coatings. As the requirements of high reproducibility of complex workpieces increase, an optimal thermal spraying trajectory should not only guarantee an accurate control of spray parameters defined by users (e.g., scanning speed, spray distance, scanning step, etc.) to achieve coating thickness homogeneity but also help to homogenize the heat transfer distribution on the coating surface. A mesh-based trajectory generation approach is introduced in this work to generate path curves on a free-form component. Then, two types of meander trajectories are generated by performing a different connection method. Additionally, this paper presents a research approach for introducing the heat transfer analysis into the trajectory planning process. Combining heat transfer analysis with trajectory planning overcomes the defects of traditional trajectory planning methods (e.g., local over-heating), which helps form the uniform temperature field by optimizing the time sequence of path curves. The influence of two different robot trajectories on the process of heat transfer is estimated by coupled FEM models which demonstrates the effectiveness of the presented optimization approach.

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.

Thermally sprayed prepregs for thixoforging of UD fiber reinforced light metal MMCs

NASA Astrophysics Data System (ADS)

Silber, Martin; Wenzelburger, Martin; Gadow, Rainer

2007-04-01

Low density and good mechanical properties are the basic requirements for lightweight structures in automotive and aerospace applications. With their high specific strength and strain to failure values, aluminum alloys could be used for such applications. Only the insufficient stiffness and thermal and fatigue strength prevented their usage in high-end applications. One possibility to solve this problem is to reinforce the light metal with unidirectional fibers. The UD fiber allows tailoring of the reinforcement to meet the direction of the component's load. In this study, the production of thermally sprayed prepregs for the manufacturing of continuous fiber reinforced MMC by thixoforging is analysed. The main aim is to optimize the winding procedure, which determines the fiber strand position and tension during the coating process. A method to wind and to coat the continuous fibers with an easy-to-use handling technique for the whole manufacturing process is presented. The prepregs were manufactured by producing arc wire sprayed AlSi6 coatings on fibers bundles. First results of bending experiments showed appropriate mechanical properties.

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Vackel, Andrew; Dwivedi, Gopal; Sampath, Sanjay

2015-07-01

Thermal spray coatings are used extensively for the protection and life extension of engineering components exposed to harsh wear and/or corrosion during service in aerospace, energy, and heavy machinery sectors. Cermet coatings applied via high-velocity thermal spray are used in aggressive wear situations almost always coupled with corrosive environments. In several instances (e.g., landing gear), coatings are considered as part of the structure requiring system-level considerations. Despite their widespread use, the technology has lacked generalized scientific principles for robust coating design, manufacturing, and performance analysis. Advances in process and in situ diagnostics have provided significant insights into the process-structure-property-performance correlations providing a framework-enhanced design. In this overview, critical aspects of materials, process, parametrics, and performance are discussed through exemplary studies on relevant compositions. The underlying connective theme is understanding and controlling residual stresses generation, which not only addresses process dynamics but also provides linkage for process-property relationship for both the system (e.g., fatigue) and the surface (wear and corrosion). The anisotropic microstructure also invokes the need for damage-tolerant material design to meet future goals.

Implementation and Development of the Incremental Hole Drilling Method for the Measurement of Residual Stress in Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Valente, T.; Bartuli, C.; Sebastiani, M.; Loreto, A.

2005-12-01

The experimental measurement of residual stresses originating within thick coatings deposited by thermal spray on solid substrates plays a role of fundamental relevance in the preliminary stages of coating design and process parameters optimization. The hole-drilling method is a versatile and widely used technique for the experimental determination of residual stress in the most superficial layers of a solid body. The consolidated procedure, however, can only be implemented for metallic bulk materials or for homogeneous, linear elastic, and isotropic materials. The main objective of the present investigation was to adapt the experimental method to the measurement of stress fields built up in ceramic coatings/metallic bonding layers structures manufactured by plasma spray deposition. A finite element calculation procedure was implemented to identify the calibration coefficients necessary to take into account the elastic modulus discontinuities that characterize the layered structure through its thickness. Experimental adjustments were then proposed to overcome problems related to the low thermal conductivity of the coatings. The number of calculation steps and experimental drilling steps were finally optimized.

Characterization of Phase Separation Propensity for Amorphous Spray Dried Dispersions.

PubMed

McNamara, Daniel; Yin, Shawn; Pan, Duohai; Crull, George; Timmins, Peter; Vig, Balvinder

2017-02-06

A generalized screening approach, applying isothermal calorimetry at 37 °C 100% RH, to formulations of spray dried dispersions (SDDs) for two active pharmaceutical ingredients (APIs) (BMS-903452 and BMS-986034) is demonstrated. APIs 452 and 034, with similar chemotypes, were synthesized and promoted during development for oral dosing. Both APIs were formulated as SDDs for animal exposure studies using the polymer hydroxypropylmethlycellulose acetyl succinate M grade (HPMCAS-M). 452 formulated at 30% (wt/wt %) was an extremely robust SDD that was able to withstand 40 °C 75% RH open storage conditions for 6 months with no physical evidence of crystallization or loss of dissolution performance. Though 034 was a chemical analogue with similar physical chemical properties to 452, a physically stable SDD of 034 could not be formulated in HPMCAS-M at any of the drug loads attempted. This study was used to develop experience with specific physical characterization laboratory techniques to evaluate the physical stability of SDDs and to characterize the propensity of SDDs to phase separate and possibly crystallize. The screening strategy adopted was to stress the formulated SDDs with a temperature humidity screen, within the calorimeter, and to apply orthogonal analytical techniques to gain a more informed understanding of why these SDDs formulated with HPMCAS-M demonstrated such different physical stability. Isothermal calorimetry (thermal activity monitor, TAM) was employed as a primary stress screen wherein the SDD formulations were monitored for 3 days at 37 °C 100% RH for signs of phase separation and possible crystallization of API. Powder X-ray diffraction (pXRD), modulated differential scanning calorimetry (mDSC), Fourier transform infrared spectroscopy (FTIR), and solid state nuclear magnetic resonance (ssNMR) were all used to examine formulated SDDs and neat amorphous drug. 452 SDDs formulated at 30% (wt/wt %) or less did not show phase separation behavior upon exposure to 37 °C 100% RH for 3 days. 034 SDD formulations from 10 through 50% (wt/wt %) all demonstrated thermal traces consistent with exothermic phase separation events over 3 days at 37 °C 100% RH in the TAM. However, only the 15, 30, and 50% containing 034 samples showed pXRD patterns consistent with crystalline material in post-TAM samples. Isothermal calorimetry is a useful screening tool to probe robust SDD physical performance and help investigate the level of drug polymer miscibility under a humid stress. Orthogonal analytical techniques such as pXRD, ssNMR, and FTIR were key in this SDD formulation screening to gain physical understanding and confirm or refute whether physical changes occur during the observed thermal events characterized by the calorimetric screening experiments.

Large photorefractive effect in a thermally decomposed polymer compared with that in molecularly doped systems

NASA Astrophysics Data System (ADS)

Yokoyama, Kenji; Arishima, Koichi; Sukegawa, Ken

1994-07-01

Photorefractive polymers with the same electro-optic effect were fabricated to investigate the photorefractive effects in different photoconductive systems. The photoconduction in the polymers was varied by the addition of squarylium dye to diethylaminobenzaldehyde-diphenylhydrazone (DEH), by the formation of a charge-transfer complex between tetracyanoquinodimethane and DEH, and by the thermal decomposition of DEH. The largest photorefractive effect was observed in the thermally decomposed polymer among these polymers. A diffraction efficiency of 1.1% and a beam-coupling gain coefficient of 10 cm-1 were achieved in a 34.9 V/μm dc electric field.

Thermal design of the space shuttle external tank

NASA Technical Reports Server (NTRS)

Bachrtel, F. D.; Vaniman, J. L.; Stuckey, J. M.; Gray, C.; Widofsky, B.

1985-01-01

The shuttle external tank thermal design presents many challenges in meeting the stringent requirements established by the structures, main propulsion systems, and Orbiter elements. The selected thermal protection design had to meet these requirements, and ease of application, suitability for mass production considering low weight, cost, and high reliability. This development led to a spray-on-foam (SOFI) which covers the entire tank. The need and design for a SOFI material with a dual role of cryogenic insulation and ablator, and the development of the SOFI over SLA concept for high heating areas are discussed. Further issuses of minimum surface ice/frost, no debris, and the development of the TPS spray process considering the required quality and process control are examined.

Electrospray painted article containing thermally exfoliated graphite oxide and method for their manufacture

NASA Technical Reports Server (NTRS)

Prud'Homme, Robert K. (Inventor); Aksay, Ilhan A. (Inventor); Korkut, Sibel (Inventor)

2011-01-01

A painted polymer part containing a conductive polymer composition containing at least one polymer and a modified graphite oxide material, which is a thermally exfoliated graphite oxide with a surface area of from about 300 sq m/g to 2600 sq m/g, wherein the painted polymer part has been electrospray painted.

Synthesis of thermally stable polymers

NASA Technical Reports Server (NTRS)

Butler, G. B.

1978-01-01

The reaction of bis triazo linediones with divinyl esters and substituted styrenes was investigated. Twenty new polymers were derived via reaction of two previously synthesized bis triazol linediones and four new bis atriazol linediones with eight styrenes. The structure and polymer properties of these thermally stable polymers was examined. The reaction of triazo linediones with enol esters was also considered.

Determination of Physical and Chemical Structure of New High-Temperature Polymers

DTIC Science & Technology

toward determination of the molecular weight of both perfluorosebacate and perfluoroalkyl ether-linked polymers. In addition, solubility, thermal...thermal properties, and molecular weight. Several samples of the perfluoroalkyl bibenzoxazole polymers were examined. Considerable effort was directed...stability and subambient DTA of the perfluoroalkyl ether- linked polymers (elastomers) were investigated. Samples of the aromatic heterocyclic-ladder type

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.

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.

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.

Towards an aerogel-based coating for aerospace applications: reconstituting aerogel particles via spray drying

NASA Astrophysics Data System (ADS)

Bheekhun, N.; Abu Talib, A. R.; Mustapha, S.; Ibrahim, R.; Hassan, M. R.

2016-10-01

Silica aerogel is an ultralight and highly porous nano-structured ceramic with its thermal conductivity being the lowest than any solids. Although aerogels possess fascinating physical properties, innovative solutions to tackle today's problems were limited due to their relative high manufacturing cost in comparison to conventional materials. Recently, some producers have brought forward quality aerogels at competitive costs, and thereby opening a panoply of applied research in this field. In this paper, the feasibility of spray-drying silica aerogel to tailor its granulometric property is studied for thermal spraying, a novel application of aerogels that is never tried before in the academic arena. Aerogel-based slurries with yttria stabilised zirconia as a secondary ceramic were prepared and spray-dried according to modified T aguchi experimental design in order to appreciate the effect of both the slurry formulation and drying conditions such as the solid content, the ratio of yttria stabilised zirconia:aerogel added, the amount of dispersant and binder, inlet temperature, atomisation pressure and feeding rate on the median particle size of the resulting spray-dried powder. The latter was found to be affected by all the aforementioned independent variables at different degree of significance and inclination. Based on the derived relationships, an optimised condition to achieve maximum median particle size was then predicted.

