Characterization and Optimization of Arc Spray Process Parameters for Synthesis of TiO<SUB>2</SUB> Nanoparticles

Abstract Total quality management requires definite process control as well as online diagnostics, if applied in industrial surface refinement by thermal spraying. A concept for integrated online diagnostics for the high velocity oxygen fuel (HVOF) flame spray process is presented using Siemens S7-300 programmable logic controller and PC-based Siemens WinCC (Windows Control Center) visualization software. The standard functionality of the WinCC programming environment can be extended by C-scripts. The integrated database allows to protocol the relevant process parameters periodically for total quality assurance. Also particle flux imaging software tools can be implemented to adjust online process parameters and for process diagnostic purposes. The Siemens bus system hierarchy thereby provides high speed communication skills for field bus level data exchange and for supervising system components, e.g. CCD-cameras. The interconnection between S7-300 PLC, 6-axis-robot and a novel WinCC software tool enables definite automatic changes of recipes during the coating process to generate functionally graded coatings.

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The Electric Arc Spray Manufacture of Rapid Production Tooling: A Case Study

Thermal Spray 1998: Proceedings from the International Thermal Spray Conference ◽

10.31399/asm.cp.itsc1998p1223 ◽

1998 ◽

Author(s):

A.P. Newbery ◽

P.S. Grant ◽

R.M. Jordan ◽

A.D. Roche ◽

T.C. Carr

Keyword(s):

Injection Moulding ◽

Low Cost ◽

Spray Forming ◽

Electric Arc ◽

Internal Stresses ◽

Forming Process ◽

Polymer Injection ◽

Spray Process ◽

Arc Spray ◽

The U.S

Abstract The manufacture of tooling using the electric arc spray process to spray steel directly onto a master pattern offers substantial reductions in the lead times required to make complex tooling for polymer injection moulding and other applications. The process of spray forming is fast, efficient, and low cost, and has been shown to be dimensionally accurate with proper control over the residual stresses that develop during spraying. Poor dimensional control because of high internal stresses in thick arc sprayed steel coatings is well known, but these problems can be avoided by the use of correct spraying conditions. This paper describes the STD SPRAYFORM process for the manufacture of tooling for the polymer injection moulding of a component for a leading company in the U.S. The steps in the spray forming process, both before and after spraying, are described. The spray forming route competed directly with a traditional method for toolmaking and considerably reduced the lead time from order to completion. The tooling produced by spray forming has been operating commercially in production in the U.S. and has to date produced in the region of half a million parts without appreciable wear. The incorporation of contoured cooling channels during spraying has enabled plastic injection moulding cycle times to be decreased by 15%.

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