spray parameters
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Author(s):  
Rogerio S. Lima

AbstractThere is a strong driving force to improve the production efficiency of thermal barrier coatings (TBCs) manufactured via air plasma spray (APS). To address this need, the high-enthalpy APS torch Axial III Plus was employed to successfully manufacture TBCs by spraying a commercial YSZ feedstock at powder feed rate of 100 g/min using an optimized set of N2/H2 spray parameters; which yielded an impressive YSZ deposition efficiency (DE) value of 70%. This exact same set of optimized spray parameters was used to manufacture the same identical YSZ TBC (over ~160 µm-thick bond-coated substrates) but at two distinct YSZ thickness levels: (i) ~420 µm-thick and (ii) ~930 µm-thick. In spite of the high YSZ feed rate and DE levels, the YSZ TBC revealed a ~14% porous (conventional looking) microstructure, without segmented cracking or horizontal delamination at both thickness levels. The bond strength values measured via the ASTM C633 standard for the ~420 µm-thick and ~930 µm-thick YSZ TBCs were ~13.0 and ~11.6 MPa (respectively); which are among at the upper end values reported in the literature. After the first objective was attained, the second key objective of this work was to evaluate the thermal insulating effectiveness of these two as-sprayed YSZ TBCs. To achieve this objective, a thermal gradient laser-rig was employed to generate a temperature reduction (ΔT) along the TBC-coated coupons under different laser power levels. These distinct laser power levels generated YSZ TBC surface temperatures varying for 1100 to 1500 °C, for the ~420 µm-thick YSZ TBC, and from 1100 to 1680 °C YSZ TBC ~930 µm-thick YSZ TBC. The respective ΔT values for both TBCs are reported. The results of this engineering paper are promising regarding the possibility of improving considerably the manufacturing efficiency of industrial quality conventional-looking porous YSZ TBCs, by using a high-enthalpy N2-based APS torch. This is the first paper published in the open literature showing R&D results of coatings manufactured via the Axial III Plus APS torch.


Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2016
Author(s):  
Surinder Singh ◽  
R. K. Singh Raman ◽  
Christopher C. Berndt ◽  
Harpreet Singh

The cold spray process is governed by the impact of high velocity feedstock particles onto a substrate without melting. Hence, the bulk material properties are retained. However, it is challenging to achieve good adhesion strength. The adhesion strength depends on factors such as the cold spray process parameters, substrate conditions, coating/substrate interactions at the interface and feedstock material properties. This review examines fundamental studies concerning the adhesion mechanisms of cold spray technology and considers the effect of cold spray input parameters such as temperature, stand-off-distance, pressure, process gas, spray angle, and traverse speed of the cold spray torch on the bonding mechanism and adhesion strength. Furthermore, the effects of substrate conditions such as temperature, hardness, roughness and material on the adhesion mechanism are highlighted. The effect of feedstock properties, such as feed rate, shape and size are summarized. Understanding the effect of these parameters is necessary to obtain the optimal input parameters that enable the best interfacial properties for a range of coating/substrate material combinations. It is expected that feedstock of spherical morphology and small particle size (<15 μm) provides optimal interfacial properties when deposited onto a mirror-finished substrate surface using high pressure cold spray. Deep insights into each parameter exposes the uncovered potential of cold spray as an additive manufacturing method.


CORROSION ◽  
10.5006/3802 ◽  
2021 ◽  
Author(s):  
Ozymandias Agar ◽  
Anne Alex ◽  
Gregory Kubacki ◽  
Ning Zhu ◽  
Luke Brewer