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.

Antibacterial polymer coatings.

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

Wilson, Mollye C.; Allen, Ashley N.; Barnhart, Meghan

2009-09-01

A series of poly(sulfone)s with quaternary ammonium groups and another series with aldehyde groups are synthesized and tested for biocidal activity against vegetative bacteria and spores, respectively. The polymers are sprayed onto substrates as coatings which are then exposed to aqueous suspensions of organisms. The coatings are inherently biocidal and do not release any agents into the environment. The coatings adhere well to both glass and CARC-coated coupons and they exhibit significant biotoxicity. The most effective quaternary ammonium polymers kills 99.9% of both gram negative and gram positive bacteria and the best aldehyde coating kills 81% of the spores onmore » its surface.« less

Thermal Conductivity and Water Vapor Stability of Ceramic HfO2-Based Coating Materials

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Fox, Dennis S.; Bansal, Narottam P.; Miller, Robert A.

2004-01-01

HfO2-Y2O3 and La2Zr2O7 are candidate thermal/environmental barrier coating materials for gas turbine ceramic matrix composite (CMC) combustor liner applications because of their relatively low thermal conductivity and high temperature capability. In this paper, thermal conductivity and high temperature phase stability of plasma-sprayed coatings and/or hot-pressed HfO2-5mol%Y2O3, HfO2-15mol%Y2O3 and La2Zr2O7 were evaluated at temperatures up to 1700 C using a steady-state laser heat-flux technique. Sintering behavior of the plasma-sprayed coatings was determined by monitoring the thermal conductivity increases during a 20-hour test period at various temperatures. Durability and failure mechanisms of the HfO2-Y2O3 and La2Zr2O7 coatings on mullite/SiC Hexoloy or CMC substrates were investigated at 1650 C under thermal gradient cyclic conditions. Coating design and testing issues for the 1650 C thermal/environmental barrier coating applications will also be discussed.

Measurement of in-plane thermal conductivity in polymer films

NASA Astrophysics Data System (ADS)

Wei, Qingshuo; Uehara, Chinatsu; Mukaida, Masakazu; Kirihara, Kazuhiro; Ishida, Takao

2016-04-01

Measuring the in-plane thermal conductivity of organic thermoelectric materials is challenging but is critically important. Here, a method to study the in-plane thermal conductivity of free-standing films (via the use of commercial equipment) based on temperature wave analysis is explored in depth. This subject method required a free-standing thin film with a thickness larger than 10 μm and an area larger than 1 cm2, which are not difficult to obtain for most solution-processable organic thermoelectric materials. We evaluated thermal conductivities and anisotropic ratios for various types of samples including insulating polymers, undoped semiconducting polymers, doped conducting polymers, and one-dimensional carbon fiber bulky papers. This approach facilitated a rapid screening of in-plane thermal conductivities for various organic thermoelectric materials.

Enhancing the thermal dissipation of a light-converting composite for quantum dot-based white light-emitting diodes through electrospinning nanofibers

NASA Astrophysics Data System (ADS)

Zheng, Huai; Lei, Xiang; Cheng, Ting; Liu, Sheng; Zeng, Xiaoliang; Sun, Rong

2017-06-01

Quantum dots (QDs) have been developed as one of the most promising light-converting materials for white light-emitting diodes (LEDs). In current QD-based LED packaging structures, composites of QDs and polymers are used as light-converting layers. However, the ultralow thermal conductivity of such composites seriously hinders the dissipation of QD-generating heat. In this paper, we demonstrate a method to enhance the thermal dissipation of QD-polymer composites through electrospinning polymer nanofibers. QD-polymer films embedded by electrospun nanofibers were prepared. Benefitting from aligned polymer chains in the electrospun nanofibers, the through-panel and in-panel thermal conductivities of the proposed QD-polymer film increased by 39.9% and 423.1%, respectively, compared to traditional QD-polymer film. The proposed and traditional QD-polymer films were both packaged on chip on board (CoB) LEDs for experimental comparison. Compared to traditional QD-polymer film, the luminous flux and luminous efficiency of the LEDs were increased by up to 51.8% and 42.9% by the proposed QD-polymer film under a current of 800 mA, respectively. With an increase in the driving current from 20-800 mA, the correlated color temperature (CCT) variation decreased by 72.7%. The maximum temperatures in the QD-polymer films were reduced from 419 K-411 K under a driving current of 200 mA.

Carbon nanotube reinforced aluminum based nanocomposite fabricated by thermal spray forming

NASA Astrophysics Data System (ADS)

Laha, Tapas

The present research concentrates on the fabrication of bulk aluminum matrix nanocomposite structures with carbon nanotube reinforcement. The objective of the work was to fabricate and characterize multi-walled carbon nanotube (MWCNT) reinforced hypereutectic Al-Si (23 wt% Si, 2 wt% Ni, 1 wt% Cu, rest Al) nanocomposite bulk structure with nanocrystalline matrix through thermal spray forming techniques viz. plasma spray forming (PSF) and high velocity oxy-fuel (HVOF) spray forming. This is the first research study, which has shown that thermal spray forming can be successfully used to synthesize carbon nanotube reinforced nanocomposites. Microstructural characterization based on quantitative microscopy, scanning and transmission electron microscopy (SEM and TEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), Raman spectroscopy and X ray photoelectron spectroscopy (XPS) confirms (i) retention and macro/sub-macro level homogenous distribution of multiwalled carbon nanotubes in the Al-Si matrix and (ii) evolution of nanostructured grains in the matrix. Formation of ultrathin beta-SiC layer on MWCNT surface, due to chemical reaction of Si atoms diffusing from Al-Si alloy and C atoms from the outer walls of MWCNTs has been confirmed theoretically and experimentally. The presence of SiC layer at the interface improves the wettability and the interfacial adhesion between the MWCNT reinforcement and the Al-Si matrix. Sintering of the as-sprayed nanocomposites was carried out in an inert environment for further densification. As-sprayed PSF nanocomposite showed lower microhardness compared to HVOF, due to the higher porosity content and lower residual stress. The hardness of the nanocomposites increased with sintering time due to effective pore removal. Uniaxial tensile test on CNT-bulk nanocomposite was carried out, which is the first ever study of such nature. The tensile test results showed inconsistency in the data attributed to inhomogeneous microstructure and limitation of the test samples geometry. The elastic moduli of nanocomposites were computed using different micromechanics models and compared with experimentally measured values. The elastic moduli of nanocomposites measured by nanoindentation technique, increased gradually with sintering attributed to porosity removal. The experimentally measured values conformed better with theoretically predicted values, particularly in the case of Hashin-Shtrikman bound method.

Comparison between hot-melt extrusion and spray-drying for manufacturing solid dispersions of the graft copolymer of ethylene glycol and vinylalcohol.

PubMed

Guns, Sandra; Dereymaker, Aswin; Kayaert, Pieterjan; Mathot, Vincent; Martens, Johan A; Van den Mooter, Guy

2011-03-01

To investigate the effect of the manufacturing method (spray-drying or hot-melt extrusion) on the kinetic miscibility of miconazole and the graft copolymer poly(ethyleneglycol-g-vinylalcohol). The effect of heat pre-treatment of solutions used for spray-drying and the use of spray-dried copolymer as excipient for hot-melt extrusion was investigated. The solid dispersions were prepared at different drug-polymer ratios and analyzed with modulated differential scanning calorimetry and X-ray powder diffraction. Miconazole either mixed with the PEG-fraction of the copolymer or crystallized in the same or a different polymorph as the starting material. The kinetic miscibility was higher for the solid dispersions obtained from solutions which were pre-heated compared to those spray-dried from solutions at ambient temperature. Hot-melt extrusion resulted in an even higher mixing capability. Here the use of the spray-dried copolymer did not show any benefit concerning the kinetic miscibility of the drug and copolymer, but it resulted in a remarkable decrease in the torque experienced by the extruder allowing extrusion at lower temperature and torque. The manufacturing method has an influence on the mixing capacity and phase behavior of solid dispersions. Heat pre-treatment of the solutions before spray-drying can result in a higher kinetic miscibility. Amorphization of the copolymer by spray-drying before using it as an excipient for hot-melt extrusion can be a manufacturing benefit.

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.

Studying Thermally Induced Chemical and Physical Transformations in Common Synthetic Polymers: A Laboratory Project

NASA Astrophysics Data System (ADS)

Hodgson, Steven C.; Orbell, John D.; Bigger, Stephen W.; Scheirs, John

2000-06-01

A simple project is described for introducing students to some experimental procedures commonly used to measure the effects of thermal treatment on synthetic polymers. The thermally induced changes that occur in the commodity polymers low-density polyethylene (LDPE), poly(ethylene terephthalate) (PET), and poly(vinyl chloride) (PVC) are examined as a function of the time of thermal treatment in an air-circulating oven. In particular, simple procedures are described for determining (i) the polymer hydroperoxide (POOH) content and carbonyl index (CI) of LDPE, (ii) the extent of whitening of PET, and (iii) the extent of discoloration or "yellowing" of PVC, all of which change during thermal treatment. The POOH content of LDPE is determined using a ferrometric method and the CI of this polymer is measured by both Fourier transform infrared spectroscopy and a staining technique involving 2,4-dinitrophenylhydrazine. The thermal oxidation of LDPE and the kinetics of formation of its POOH and carbonyl species are discussed with reference to the accepted mechanism for the autooxidation of polyolefins. The whitening of PET and the yellowing of PVC during thermal treatment are explained by means of a crystallization process and a "zip" dehydrochlorination reaction, respectively.

Higher Temperature Thermal Barrier Coatings with the Combined Use of Yttrium Aluminum Garnet and the Solution Precursor Plasma Spray Process

NASA Astrophysics Data System (ADS)

Gell, Maurice; Wang, Jiwen; Kumar, Rishi; Roth, Jeffery; Jiang, Chen; Jordan, Eric H.

2018-04-01

Gas-turbine engines are widely used in transportation, energy and defense industries. The increasing demand for more efficient gas turbines requires higher turbine operating temperatures. For more than 40 years, yttria-stabilized zirconia (YSZ) has been the dominant thermal barrier coating (TBC) due to its outstanding material properties. However, the practical use of YSZ-based TBCs is limited to approximately 1200 °C. Developing new, higher temperature TBCs has proven challenging to satisfy the multiple property requirements of a durable TBC. In this study, an advanced TBC has been developed by using the solution precursor plasma spray (SPPS) process that generates unique engineered microstructures with the higher temperature yttrium aluminum garnet (YAG) to produce a TBC that can meet and exceed the major performance standards of state-of-the-art air plasma sprayed YSZ, including: phase stability, sintering resistance, CMAS resistance, thermal cycle durability, thermal conductivity and erosion resistance. The temperature improvement for hot section gas turbine materials (superalloys & TBCs) has been at the rate of about 50 °C per decade over the last 50 years. In contrast, SPPS YAG TBCs offer the near-term potential of a > 200 °C improvement in temperature capability.

