Simulation of Thermal Plasma Spraying of Partially Molten Ceramics: Effect of Carrier Gas on Particle Deposition and Phase Change Phenomena

2000 ◽  
Vol 123 (1) ◽  
pp. 188-196 ◽  
Author(s):  
I. Ahmed ◽  
T. L. Bergman
Keyword(s):  
Plasma Spraying ◽  
Thermal Plasma ◽  
Particle Deposition ◽  
Three Dimensional ◽  
Carrier Gas ◽  
Thermal Plasma Spraying ◽  
History Of ◽  
Powder Particles ◽  
Phase Change Phenomena ◽  
Dimensional Simulation

A three-dimensional simulation of the thermal plasma spraying process is reported. In particular, the effect of the radial injection of a carrier gas is taken into account for a dilute spray. The thermal history of powder particles of different sizes is predicted. It is shown that introduction of a carrier gas can lead to a significant modification of the plasma jet, and can have an effect on the thermal histories of the injected particles. The study is motivated by the processing of non-traditional materials, specifically nanostructured ceramics.

Simulation of Thermal Plasma Spraying of Partially Molten Ceramics: Effect of Carrier Gas on Particle Deposition and Phase Change Phenomena

2000 ◽  
Author(s):  
I. Ahmed ◽  
T. L. Bergman
Keyword(s):  
Plasma Spraying ◽  
Thermal Plasma ◽  
Particle Deposition ◽  
Carrier Gas ◽  
Thermal Plasma Spraying ◽  
History Of ◽  
Powder Particles ◽  
Phase Change Phenomena ◽  
Plasma Spraying Process ◽  
Nanostructured Ceramics

Abstract A 3D simulation of the thermal plasma spraying process is reported. In particular, the effect of the radial injection of a carrier gas is taken into account for a dilute spray. The thermal history of powder particles of different sizes is predicted. It is shown that introduction of a carrier gas can lead to a significant modification of the plasma jet, and can have an effect on the thermal histories of the injected particles. The study is motivated by the processing of non-traditional materials, specifically nanostructured ceramics.

Three-Dimensional Simulation of Plasma Spray Jet

2003 ◽  
Author(s):  
H. Xiong ◽  
L. L. Zheng ◽  
S. Sampath ◽  
Jim Fincke ◽  
Richard Williamson
Keyword(s):  
Plasma Spray ◽  
Gas Flow ◽  
Probability Distributions ◽  
Three Dimensional ◽  
Plasma Jet ◽  
Carrier Gas ◽  
Spray Process ◽  
Lagrangian Coordinate ◽  
Dimensional Simulation ◽  
Physical Phenomena

A three-dimensional computational model has been developed to describe the compressible, multi-component, turbulent, reacting plasma jet coupled with the orthogonal injection of carrier gas and particles. This model has been applied to plasma spray process that includes physical phenomena such as heating, melting, accelerating, and evaporation of in-flight particles. The entrained particles, NiCrAlY and ZrO2, are discretely treated in a Lagrangian coordinate and stochastically generated by sampling from the probability distributions of the particle size and its velocity at the injection nozzle. In this study, special attention has been directed to the effects of carrier gas injection on the characteristics of plasma jet. The computational results show that the injection of carrier gas from the orthogonal injector above the plasma jet introduce the 3-D phenomena of plasma gas flow. The plasma jet is defected and the thermo-fluid flow near the injector is locally deformed.

Novel Zirconia Composite Coatings Fabricated by Twin Hybrid Plasma Spraying

2005 ◽  
Vol 475-479 ◽  
pp. 2883-2886
Author(s):  
Heji Huang ◽  
Keisuke Eguchi ◽  
Makoto Kambara ◽  
Toyonobu Yoshida
Keyword(s):  
Plasma Spraying ◽  
Thermal Plasma ◽  
Composite Coatings ◽  
Layered Composite ◽  
Zirconia Coating ◽  
System A ◽  
Thermal Plasma Spraying ◽  
Optimization Study ◽  
Hybrid Plasma ◽  
Microscopic Techniques

With a newly established 300kW twin hybrid plasma spraying system, a peculiar layered composite zirconia coating was successfully deposited. The coating is consisting of splats and dendritic columns, which come from thermal plasma spraying and thermal plasma PVD, respectively. A 120µm-thick composite coating was deposited in 10 minutes at the corresponding growth rate of 100µm/min, if the rotation of the substrates is considered. The microstructure of such composite coatings has been characterized using a variety of microscopic techniques as part of a process optimization study.

Development of coating by thermal plasma spraying under very low-pressure condition <1mbar

Vacuum ◽  
2005 ◽  
Vol 77 (2) ◽  
pp. 145-150 ◽  
Author(s):  
Zahir Salhi ◽  
Didier Klein ◽  
Patrick Gougeon ◽  
Christian Coddet
Keyword(s):  
Plasma Spraying ◽  
Thermal Plasma ◽  
Low Pressure ◽  
Pressure Condition ◽  
Thermal Plasma Spraying

A Computational Examination of the Sources of Statistical Variance in Particle Parameters During Thermal Plasma Spraying

2000 ◽  
Author(s):  
R.L. Williamson ◽  
J.R. Fincke ◽  
C.H. Chang
Keyword(s):  
Particle Size ◽  
Plasma Spraying ◽  
Thermal Plasma ◽  
Plasma Jet ◽  
Operating Conditions ◽  
Injection Velocity ◽  
Valuable Insight ◽  
Thermal Plasma Spraying ◽  
Particle Parameters ◽  
Statistical Variance

Abstract Computational modeling is used to systematically examine many of the sources of statistical variance in particle parameters during thermal plasma spraying. Using the computer program LAVA, a steady-state plasma jet typical of a commercial torch at normal operating conditions, is first developed. Then, assuming a single particle composition (ZrO2) and injection location, real world complexity (e.g., turbulent dispersion, particle size and density, injection velocity and direction, etc.) is introduced "one phenomenon at a time" to distinguish and characterize its effect and enable comparisons of separate effects. A final calculation then considers all phenomena simultaneously, to enable further comparisons. Investigating each phenomenon separately provides valuable insight into particle behavior. For the typical plasma jet and injection conditions considered, particle dispersion in the injection direction is most significantly affected by (in order of decreasing importance): particle size distribution, injection velocity distribution, turbulence, and injection direction distribution or particle density distribution. Only the distribution of injection directions and turbulence affect dispersion normal to the injection direction, and are of similar magnitude in this study. With regards to particle velocity and temperature, particle size is clearly the dominant effect.

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