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

NASA Technical Reports Server (NTRS)

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

2004-01-01

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

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.

Thermal Degradation and Identification of Heat-Sensitive Polymers

ERIC Educational Resources Information Center

Clough, Stuart C.; Goldman, Emma W.

2005-01-01

A study demonstrates the thermal degradation of two heat-sensitive polymers, namely, polystyrene and poly (methyl methacrylate). The experiment described in the study introduces undergraduate students to polymer structure as well as the application of spectroscopic techniques to the solution of structural problems.

Characteristics of Fe powders prepared by spray pyrolysis from a spray solution with ethylene glycol as the source material of heat pellet

NASA Astrophysics Data System (ADS)

Koo, H. Y.; Kim, J. H.; Hong, S. K.; Ko, Y. N.; Jang, H. C.; Jung, D. S.; Han, J. M.; Hong, Y. J.; Kang, Y. C.; Kang, S. H.; Cho, S. B.

2012-06-01

Fe powders as the heat pellet material for thermal batteries are prepared from iron oxide powders obtained by spray pyrolysis from a spray solution of iron nitrate with ethylene glycol. The iron oxide powders with hollow and thin wall structure produce Fe powders with elongated structure and fine primary particle size at a low reducing temperature of 615 °C. The mean size of the primary Fe powders with elongated structure decreases with increasing concentration of ethylene glycol dissolved into the spray solution. The heat pellets prepared from the fine-size Fe powders with elongated structure have good ignition sensitivities below 1 watt. The heat pellets formed from the Fe powders obtained from the spray solution with 0.5 M EG have an extremely high burn rate of 26 cms-1.

A New Finite-Conductivity Droplet Evaporation Model Including Liquid Turbulence Effect

NASA Technical Reports Server (NTRS)

Balasubramanyam, M. S.; Chen, C. P.; Trinh, H. P.

2006-01-01

A new approach to account for finite thermal conductivity and turbulence effects within atomizing droplets of an evaporating spray is presented in this paper. The model is an extension of the T-blob and T-TAB atomization/spray model of Trinh and Chen [9]. This finite conductivity model is based on the two-temperature film theory in which the turbulence characteristics of the droplet are used to estimate the effective thermal diffusivity for the liquid-side film thickness. Both one-way and two-way coupled calculations were performed to investigate the performance cf this model against the published experimental data.

Characterization of Nanocomposites by Thermal Analysis

PubMed Central

Corcione, Carola Esposito; Frigione, Mariaenrica

2012-01-01

In materials research, the development of polymer nanocomposites (PN) is rapidly emerging as a multidisciplinary research field with results that could broaden the applications of polymers to many different industries. PN are polymer matrices (thermoplastics, thermosets or elastomers) that have been reinforced with small quantities of nano-sized particles, preferably characterized by high aspect ratios, such as layered silicates and carbon nanotubes. Thermal analysis (TA) is a useful tool to investigate a wide variety of properties of polymers and it can be also applied to PN in order to gain further insight into their structure. This review illustrates the versatile applications of TA methods in the emerging field of polymer nanomaterial research, presenting some examples of applications of differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), dynamic mechanical thermal analysis (DMTA) and thermal mechanical analysis (TMA) for the characterization of nanocomposite materials.

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.

Potential hazard of volatile organic compounds contained in household spray products

NASA Astrophysics Data System (ADS)

Rahman, Md Mahmudur; Kim, Ki-Hyun

2014-03-01

To assess the exposure levels of hazardous volatile pollutants released from common household spray products, a total of 10 spray products consisting of six body spray and four air spray products have been investigated. The body spray products included insect repellents (two different products), medicated patch, deodorant, hair spray, and humectant, whereas the air spray products included two different insecticides (mosquito and/or cockroach), antibacterial spray, and air freshener. The main objective of this study was to measure concentrations of 15 model volatile organic compounds (VOCs) using GC/MS coupled with a thermal desorber. In addition, up to 34 ‘compounds lacking authentic standards or surrogates (CLASS)' were also quantified based on the effective carbon number (ECN) theory. According to our analysis, the most common indoor pollutants like benzene, toluene, styrene, methyl ethyl ketone, and butyl acetate have been detected frequently in the majority of spray products with the concentration range of 5.3-125 mg L-1. If one assumes that the amount of spray products released into air reaches the 0.3 mL level for a given space size of 5 m3, the risk factor is expected to exceed the carcinogenic risk level set for benzene (10-5) by the U.S. EPA.

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.

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.

LSPRAY-IV: A Lagrangian Spray Module

NASA Technical Reports Server (NTRS)

Raju, M. S.

2012-01-01

LSPRAY-IV is a Lagrangian spray solver developed for application with parallel computing and unstructured grids. It is designed to be massively parallel and could easily be coupled with any existing gas-phase flow and/or Monte Carlo Probability Density Function (PDF) solvers. The solver accommodates the use of an unstructured mesh with mixed elements of either triangular, quadrilateral, and/or tetrahedral type for the gas flow grid representation. It is mainly designed to predict the flow, thermal and transport properties of a rapidly vaporizing spray. Some important research areas covered as a part of the code development are: (1) the extension of combined CFD/scalar-Monte- Carlo-PDF method to spray modeling, (2) the multi-component liquid spray modeling, and (3) the assessment of various atomization models used in spray calculations. The current version contains the extension to the modeling of superheated sprays. The manual provides the user with an understanding of various models involved in the spray formulation, its code structure and solution algorithm, and various other issues related to parallelization and its coupling with other solvers.

Thermal conductivity of spray-on foam insulations for aerospace applications

NASA Astrophysics Data System (ADS)

Barrios, Matt; Vanderlaan, Mark; Van Sciver, Steven

2012-06-01

A guarded-hot-plate apparatus [1] has been developed to measure the thermal conductivity of spray-on foam insulations (SOFI) at temperatures ranging from 30 K to 300 K. The foam tested in the present study is NCFI 24-124, a polyisocyanurate foam used on the External Tanks of the Space Shuttle. The foam was tested first in ambient pressure air, then evacuated and tested once more. These thermal conductivities were compared to the thermal conductivity taken from a sample immediately after being subjected to conditions similar to those experienced by the foam while on the launch pad at Kennedy Space Center. To mimic the conditions experienced on the launch pad, an apparatus was built to enclose one side of the foam sample in a warm, humid environment while the other side of the sample contacts a stainless steel surface held at 77 K. The thermal conductivity data obtained is also compared to data found in the literature.

Claisen thermally rearranged (CTR) polymers

PubMed Central

Tena, Alberto; Rangou, Sofia; Shishatskiy, Sergey; Filiz, Volkan; Abetz, Volker

2016-01-01

Thermally rearranged (TR) polymers, which are considered the next-generation of membrane materials because of their excellent transport properties and high thermal and chemical stability, are proven to have significant drawbacks because of the high temperature required for the rearrangement and low degree of conversion during this process. We demonstrate that using a [3,3]-sigmatropic rearrangement, the temperature required for the rearrangement of a solid glassy polymer was reduced by 200°C. Conversions of functionalized polyimide to polybenzoxazole of more than 97% were achieved. These highly mechanically stable polymers were almost five times more permeable and had more than two times higher degrees of conversion than the reference polymer treated under the same conditions. Properties of these second-generation TR polymers provide the possibility of preparing efficient polymer membranes in a form of, for example, thin-film composite membranes for various gas and liquid membrane separation applications. PMID:27482538

Claisen thermally rearranged (CTR) polymers.

PubMed

Tena, Alberto; Rangou, Sofia; Shishatskiy, Sergey; Filiz, Volkan; Abetz, Volker

2016-07-01

Thermally rearranged (TR) polymers, which are considered the next-generation of membrane materials because of their excellent transport properties and high thermal and chemical stability, are proven to have significant drawbacks because of the high temperature required for the rearrangement and low degree of conversion during this process. We demonstrate that using a [3,3]-sigmatropic rearrangement, the temperature required for the rearrangement of a solid glassy polymer was reduced by 200°C. Conversions of functionalized polyimide to polybenzoxazole of more than 97% were achieved. These highly mechanically stable polymers were almost five times more permeable and had more than two times higher degrees of conversion than the reference polymer treated under the same conditions. Properties of these second-generation TR polymers provide the possibility of preparing efficient polymer membranes in a form of, for example, thin-film composite membranes for various gas and liquid membrane separation applications.

Study of biodegradable polymers for ``green'' devices

NASA Astrophysics Data System (ADS)

Perez, Carlos; Jiang, Xiaomei; Jiang Group Team

2015-03-01

Π - conjugated polymers such as polythiophenes are conventional picks for cost-effective organic solar cells. However, these organic semiconductors are not environment-friendly since the polymer back bones require temperature higher than 3000C to be decomposed, thus will cause potential environment problems upon disposal. In this work, the optical and electronic properties of biodegradable polymers, conjugated poly(disulfidediamine), were examined via continuous wave laser spectroscopy, FTIR spectroscopy and conductivity measurement. We found that the attachment of a side chain to aromatic ring increases both photo and thermal stability, as well as higher conductivity. Thermal annealing improved the film morphological, photophysical and electronic properties. Photo-Induced Absorption (PIA) reveals different features comparing with conventional pi-conjugated polymers. No observation of long-lived photoexcitations such as polarons or triplets which are common with pi-conjugated polymers. Instead, we found the formation of low energy species upon thermal annealing in these biodegradable polymers.

The Impact of Halloysite on the Thermo-Mechanical Properties of Polymer Composites.

PubMed

Gaaz, Tayser Sumer; Sulong, Abu Bakar; Kadhum, Abdul Amir H; Al-Amiery, Ahmed A; Nassir, Mohamed H; Jaaz, Ahed Hameed

2017-05-20

Nanotubular clay minerals, composed of aluminosilicate naturally structured in layers known as halloysite nanotubes (HNTs), have a significant reinforcing impact on polymer matrixes. HNTs have broad applications in biomedical applications, the medicine sector, implant alloys with corrosion protection and manipulated transportation of medicines. In polymer engineering, different research studies utilize HNTs that exhibit a beneficial enhancement in the properties of polymer-based nanocomposites. The dispersion of HNTs is improved as a result of pre-treating HNTs with acids. The HNTs' percentage additive up to 7% shows the highest improvement of tensile strength. The degradation of the polymer can be also significantly improved by doping a low percentage of HNTs. Both the mechanical and thermal properties of polymers were remarkably improved when mixed with HNTs. The effects of HNTs on the mechanical and thermal properties of polymers, such as ultimate strength, elastic modulus, impact strength and thermal stability, are emphasized in this study.

Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Nesbitt, James A.; McCue, Terry R.; Barrett, Charles A.; Miller, Robert A.

2002-01-01

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to enable further increases in engine temperatures. However, the coating performance and durability become a major concern under the increasingly harsh thermal cycling conditions. Advanced zirconia- and hafnia-based cluster oxide thermal barrier coatings with lower thermal conductivity and improved thermal stability are being developed using a high-heat-flux laser-rig based test approach. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of numerous candidate coating materials was carried out using conventional furnace cyclic tests. In this paper, furnace thermal cyclic behavior of the advanced plasma-sprayed zirconia-yttria-based thermal barrier coatings that were co-doped with multi-component rare earth oxides was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied by using scanning electron microscopy combined with X-ray diffraction phase analysis after the furnace tests. The coating cyclic lifetime will be discussed in relation to coating phase structures, total dopant concentrations, and other properties.

Thermally switchable dielectrics

DOEpatents

Dirk, Shawn M.; Johnson, Ross S.

2013-04-30

Precursor polymers to conjugated polymers, such as poly(phenylene vinylene), poly(poly(thiophene vinylene), poly(aniline vinylene), and poly(pyrrole vinylene), can be used as thermally switchable capacitor dielectrics that fail at a specific temperature due to the non-conjugated precursor polymer irreversibly switching from an insulator to the conjugated polymer, which serves as a bleed resistor. The precursor polymer is a good dielectric until it reaches a specific temperature determined by the stability of the leaving groups. Conjugation of the polymer backbone at high temperature effectively disables the capacitor, providing a `built-in` safety mechanism for electronic devices.

Thermal Expansion of Vacuum Plasma Sprayed Coatings

NASA Technical Reports Server (NTRS)

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

2010-01-01

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

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

NASA Technical Reports Server (NTRS)

Patel, Anil K.; Meeks, C.

1998-01-01

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

Overview of meteorological measurements for aerial spray modeling.

PubMed

Rafferty, J E; Biltoft, C A; Bowers, J F

1996-06-01

The routine meteorological observations made by the National Weather Service have a spatial resolution on the order of 1,000 km, whereas the resolution needed to conduct or model aerial spray applications is on the order of 1-10 km. Routinely available observations also do not include the detailed information on the turbulence and thermal structure of the boundary layer that is needed to predict the transport, dispersion, and deposition of aerial spray releases. This paper provides an overview of the information needed to develop the meteorological inputs for an aerial spray model such as the FSCBG and discusses the different types of instruments that are available to make the necessary measurements.

Synthesis, crystal structure and catalytic effect on thermal decomposition of RDX and AP: An energetic coordination polymer [Pb{sub 2}(C{sub 5}H{sub 3}N{sub 5}O{sub 5}){sub 2}(NMP)·NMP]{sub n}

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

Liu, Jin-jian; Yancheng Teachers College, Yancheng 224002; Liu, Zu-Liang, E-mail: liuzl@mail.njust.edu.cn

2013-04-15

An energetic lead(II) coordination polymer based on the ligand ANPyO has been synthesized and its crystal structure has been got. The polymer was characterized by FT-IR spectroscopy, elemental analysis, DSC and TG-DTG technologies. Thermal analysis shows that there are one endothermic process and two exothermic decomposition stages in the temperature range of 50–600 °C with final residues 57.09%. The non-isothermal kinetic has also been studied on the main exothermic decomposition using the Kissinger's and Ozawa–Doyle's methods, the apparent activation energy is calculated as 195.2 KJ/mol. Furthermore, DSC measurements show that the polymer has significant catalytic effect on the thermal decompositionmore » of ammonium perchlorate. - Graphical abstract: An energetic lead(II) coordination polymer of ANPyO has been synthesized, structurally characterized and properties tested. Highlights: ► We have synthesized and characterized an energetic lead(II) coordination polymer. ► We have measured its molecular structure and thermal decomposition. ► It has significant catalytic effect on thermal decomposition of AP.« less

Synthesis, characterization and anti-microbial activity of phenylurea-formaldehyde resin (PUF) and its polymer metal complexes (PUF-Mn(II)

NASA Astrophysics Data System (ADS)

Ahamad, Tansir; Alshehri, Saad M.

2012-10-01

Phenylurea-formaldehyde polymer (PUF) was synthesized via polycondensation of phenylurea and formaldehyde in basic medium, its polymer-metal complexes [PUF-M(II)] were prepared with Mn(II), Co(II), Ni(II), Cu(II), and Zn(II) ions. PUF and PUF-M(II) were characterized with magnetic moment measurements, elemental and spectral (UV-visible, FTIR, 1H-NMR, 13C-NMR and ESR) analysis. The thermal behaviors of all the synthesized polymers were carried out using thermogravimetric analysis (TGA) and differential thermal analysis (DTA). The thermal data revealed that all of the PUF-M(II) showed higher thermal stabilities than the PUF and also ascribed that the PUF-Cu(II) showed better thermal stability than the other PUF-M(II). The kinetic parameters such as activation energy, pre-exponential factor etc., were evaluated for these polymer metal complexes using Coats-Redfern equation. In addition, the antimicrobial activity of the synthesized polymers was tested against several microorganisms using agar well diffusion methods. Among all of the PUF-M(II), the antimicrobial activity of the PUF-Cu(II) showed the highest zone of inhibition because of its higher stability constant and may be used in biomedical applications.

Thermally conductive polymers

NASA Technical Reports Server (NTRS)

Byrd, N. R.; Jenkins, R. K.; Lister, J. L. (Inventor)

1971-01-01

A thermally conductive polymer is provided having physical and chemical properties suited to use as a medium for potting electrical components. The polymer is prepared from hydroquinone, phenol, and formaldehyde, by conventional procedures employed for the preparation of phenol-formaldehyde resins. While the proportions of the monomers can be varied, a preferred polymer is formed from the monomers in a 1:1:2.4 molar or ratio of hydroquinone:phenol:formaldehyde.

Thermal Expansion and Diffusion Coefficients of Carbon Nanotube-Polymer Composites

NASA Technical Reports Server (NTRS)

Wei, Chengyu; Srivastava, Deepak; Cho, Kyeongjae; Biegel, Bryan (Technical Monitor)

2001-01-01

Classical molecular dynamics (MD) simulations employing Brenner potential for intra-nanotube interactions and van der Waals forces for polymer-nanotube interface have been used to investigate thermal expansion and diffusion characteristics of carbon nanotube-polyethylene composites. Addition of carbon nanotubes to polymer matrix is found to significantly increase the glass transition temperature Tg, and thermal expansion and diffusion coefficients in the composite above Tg. The increase has been attributed to the temperature dependent increase of the excluded volume for the polymer chains, and the findings could have implications in the composite processing, coating and painting applications.

Development of a Microelectromechanical System for Small Satellite Thermal Control

DTIC Science & Technology

2004-05-06

polymer frame or post over a silicon substrate. The membrane should be coated with a high emissivity material. This design was based on the principle...allowing heat conduction to the silicon. While the device was off, both the poor thermal conductivity of the polymer and the gap between membrane and...EnergyThermally Isolating Vacuum and Polymer Heat Conduction (a) (b) Figure 4. Heat conduction and radiation in the on and off states

Innovative hybrid optics: combining the thermal stability of glass with low manufacturing cost of polymers

NASA Astrophysics Data System (ADS)

Doushkina, Valentina

2010-08-01

Innovative hybrid glass-polymer optical solutions on a component, module, or system level offer thermal stability of glass with low manufacturing cost of polymers reducing component weight, enhancing the safety and appeal of the products. Narrow choice of polymer materials is compensated by utilizing sophisticated optical surfaces such as refractive, reflective, and diffractive substrates with spherical, aspherical, cylindrical, and freeform prescriptions. Current advancements in polymer technology and injection molding capabilities placed polymer optics in the heart of many high tech devices and applications including Automotive Industry, Defense & Aerospace; Medical/Bio Science; Projection Displays, Sensors, Information Technology, Commercial and Industrial. This paper is about integration of polymer and glass optics for enhanced optical performance with reduced number of components, thermal stability, and low manufacturing cost. The listed advantages are not achievable when polymers or glass optics are used as stand-alone. The author demonstrates that integration of polymer and glass on component or optical system level on one hand offers high resolution and diffraction limited image quality, similar to the glass optics with stable refractive index and stable thermal performance when design is athermalized within the temperature range. On the other hand, the integrated hybrid solution significantly reduces cost, weight, and complexity, just like the polymer optics. The author will describe the design and analyzes process of combining glass and polymer optics for variety of challenging applications such as fast optics with low F/#, wide field of view lenses or systems, free form optics, etc.

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

Synthesis and characterization of new polyamides derived from alanine and valine derivatives

PubMed Central

2012-01-01

Background Many efforts have been recently devoted to design, investigate and synthesize biocompatible, biodegradable polymers for applications in medicine for either the fabrication of biodegradable devices or as drug delivery systems. Many of them consist of condensation of polymers having incorporated peptide linkages susceptible to enzymatic cleavage. Polyamides (PAs) containing α-amino acid residues such as L-leucine, L-alanine and L-phenylalanine have been reported as biodegradable materials. Furthermore, polyamides (PAs) derived from C10 and C14 dicarboxylic acids and amide-diamines derived from 1,6-hexanediamine or 1,12-dodecanediamine and L-phenylalanine, L-valyl-L-phenylalanine or L-phenylalanyl-L-valine residues have been reported as biocompatible polymers. We have previously described the synthesis and thermal properties of a new type of polyamides-containing amino acids based on eight new symmetric meta-oriented protected diamines derived from coupling of amino acids namely; Fomc-glycine, Fmoc-alanine, Fomc-valine and Fomc-leucine with m-phenylene diamine or 2,6-diaminopyridine. Results revealed that incorporation of pyridine onto the polymeric backbone of all series decreases the thermal stability. Here we describe another family of polyamides based on benzene dicarboxylic acid, pyridine dicarboxylic acid, and α-amino acid linked to benzidine and 4,4′-oxydianiline to study the effect of the dicarboxylic acid as well as the amino acids on the nature and thermal stability of the polymers. Results We report here the preparation of a new type of polyamides based on benzene dicarboxylic acid, pyridine dicarboxylic acid, and α-amino acid linked to benzidine and 4,4′-oxydianiline to study the effect of the dicarboxylic acid as well as the amino acids on the nature and thermal stability of polymers. The thermal properties of the polymers were evaluated by different techniques. Results revealed that structure-thermal property correlation based on changing the dicarboxylic acid monomer or the diamine monomer demonstrated an interesting connection between a single change (changing the dicarboxylic acids in each series while the diamine is fixed) and thermal properties. The newly prepared polymers may possess biodegradability and thus may find some applications as novel biomaterials. Conclusions The thermal properties of the new type of polyamides based on benzene dicarboxylic acid, pyridine dicarboxylic acid, and α-amino acid (alanine and valine) linked to benzidine and 4,4′-oxydianiline were evaluated by thermal gravimetric (TG), differential thermal gravimetric (DTG) and differential thermal analysis (DTA) techniques. Results revealed that the structure-thermal property correlation based on changing the dicarboxylic acid monomer or the diamine monomer demonstrated an interesting connection between a single change (changing the dicarboxylic acids in each series while the diamine is fixed) and thermal properties. In addition, pyridine-containing polymers exhibited semicrystalline characteristic with melting temperature, Tm. where none of the valine-containing polymers showed a melting and crystallization peak indicating that the polymers were amorphous. This is expected since L-valine side chain can inhibit close packing and eliminate crystallization. The newly prepared polymers may possess biodegradability and thus may find some applications as novel biomaterials. PMID:23122321

The Prospect of Y2SiO5-Based Materials as Protective Layer in Environmental Barrier Coatings

NASA Astrophysics Data System (ADS)

García, E.; Miranzo, P.; Osendi, M. I.

2013-06-01

Bulk yttrium monosilicate (Y2SiO5) possesses interesting properties, such as low thermal expansion coefficient and stability in water vapor atmospheres, which make it a promising protective layer for SiC-based composites, intended for the hottest parts in the future gas turbines. Because protective layers are commonly applied by thermal spraying techniques, it is important to analyze the changes in structure and properties that these methods may produce in yttrium silicate coatings. In this work, two SiO2-Y2O3 compositions were flame sprayed in the form of coatings and beads. In parallel, the beads were spark plasma sintered at relatively low temperature to obtain partially amorphous bulk specimens that are used as model bulk material. The thermal aging—air and water vapor atmosphere—caused extensive nucleation of Y2SiO5 and Y2Si2O7 in both the bulk and coating. The rich water vapor condition caused the selective volatilization of SiO2 from Y2Si2O7 at the specimen surface leaving a very characteristic micro-ridged Y2SiO5 zones—either in coatings or sintered bodies. An important increase in the thermal conductivity of the aged materials was measured. The results of this work may be used as a reference body for the production of Y2SiO5 coatings using thermal spraying techniques.

Thermal modelling of various thermal barrier coatings in a high heat flux rocket engine

NASA Technical Reports Server (NTRS)

Nesbitt, James A.

1989-01-01

Traditional Air Plasma Sprayed (APS) ZrO2-Y2O3 Thermal Barrier Coatings (TBC's) and Low Pressure Plasma Sprayed (LPPS) ZrO2-Y2O3/Ni-Cr-Al-Y cermet coatings were tested in a H2/O2 rocked engine. The traditional ZrO2-Y2O3 (TBC's) showed considerable metal temperature reductions during testing in the hydrogen-rich environment. A thermal model was developed to predict the thermal response of the tubes with the various coatings. Good agreement was observed between predicted temperatures and measured temperatures at the inner wall of the tube and in the metal near the coating/metal interface. The thermal model was also used to examine the effect of the differences in the reported values of the thermal conductivity of plasma sprayed ZrO2-Y2O3 ceramic coatings, the effect of 100 micron (0.004 in.) thick metallic bond coat, the effect of tangential heat transfer around the tube, and the effect or radiation from the surface of the ceramic coating. It was shown that for the short duration testing in the rocket engine, the most important of these considerations was the effect of the uncertainty in the thermal conductivity of temperatures (greater than 100 C) predicted in the tube. The thermal model was also used to predict the thermal response of the coated rod in order to quantify the difference in the metal temperatures between the two substrate geometries and to explain the previously-observed increased life of coatings on rods over that on tubes. A thermal model was also developed to predict heat transfer to the leading edge of High Pressure Fuel Turbopump (HPFTP) blades during start-up of the space shuttle main engines. The ability of various TBC's to reduce metal temperatures during the two thermal excursions occurring on start-up was predicted. Temperature reductions of 150 to 470 C were predicted for 165 micron (0.0065 in.) coatings for the greater of the two thermal excursions.

Differentially pumped spray deposition as a rapid screening tool for organic and perovskite solar cells.

PubMed

Jung, Yen-Sook; Hwang, Kyeongil; Scholes, Fiona H; Watkins, Scott E; Kim, Dong-Yu; Vak, Doojin

2016-02-08

We report a spray deposition technique as a screening tool for solution processed solar cells. A dual-feed spray nozzle is introduced to deposit donor and acceptor materials separately and to form blended films on substrates in situ. Using a differential pump system with a motorised spray nozzle, the effect of film thickness, solution flow rates and the blend ratio of donor and acceptor materials on device performance can be found in a single experiment. Using this method, polymer solar cells based on poly(3-hexylthiophene) (P3HT):(6,6)-phenyl C61 butyric acid methyl ester (PC61BM) are fabricated with numerous combinations of thicknesses and blend ratios. Results obtained from this technique show that the optimum ratio of materials is consistent with previously reported values confirming this technique is a very useful and effective screening method. This high throughput screening method is also used in a single-feed configuration. In the single-feed mode, methylammonium iodide solution is deposited on lead iodide films to create a photoactive layer of perovskite solar cells. Devices featuring a perovskite layer fabricated by this spray process demonstrated a power conversion efficiencies of up to 7.9%.

Optimization of Cold Spray Deposition of High-Density Polyethylene Powders

NASA Astrophysics Data System (ADS)

Bush, Trenton B.; Khalkhali, Zahra; Champagne, Victor; Schmidt, David P.; Rothstein, Jonathan P.

2017-10-01

When a solid, ductile particle impacts a substrate at sufficient velocity, the resulting heat, pressure and plastic deformation can produce bonding between the particle and the substrate. The use of a cool supersonic gas flow to accelerate these solid particles is known as cold spray deposition. The cold spray process has been commercialized for some metallic materials, but further research is required to unlock the exciting potential material properties possible with polymeric particles. In this work, a combined computational and experimental study was employed to study the cold spray deposition of high-density polyethylene powders over a wide range of particle temperatures and impact velocities. Cold spray deposition of polyethylene powders was demonstrated across a range broad range of substrate materials including several different polymer substrates with different moduli, glass and aluminum. A material-dependent window of successful deposition was determined for each substrate as a function of particle temperature and impact velocity. Additionally, a study of deposition efficiency revealed the optimal process parameters for high-density polyethylene powder deposition which yielded a deposition efficiency close to 10% and provided insights into the physical mechanics responsible for bonding while highlighting paths toward future process improvements.

Atomization and combustion performance of antimisting kerosene and jet fuel

NASA Technical Reports Server (NTRS)

Fleeter, R.; Parikh, P.; Sarohia, V.

1983-01-01

Combustion performance of antimisting kerosene (AMK) containing FM-9 polymer was investigated at various levels of degradation (restoration of AMK for normal use in a gas turbine engine). To establish the relationship of degradation and atomization to performance in an aircraft gas turbine combustor, sprays formed by the nozzle of a JT8-D combustor with Jet A and AMK at 1 atmosphere (atm) (14.1 lb/square in absolute) pressure and 22 C at several degradation levels were analyzed. A new spray characterization technique based on digital image analysis of high resolution, wide field spray images formed under pulsed ruby laser sheet illumination was developed. Combustion tests were performed for these fuels in a JT8-D single can combustor facility to measure combustion efficiency and the lean extinction limit. Correlation of combustion performance under simulated engine operating conditions with nozzle spray Sauter mean diameter (SMD) measured at 1 atm and 22 C were observed. Fuel spray SMD and hence the combustion efficiency are strongly influenced by fuel degradation level. Use of even the most highly degraded AMK tested (filter ratio = 1.2) resulted in an increase in fuel consumption of 0.08% to 0.20% at engine cruise conditions.

Differentially pumped spray deposition as a rapid screening tool for organic and perovskite solar cells

PubMed Central

Jung, Yen-Sook; Hwang, Kyeongil; Scholes, Fiona H.; Watkins, Scott E.; Kim, Dong-Yu; Vak, Doojin

2016-01-01

We report a spray deposition technique as a screening tool for solution processed solar cells. A dual-feed spray nozzle is introduced to deposit donor and acceptor materials separately and to form blended films on substrates in situ. Using a differential pump system with a motorised spray nozzle, the effect of film thickness, solution flow rates and the blend ratio of donor and acceptor materials on device performance can be found in a single experiment. Using this method, polymer solar cells based on poly(3-hexylthiophene) (P3HT):(6,6)-phenyl C61 butyric acid methyl ester (PC61BM) are fabricated with numerous combinations of thicknesses and blend ratios. Results obtained from this technique show that the optimum ratio of materials is consistent with previously reported values confirming this technique is a very useful and effective screening method. This high throughput screening method is also used in a single-feed configuration. In the single-feed mode, methylammonium iodide solution is deposited on lead iodide films to create a photoactive layer of perovskite solar cells. Devices featuring a perovskite layer fabricated by this spray process demonstrated a power conversion efficiencies of up to 7.9%. PMID:26853266

Spray-congealed microparticles for drug delivery - an overview of factors influencing their production and characteristics.

PubMed

Oh, Ching Mien; Guo, Qiyun; Wan Sia Heng, Paul; Chan, Lai Wah

2014-07-01

In any manufacturing process, the success of producing an end product with the desired properties and yield depends on a range of factors that include the equipment, process and formulation variables. It is the interest of manufacturers and researchers to understand each manufacturing process better and ascertain the effects of various manufacturing-associated factors on the properties of the end product. Unless the manufacturing process is well understood, it would be difficult to set realistic limits for the process variables and raw material specifications to ensure consistently high-quality and reproducible end products. Over the years, spray congealing has been used to produce particulates by the food and pharmaceutical industries. The latter have used this technology to develop specialized drug delivery systems. In this review, basic principles as well as advantages and disadvantages of the spray congealing process will be covered. Recent developments in spray congealing equipment, process variables and formulation variables such as the matrix material, encapsulated material and additives will also be discussed. Innovative equipment designs and formulations for spray congealing have emerged. Judicious choice of atomizers, polymers and additives is the key to achieve the desired properties of the microparticles for drug delivery.

Flow visualization of a rocket injector spray using gelled propellant simulants

NASA Technical Reports Server (NTRS)

Green, James M.; Rapp, Douglas C.; Roncace, James

1991-01-01

A study was conducted at NASA-Lewis to compare the atomization characteristics of gelled and nongelled propellant simulants. A gelled propellant simulant composed of water, sodium hydroxide, and an acrylic acid polymer resin (as the gelling agent) was used to simulate the viscosity of an aluminum/PR-1 metallized fuel gel. Water was used as a comparison fluid to isolate the rheological effects of the water-gel and to simulate nongelled RP-1. The water-gel was injected through the central orifice of a triplet injector element and the central post of a coaxial injector element. Nitrogen gas flowed through the outer orifices of the triplet injector element and through the annulus of the coaxial injector element and atomized the gelled and nongelled liquids. Photographs of the water-gel spray patterns at different operating conditions were compared with images obtained using water and nitrogen. A laser light was used for illumination of the sprays. The results of the testing showed that the water sprays produced a finer and more uniform atomization than the water-gel sprays. Rheological analysis of the water-gel showed poor atomization caused by high viscosity of water-gel delaying the transition to turbulence.

Preparation of poly(vinyl alcohol)/chitosan/starch blends and studies on thermal and surface properties

NASA Astrophysics Data System (ADS)

Nasalapure, Anand V.; Chalannavar, Raju K.; Malabadi, Ravindra B.

2018-05-01

Biopolymers are abundantly available from its natural sources of extraction. Chitosan(CH) is one of the widely used natural polymer which is perspective natural polysaccharide. Natural polymer blend with synthetic polymer enhances property of the material such as polyvinyl alcohol (PVA). PVA is nontoxic degradable synthetic polymer and very good film forming polymer. In this study prepared hybrid based film by adding starch into Chitosan/PVA which slighlty increased the surface and thermal property of ternary blend film.

High through-plane thermal conduction of graphene nanoflake filled polymer composites melt-processed in an L-shape kinked tube.

PubMed

Jung, Haejong; Yu, Seunggun; Bae, Nam-Seok; Cho, Suk Man; Kim, Richard Hahnkee; Cho, Sung Hwan; Hwang, Ihn; Jeong, Beomjin; Ryu, Ji Su; Hwang, Junyeon; Hong, Soon Man; Koo, Chong Min; Park, Cheolmin

2015-07-22

Design of materials to be heat-conductive in a preferred direction is a crucial issue for efficient heat dissipation in systems using stacked devices. Here, we demonstrate a facile route to fabricate polymer composites with directional thermal conduction. Our method is based on control of the orientation of fillers with anisotropic heat conduction. Melt-compression of solution-cast poly(vinylidene fluoride) (PVDF) and graphene nanoflake (GNF) films in an L-shape kinked tube yielded a lightweight polymer composite with the surface normal of GNF preferentially aligned perpendicular to the melt-flow direction, giving rise to a directional thermal conductivity of approximately 10 W/mK at 25 vol % with an anisotropic thermal conduction ratio greater than six. The high directional thermal conduction was attributed to the two-dimensional planar shape of GNFs readily adaptable to the molten polymer flow, compared with highly entangled carbon nanotubes and three-dimensional graphite fillers. Furthermore, our composite with its density of approximately 1.5 g/cm(3) was mechanically stable, and its thermal performance was successfully preserved above 100 °C even after multiple heating and cooling cycles. The results indicate that the methodology using an L-shape kinked tube is a new way to achieve polymer composites with highly anisotropic thermal conduction.

Mathematical modelling of powder material motion and transportation in high-temperature flow core during plasma coatings application

NASA Astrophysics Data System (ADS)

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

2018-03-01

A problem of mathematical modelling of powder material motion and transportation in gas thermal flow core has been addressed. Undertaken studies indicate significant impact on dynamics of motion of sprayed particles of phenomenological law for drag coefficient and accounting momentum loss of a plasma jet upon acceleration of these particles and their diameter. It is determined that at great dispersion of spraying particles, they reach detail surface at different velocity and significant particles separation takes place at spraying spot. According to the results of mathematical modelling, requirements for admissible dispersion of diameters of particles used for spraying have been formulated. Research has also allowed reducing separation of particles at the spraying spot due to the selection of the method of powder feed to the anode channel of the plasma torch.

Thermal barrier coating life-prediction model development. Annual report no. 2

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

Strangman, T. E.; Neumann, J.; Liu, A.

1986-10-01

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 specimenmore » 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.« less

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.

Optical spectroscopy of arrays of Ag-Au nanoparticles obtained by vacuum-thermal evaporation

NASA Astrophysics Data System (ADS)

Gromov, D. G.; Mel'nikov, I. V.; Savitskii, A. I.; Trifonov, A. Yu.; Redichev, E. N.; Astapenko, V. A.

2017-03-01

The possibility of creating irregular arrays of bimetallic Ag-Au nanoparticles is investigated. The ability to manipulate their optical properties based on the simple engineering processes of thermal spraying followed by low-temperature annealing is demonstrated.

Pulmonary delivery of antitubercular drugs using spray-dried lipid-polymer hybrid nanoparticles.

PubMed

Bhardwaj, Ankur; Mehta, Shuchi; Yadav, Shailendra; Singh, Sudheer K; Grobler, Anne; Goyal, Amit Kumar; Mehta, Abhinav

2016-09-01

The present study aimed to develop lipid-polymer hybrid nanoparticles (LPNs) for the combined pulmonary delivery of isoniazid (INH) and ciprofloxacin hydrochloride (CIP HCl). Drug-loaded LPNs were prepared by the double-emulsification solvent evaporation method using the three-factor three-level Box-Behnken design. The optimized formulation had a size of 111.81 ± 1.2 nm, PDI of 0.189 ± 1.4, and PDE of 63.64 ± 2.12% for INH-loaded LPN, and a size of 172.23 ± 2.31 nm, PDI of 0.169 ± 1.23, and PDE of 68.49 ± 2.54% for CIP HCl-loaded LPN. Drug release was found to be sustained and controlled at lower pH and followed the Peppas model. The in vitro uptake study in alveolar macrophage (AM) showed that uptake of the drugs was increased significantly if administered in the form of LPN. The stability study proved the applications of adding PLGA in LPN as the polymeric core, which leads to a much more stable product as compared to other novel drug delivery systems. Spray drying was done to produce an inhalable, dry, powdered form of drug-loaded LPN. The spray-dried (SD) powder was equally capable of producing nano-aggregates having morphology, density, flowability and reconstitutibility in the range ideal for inhaled drug delivery. The nano aggregates produced by spray drying manifested their aerosolization efficiency in terms of the higher emitted dose and fine particle fraction with lower mass median aerodynamic diameter. The in vivo study using pharmacokinetic and pharmacodynamic approaches revealed that maximum internalization efficiency was achieved by delivering LPN in SD powdered forms by pulmonary route.

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

NASA Technical Reports Server (NTRS)

Bill, R. C.

1979-01-01

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

Overview on Recent Developments of Bondcoats for Plasma-Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Naumenko, D.; Pillai, R.; Chyrkin, A.; Quadakkers, W. J.

2017-12-01

The performance of MCrAlY (M = Ni, Co) bondcoats for atmospheric plasma-sprayed thermal barrier coatings (APS-TBCs) is substantially affected by the contents of Co, Ni, Cr, and Al as well as minor additions of Y, Hf, Zr, etc., but also by manufacturing-related properties such as coating thickness, porosity, surface roughness, and oxygen content. The latter properties depend in turn on the exact technology and set of parameters used for bondcoat deposition. The well-established LPPS process competes nowadays with alternative technologies such as HVOF and APS. In addition, new technologies have been developed for bondcoats manufacturing such as high-velocity APS or a combination of HVOF and APS for application of a flashcoat. Future developments of the bondcoat systems will likely include optimization of thermal spraying methods for obtaining complex bondcoat roughness profiles required for extended APS-TBC lifetimes. Introduction of the newest generation single-crystal superalloys possessing low Cr and high Al and refractory metals (Re, Ru) contents will require definition of new bondcoat compositions and/or multilayered bondcoats to minimize interdiffusion issues. The developments of new bondcoat compositions may be substantially facilitated using thermodynamic-kinetic modeling, the vast potential of which has been demonstrated in recent years.

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.

Relation Between the Arc-Root Fluctuations, the Cold Boundary Layer Thickness and the Particle Thermal Treatment

NASA Astrophysics Data System (ADS)

Noguès, E.; Fauchais, P.; Vardelle, M.; Granger, P.

2007-12-01

In plasma spraying, the arc-root fluctuations, modifying the length and characteristics of the plasma jet, have an important influence on particle thermal treatment. These voltage fluctuations are strongly linked to the thickness of the cold boundary layer (CBL), surrounding the arc column. This thickness depends on the plasma spray parameters (composition and plasma forming gas mass flow rate, arc current, etc.) and the plasma torch design (anode-nozzle internal diameter and shape, etc.). In order to determine the influence of these different spray parameters on the CBL properties and voltage fluctuations, experiments were performed with two different plasma torches from Sulzer Metco. The first one is a PTF4 torch with a cylindrical anode-nozzle, working with Ar-H2 plasma gas mixtures and the second one is a 3MB torch with either a conical or a cylindrical anode-nozzle, working with N2-H2 plasma gas mixtures. Moreover, arc voltage fluctuations influence on particle thermal treatment was studied through the measurements of transient temperature and velocity of particles, issued from an yttria partially stabilized zirconia powder with a size distribution between 5 and 25 μm.

Enhanced thermal stability of a polymer solar cell blend induced by electron beam irradiation in the transmission electron microscope.

PubMed

Bäcke, Olof; Lindqvist, Camilla; de Zerio Mendaza, Amaia Diaz; Gustafsson, Stefan; Wang, Ergang; Andersson, Mats R; Müller, Christian; Kristiansen, Per Magnus; Olsson, Eva

2017-05-01

We show by in situ microscopy that the effects of electron beam irradiation during transmission electron microscopy can be used to lock microstructural features and enhance the structural thermal stability of a nanostructured polymer:fullerene blend. Polymer:fullerene bulk-heterojunction thin films show great promise for use as active layers in organic solar cells but their low thermal stability is a hindrance. Lack of thermal stability complicates manufacturing and influences the lifetime of devices. To investigate how electron irradiation affects the thermal stability of polymer:fullerene films, a model bulk-heterojunction film based on a thiophene-quinoxaline copolymer and a fullerene derivative was heat-treated in-situ in a transmission electron microscope. In areas of the film that exposed to the electron beam the nanostructure of the film remained stable, while the nanostructure in areas not exposed to the electron beam underwent large phase separation and nucleation of fullerene crystals. UV-vis spectroscopy shows that the polymer:fullerene films are stable for electron doses up to 2000kGy. Copyright © 2016 Elsevier B.V. All rights reserved.

Enhanced thermal stability of a polymer solar cell blend induced by electron beam irradiation in the transmission electron microscope.

PubMed

Bäcke, Olof; Lindqvist, Camilla; de Zerio Mendaza, Amaia Diaz; Gustafsson, Stefan; Wang, Ergang; Andersson, Mats R; Müller, Christian; Kristiansen, Per Magnus; Olsson, Eva

2017-02-01

We show by in situ microscopy that the effects of electron beam irradiation during transmission electron microscopy can be used to lock microstructural features and enhance the structural thermal stability of a nanostructured polymer:fullerene blend. Polymer:fullerene bulk-heterojunction thin films show great promise for use as active layers in organic solar cells but their low thermal stability is a hindrance. Lack of thermal stability complicates manufacturing and influences the lifetime of devices. To investigate how electron irradiation affects the thermal stability of polymer:fullerene films, a model bulk-heterojunction film based on a thiophene-quinoxaline copolymer and a fullerene derivative was heat-treated in-situ in a transmission electron microscope. In areas of the film that exposed to the electron beam the nanostructure of the film remained stable, while the nanostructure in areas not exposed to the electron beam underwent large phase separation and nucleation of fullerene crystals. UV-vis spectroscopy shows that the polymer:fullerene films are stable for electron doses up to 2000kGy. Copyright © 2017 Elsevier B.V. All rights reserved.

Controlling Flows Of Two Ingredients For Spraying

NASA Technical Reports Server (NTRS)

Chandler, Huel H.

1995-01-01

Closed-loop servo control subsystem incorporated, as modification, into system controlling flows of two ingredients mixed and sprayed to form thermally insulating foams on large tanks. Provides steady flows at specified rates. Foams produced smoother and of higher quality. Continued use of system results in substantial reduction in cost stemming from close control of application of foam and consequent reduced use of material.

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.

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.

Radial and temporal variations in surface heat transfer during cryogen spray cooling.

PubMed

Franco, Walfre; Liu, Jie; Wang, Guo-Xiang; Nelson, J Stuart; Aguilar, Guillermo

2005-01-21

Cryogen spray cooling (CSC) is a heat extraction process that protects the epidermis from thermal damage during dermatologic laser surgery. The objective of the present work is to investigate radial and temporal variations in the heat transferred through the surface of a skin phantom during CSC. A fast-response thermal sensor is used to measure surface temperatures every 1 mm across a 16 mm diameter of the sprayed surface of the phantom. An analytical expression based on Fourier's law and Duhamel's theorem is used to compute surface heat fluxes from temperature measurements. Results show that radial and temporal variations of the boundary conditions have a strong influence on the homogeneity of heat extraction from the skin phantom. However, there is a subregion of uniform cooling whose size is time dependent. It is also observed that the surface heat flux undergoes a marked dynamic variation, with a maximum heat flux occurring at the centre of the sprayed surface early in the spurt followed by a quick decrease. The study shows that radial and temporal variations of boundary conditions must be taken into account and ideally controlled to guarantee uniform protection during CSC of human skin.

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

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.

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.

Optical monitoring systems for thermal spray processes: droplets behavior and substrate pre-treatments

NASA Astrophysics Data System (ADS)

Kawaguchi, Y.; Kobayashi, N.; Yamagata, Y.; Miyazaki, F.; Yamasaki, M.; Tanaka, J.; Muraoka, K.

2017-11-01

Thermal spray is a technique to form molten droplets using either plasma- or combustion-heating, which impinge upon substrates to form coating layers for various purposes, such as anti-corrosion and anti-wear layers. Although it is an established technique having a history of more than a century, operations of spray guns together with preparing suitable substrate surfaces for obtaining good coating layers still rely on experienced technicians. Because of the necessity of meeting more and more stringent requirements for coating quality and cost from customers, there has been a strong need to try to monitor spray processes, so as to obtain the best possible spray coating layers. The basic requirements for such monitoring systems are *reasonably cheap, *easy operation for laypersons, *easy access to targets to be investigated, and *an in-situ capability. The purpose of the present work is to provide suitable optical monitoring systems for (1) droplets behavior and (2) substrate pre-treatments. For the former (1), the first result was already presented at the 17th laser-aided plasma diagnostics meeting (LAPD17) in 2015 in Sapporo, and the results of its subsequent applications into real spray environments are shown in this article in order to validate the previous proposal. Topic (2) is new in the research program, and the proof-of-principle experiment for the proposed method yielded a favorable result. Based on this positive result, an overall strategy is being planned to fulfill the final objective of the optical monitoring of substrate pre-treatments. Details of these two programs (1) and (2) together with the present status are described.

Effect of Layer-Graded Bond Coats on Edge Stress Concentration and Oxidation Behavior of Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Ghosn, Louis J.; Miller, Robert A.

1998-01-01

Thermal barrier coating (TBC) durability is closely related to design, processing and microstructure of the coating Z, tn systems. Two important issues that must be considered during the design of a thermal barrier coating are thermal expansion and modulus mismatch between the substrate and the ceramic layer, and substrate oxidation. In many cases, both of these issues may be best addressed through the selection of an appropriate bond coat system. In this study, a low thermal expansion and layer-graded bond coat system, that consists of plasma-sprayed FeCoNiCrAl and FeCrAlY coatings, and a high velocity oxyfuel (HVOF) sprayed FeCrAlY coating, is developed to minimize the thermal stresses and provide oxidation resistance. The thermal expansion and oxidation behavior of the coating system are also characterized, and the strain isolation effect of the bond coat system is analyzed using the finite element method (FEM). Experiments and finite element results show that the layer-graded bond coat system possesses lower interfacial stresses. better strain isolation and excellent oxidation resistance. thus significantly improving the coating performance and durability.

Study of thermal stability and degradation of fire resistant candidate polymers for aircraft interiors

NASA Technical Reports Server (NTRS)

Hsu, M. T. S.

1976-01-01

The thermochemistry of bismaleimide resins and phenolphthalein polycarbonate was studied. Both materials are fire-resistant polymers and may be suitable for aircraft interiors. The chemical composition of the polymers has been determined by nuclear magnetic resonance and infrared spectroscopy and by elemental analysis. Thermal properties of these polymers have been characterized by thermogravimetric analyses. Qualitative evaluation of the volatile products formed in pyrolysis under oxidative and non-oxidative conditions has been made using infrared spectrometry. The residues after pyrolysis were analyzed by elemental analysis. The thermal stability of composite panel and thermoplastic materials for aircraft interiors was studied by thermogravimetric analyses.

Anisotropic Thermal Diffusivities of Plasma-Sprayed Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Akoshima, Megumi; Takahashi, Satoru

2017-09-01

Thermal barrier coatings (TBCs) are used to shield the blades of gas turbines from heat and wear. There is a pressing need to evaluate the thermal conductivity of TBCs in the thermal design of advanced gas turbines with high energy efficiency. These TBCs consist of a ceramic-based top coat and a bond coat on a superalloy substrate. Usually, the focus is on the thermal conductivity in the thickness direction of the TBC because heat tends to diffuse from the surface of the top coat to the substrate. However, the in-plane thermal conductivity is also important in the thermal design of gas turbines because the temperature distribution within the turbine cannot be ignored. Accordingly, a method is developed in this study for measuring the in-plane thermal diffusivity of the top coat. Yttria-stabilized zirconia top coats are prepared by thermal spraying under different conditions. The in-plane and cross-plane thermal diffusivities of the top coats are measured by the flash method to investigate the anisotropy of thermal conduction in a TBC. It is found that the in-plane thermal diffusivity is higher than the cross-plane one for each top coat and that the top coats have significantly anisotropic thermal diffusivity. The cross-sectional and in-plane microstructures of the top coats are observed, from which their porosities are evaluated. The thermal diffusivity and its anisotropy are discussed in detail in relation to microstructure and porosity.

A Laboratory to Demonstrate the Effect of Thermal History on Semicrystalline Polymers Using Rapid Scanning Rate Differential Scanning Calorimetry

ERIC Educational Resources Information Center

Badrinarayanan, Prashanth; Kessler, Michael R.

2010-01-01

A detailed understanding of the effect of thermal history on the thermal properties of semicrystalline polymers is essential for materials scientists and engineers. In this article, we describe a materials science laboratory to demonstrate the effect of parameters such as heating rate and isothermal annealing conditions on the thermal behavior of…

Thermal transport in semicrystalline polyethylene by molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Lu, Tingyu; Kim, Kyunghoon; Li, Xiaobo; Zhou, Jun; Chen, Gang; Liu, Jun

2018-01-01

Recent research has highlighted the potential to achieve high-thermal-conductivity polymers by aligning their molecular chains. Combined with other merits, such as low-cost, corrosion resistance, and light weight, such polymers are attractive for heat transfer applications. Due to their quasi-one-dimensional structural nature, the understanding on the thermal transport in those ultra-drawn semicrystalline polymer fibers or films is still lacking. In this paper, we built the ideal repeating units of semicrystalline polyethylene and studied their dependence of thermal conductivity on different crystallinity and interlamellar topology using the molecular dynamics simulations. We found that the conventional models, such as the Choy-Young's model, the series model, and Takayanagi's model, cannot accurately predict the thermal conductivity of the quasi-one-dimensional semicrystalline polyethylene. A modified Takayanagi's model was proposed to explain the dependence of thermal conductivity on the bridge number at intermediate and high crystallinity. We also analyzed the heat transfer pathways and demonstrated the substantial role of interlamellar bridges in the thermal transport in the semicrystalline polyethylene. Our work could contribute to the understanding of the structure-property relationship in semicrystalline polymers and shed some light on the development of plastic heat sinks and thermal management in flexible electronics.

A Comparative Field Study of Permastripe(Trademark) Polymer Concrete and Waterborne Airfield Pavement Markings

DTIC Science & Technology

2007-06-01

mounted to a self-propelled lawn mower (Figure 4). This resulted in acceptable Permastripe™ line thickness (25 to 30 mils). However, bead embedment...Permastripe™ markings were sprayed using a modified drywall texture application device mounted on a modified self-propelled lawn mower (Figure 4). This

Coatings Based on Nanodispersed Oxide Materials Produced by the Method of Pneumatic Spraying

NASA Astrophysics Data System (ADS)

Potekaev, A. I.; Lysak, I. A.; Malinovskaya, T. D.; Lysak, G. V.

2018-03-01

New approaches are proposed, relying on which the coatings from nanodispersed oxide materials are formed on polypropylene fibers. It is shown that in the course of the viscous fluid - solid state transition of the polymer its nanoparticles are stabilized on the surface of the formed fibers.

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

PubMed

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

2017-07-18

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.

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

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.

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.

Spray characteristics of two combined jet atomizers

NASA Astrophysics Data System (ADS)

Tambour, Y.; Portnoy, D.

The downstream changes in droplet volume concentration of a vaporizing fuel spray produced by two jet atomizers which form an overlapping zone of influence is theoretically analyzed, employing experimental data of Yule et al. (1982) for a single jet atomizer as initial conditions. One of the atomizers is located below the other at a certain distance downstream. Such an injection geometry can be found in afterburners of modern jet engines. The influence of various vertical and horizontal distances between the two atomizers on the downstream spray characteristics is investigated for a vaporizing kerosene spray in a 'cold' (293 K) and a 'hot' (450 K) environment. The analysis shows how one can control the downstream spray characteristics via the geometry of injection. Such geometrical considerations may be of great importance in the design of afterburner wall geometry and in the reduction of wall thermal damage. The injection geometry may also affect the intensity of the spray distribution which determines the mode of droplet group combustion. The latter plays an important role in improving afterburner combustion efficiency.

Dilation Behavior of Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Bejarano Lopez, Miryan Lorena

Thermal Spray (TS) is a very versatile manufacturing process to deposit thick coatings on a variety of substrates. Coatings are used in protective (i.e. wear, chemical attack, high temperature, etc.) and functional (i.e. sensors) applications. TS coatings have a unique lamellar microstructure as a result of the overlapping of millions of molten and partially-molten particles. During processing, high deformation by impact, high temperature, and rapid solidification lead to a complex hierarchical material system that contains a high amount of microstructural defects. The presence of defects in the microstructure contribute to differences in property values in comparison to bulk materials. Thermal stresses and residual strains arise from processing, thermal gradients and thermal exposure. Evaluation of thermal properties, in this case, the coefficient of thermal expansion (CTE) is of vital importance to enhance coating performance. In this dissertation, expansion measurements of various metals, alloys, ceramics, and cermet coatings; were carried out using various techniques (push rod dilatometry, x-ray diffraction XRD, digital image correlation DIC, and curvature method) to determine the dilation behavior at the atomic, micro- and macro-scale levels. The main results were. 1) Mathematical models (Turner and Kerner) used for composite materials, successfully predicted the CTE property of a TS coating where the primary phase is the coating material and the secondary phases can be oxides, precipitates, etc. (formed as a byproduct of the spraying process). CTE was found not to be affected by porosity. 2) Despite the anisotropic behavior characteristic of TS coatings, the experimental results shown that CTE results to be reasonable isotropic within the scope of this study. 3) The curvature method was found to be an alternative technique to obtain the CTE, as well as the Young's modulus of coating in a bi-material strip, with good approximation. 4) An anomalous expansion behavior during the first heating exposure was exhibited by all coatings. The effect was named here, as "thermal shakedown", and is magnified in metals and alloys. 5) Non-isothermal rapid annealing of defects was correlated to this first irreversible contraction or expansion behavior. Although observed in most thermal spray materials, two material systems, pure Al and Ni-5Al were evaluated in-depth to quantify the mechanisms contributing to this behavior: vacancy formation, dislocation annealing, grain boundaries annihilation, residual stress relief, inelastic mechanical effects, etc. Correct determination of CTE values are important for design to assure integrity and functionality of coatings. Considerations of appropriate measurements are described in this dissertation.

Nanostructured polymer-titanium composites and titanium oxide through polymer swelling in titania precursor.

PubMed

Kierys, A; Zaleski, R; Buda, W; Pikus, S; Dziadosz, M; Goworek, J

2013-06-01

Polymer (XAD7HP)/Ti 4+ nanocomposites were prepared through the swelling of polymer in titanium (IV) ethoxide as a titanium dioxide precursor. The nanocomposite beads exhibit relatively high porosity different than the porosity of the initial polymer. Thermal treatment of composite particles up to 200 °C in vacuum causes the change of their internal structure. At higher temperature, the components of composite become more tightly packed. Calcination at 600 °C and total removal of polymer produce spherically shaped TiO 2 condensed phase as determined by XRD. Thermally treated composites show the substantial change of pore dimensions within micro- and mesopores. The presence of micropores and their transformation during thermal processing was studied successfully by positron annihilation lifetime spectroscopy (PALS). The results derived from PALS experiment were compared with those obtaining from low-temperature nitrogen adsorption data.

Novel thermal annealing methodology for permanent tuning polymer optical fiber Bragg gratings to longer wavelengths.

PubMed

Pospori, A; Marques, C A F; Sagias, G; Lamela-Rivera, H; Webb, D J

2018-01-22

The Bragg wavelength of a polymer optical fiber Bragg grating can be permanently shifted by utilizing the thermal annealing method. In all the reported fiber annealing cases, the authors were able to tune the Bragg wavelength only to shorter wavelengths, since the polymer fiber shrinks in length during the annealing process. This article demonstrates a novel thermal annealing methodology for permanently tuning polymer optical fiber Bragg gratings to any desirable spectral position, including longer wavelengths. Stretching the polymer optical fiber during the annealing process, the period of Bragg grating, which is directly related with the Bragg wavelength, can become permanently longer. The methodology presented in this article can be used to multiplex polymer optical fiber Bragg gratings at any desirable spectral position utilizing only one phase-mask for their photo-inscription, reducing thus their fabrication cost in an industrial setting.

Synthesis, characterization and anti-microbial activity of phenylurea-formaldehyde resin (PUF) and its polymer metal complexes (PUF-Mn(II).

PubMed

Ahamad, Tansir; Alshehri, Saad M

2012-10-01

Phenylurea-formaldehyde polymer (PUF) was synthesized via polycondensation of phenylurea and formaldehyde in basic medium, its polymer-metal complexes [PUF-M(II)] were prepared with Mn(II), Co(II), Ni(II), Cu(II), and Zn(II) ions. PUF and PUF-M(II) were characterized with magnetic moment measurements, elemental and spectral (UV-visible, FTIR, 1H-NMR, 13C-NMR and ESR) analysis. The thermal behaviors of all the synthesized polymers were carried out using thermogravimetric analysis (TGA) and differential thermal analysis (DTA). The thermal data revealed that all of the PUF-M(II) showed higher thermal stabilities than the PUF and also ascribed that the PUF-Cu(II) showed better thermal stability than the other PUF-M(II). The kinetic parameters such as activation energy, pre-exponential factor etc., were evaluated for these polymer metal complexes using Coats-Redfern equation. In addition, the antimicrobial activity of the synthesized polymers was tested against several microorganisms using agar well diffusion methods. Among all of the PUF-M(II), the antimicrobial activity of the PUF-Cu(II) showed the highest zone of inhibition because of its higher stability constant and may be used in biomedical applications. Copyright © 2012 Elsevier B.V. All rights reserved.

A study of processing parameters in thermal-sprayed alumina and zircon mixtures

NASA Astrophysics Data System (ADS)

Li, Y.; Khor, K. A.

2002-06-01

A method of plasma spraying of alumina and zircon mixtures to form ZrO2-mullite composites has been proposed and developed. The feedstock is prepared by a combination of mechanical alloying, which allows formation of fine-grained, homogeneous solid-solution mixtures, followed by plasma spheroidization that yields rapid solidified microstructures and enhanced compositional homogeneity. The effects of ball-milling duration and milling media were studied. It was found that zirconia is a more efficient milling media and that increasing milling duration enhanced the dissociation of zircon. Flame spray and plasma spray processes were used to spheroidize the spray-dried powders. The temperature of the flame spray was found to be insufficient to melt the powders completely. The processing parameters of the plasma spray played an important role in zircon decomposition and mullite formation. Increasing the arc current or reducing secondary gas pressure caused more zircon to decompose and more mullite to form after heat treatment at 1200 °C for 3 h. Dissociation of zircon and the amount of mullite for med can be enhanced significantly when using the more efficient, computerized plasma-spraying system and increasing the ball-milling duration from 4 to 8 h.

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.

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.

Nanographene reinforced carbon/carbon composites

NASA Astrophysics Data System (ADS)

Bansal, Dhruv

Carbon/Carbon Composites (CCC) are made of carbon reinforcement in carbon matrix and have high thermal stability and fatigue resistance. CCC are used in nose cones, heat shields and disc brakes of aircrafts due to their exceptional mechanical properties at high temperature. The manufacturing process of CCC involves a carbonization stage in which unwanted elements, except carbon, are eliminated from the polymer precursor. Carbonization results in the formation of voids and cracks due to the thermal mismatch between the reinforcement and the matrix and expulsion of volatiles from the polymer matrix. Thermal cracks and voids decrease the density and mechanical properties of the manufactured CCC. In this work, Nanographene Platelets (NGP) were explored as nanofillers to fill the voids/cracks and reduce thermal shrinkage in CCC. They were first compared with Vapor Grown Carbon Nanofibers (VGCNF) by dispersion of different concentrations (0.5wt%, 1.5wt%, 3wt%) in resole-type phenolic resin and were characterized to explore their effect on rheology, heat of reaction and wetting behavior. The dispersions were then cured to form nanocomposites and were characterized for morphology, flexure and thermal properties. Finally, NGP were introduced into the carbon/carboncomposites in two stages, first by spraying in different concentrations (0.5wt%, 1.5wt%, 3wt%, 5wt %) during the prepreg formation and later during densification by directly mixing in the corresponding densification mix. The manufactured NGP reinforced CCC were characterized for microstructure, porosity, bulk density and mechanical properties (Flexure and ILSS) which were further cross-checked by non-destructive techniques (vibration and ultrasonic). In this study, it was further found that at low concentration (≤ 1.5 wt%) NGP were more effective in increasing the heat of reaction and in decreasing the viscosity of the phenolic resin. The decrease in viscosity led to better wetting properties of NGP / phenolic dispersions compared to VGCNF/phenolic dispersions. In nanocomposites, at low concentration (≤ 1.5 wt%), NGP were effective in increasing the flexure strength, char content and lowering the porosity and coefficient of thermal expansion of neat phenolic resin. At higher concentration (>1.5wt%), NGP had a tendency to agglomerate and lost their effectiveness. The behavior observed in nanocomposites continued in manufactured CCC. The highest Inter Laminar Shear Strength (ILSS), flexure strength/modulus, stiffness and density was observed at 1.5 wt% NGP. In CCC at concentrations > 1.5 wt%, the properties (ILSS, flexure, stiffness, density) decreased due to agglomeration but they were still higher compared to that of neat CCC (without NGP).

A fully spray-coated fuel cell membrane electrode assembly using Aquivion ionomer with a graphene oxide/cerium oxide interlayer

NASA Astrophysics Data System (ADS)

Breitwieser, Matthias; Bayer, Thomas; Büchler, Andreas; Zengerle, Roland; Lyth, Stephen M.; Thiele, Simon

2017-05-01

A novel multilayer membrane electrode assembly (MEA) for polymer electrolyte membrane fuel cells (PEMFCs) is fabricated in this work, within a single spray-coating device. For the first time, direct membrane deposition is used to fabricate a PEMFC by spraying the short-side-chain ionomer Aquivion directly onto the gas diffusion electrodes. The fully sprayed MEA, with an Aquivion membrane 10 μm in thickness, achieved a high power density of 1.6 W/cm2 for H2/air operation at 300 kPaabs. This is one of the highest reported values for thin composite membranes operated in H2/air atmosphere. By the means of confocal laser scanning microscopy, individual carbon fibers from the gas diffusion layer are identified to penetrate through the micro porous layer (MPL), likely causing a low electrical cell resistance in the range of 150 Ω cm2 through the thin sprayed membranes. By spraying a 200 nm graphene oxide/cerium oxide (GO/CeO2) interlayer between two layers of Aquivion ionomer, the impact of the electrical short is eliminated and the hydrogen crossover current density is reduced to about 1 mA/cm2. The peak power density of the interlayer-containing MEA drops only by 10% compared to a pure Aquivion membrane of similar thickness.