This paper describes the polarization and basic pitting behavior of 2024 and 7075 aluminum alloys produced by high pressure cold spray deposition. While cold spray is showing great promise as a solid state repair approach for metallic structures, the corrosion behavior of these materials still needs investigation, particularly in describing the potential galvanic interactions with the repaired substrate. Potentiodynamic testing was performed on cold sprayed (CS) aluminum alloys 2024 and 7075, and corresponding wrought AA2024-T3 and AA7075-T651 alloys for comparison. Testing used ASTM D1141 artificial seawater for potentiodynamic polarization, following the MIL-STD 889C standard for testing with consistent results. Pitting was investigated using 120-hour immersion tests, with subsequent photography, SEM imaging and EDS analysis of the surface. CS-2024 was found to be more active and reactive than wrought, with enhanced anodic kinetics; it experienced more aggressive pitting than the AA2024-T3 during the immersion test. CS-7075 was found to be less active and more reactive than wrought, with enhanced cathodic kinetics; the CS-7075 demonstrated reduced pitting compared to the AA7075-T651. Possible causes for these differences are discussed, including material homogeneity, CS powder intermetallics, and spray parameters. Overall, CS-2024 and CS-7075 should have little galvanic interaction with their corresponding substrates.


PLoS ONE ◽  
2021 ◽  
Vol 16 (9) ◽  
pp. e0257434
Author(s):  
Joseph P. Wood ◽  
Matthew Magnuson ◽  
Abderrahmane Touati ◽  
Jerome Gilberry ◽  
Jonathan Sawyer ◽  
...  

Although research has shown that the COVID-19 disease is most likely caused by airborne transmission of the SARS-CoV-2 virus, disinfection of potentially contaminated surfaces is also recommended to limit the spread of the disease. Use of electrostatic sprayers (ESS) and foggers to rapidly apply disinfectants over large areas or to complex surfaces has emerged with the COVID-19 pandemic. ESSs are designed to impart an electrostatic charge to the spray droplets with the goal of increasing deposition of the droplets onto surfaces, thereby promoting more efficient use of the disinfectant. The purpose of this research was to evaluate several spray parameters for different types of sprayers and foggers, as they relate to the application of disinfectants. Some of the parameters evaluated included the spray droplet size distribution, the electrostatic charge, the ability of the spray to wrap around objects, and the loss of disinfectant chemical active ingredient due to the spray process. The results show that most of the devices evaluated for droplet size distribution had an average volume median diameter ≥ 40 microns, and that four out of the six ESS tested for charge/mass produced sprays of at least 0.1 mC/kg. A minimal wrap-around effect of the spray deposition onto a cylindrical object was observed. The loss of disinfectant active ingredient to the air due to spraying was minimal for the two disinfectants tested, and concurrently, the active ingredient concentrations of the liquid disinfectants sprayed and collected 3 feet (1 meter) away from the spray nozzle do not decrease.


Coatings ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1186
Author(s):  
Lihua Gao ◽  
Fang Jia ◽  
Xiaoliang Lu

As one of the promising thermal barrier coating (TBC) candidates, stoichiometric (La0.8Gd0.2)2Ce2O7 (LGC) coatings were prepared by atmospheric plasma spraying (APS), using (La0.8Gd0.2)2Ce2.5O8 as a spray powder and optimized spray parameters. It was found that spray distance and spray power both play an important role in the phase composition and microstructure of the coating. The LGC coating exhibited lower thermal conductivities than that of La2Ce2O7 (LC) coating, which is ~0.67 W/m·K at 1200 °C. Double-ceramic-layer (DCL) optimum (La0.8Gd0.2)2Ce2O7/YSZ (LGC/YSZ) thermal barrier coating was prepared and its thermal shock behavior was investigated. The LGC/YSZ DCL TBCs had better thermal shock resistance ability than that of LC/YSZ TBCs, which was around 109 cycles at 1100 °C. However, the failure mode was similar to that of LC/YSZ DCL TBCs, which was still layer-by-layer spallation in the top ceramic layer due to the sintering of the ceramic coating.


2021 ◽  
Author(s):  
Shadi Shariatnia ◽  
Prajesh Jangale ◽  
Rohit Mishra ◽  
Amir Asadi ◽  
Dorrin Jarrahbashi

Abstract Nanoparticle spray deposition finds numerous applications in pharmaceutical, electronics, manufacturing, and energy industries and has shown great promises in engineering the functional properties of the coated parts. However, current spray deposition systems either lack the required precision in controlling the morphology of the deposited nanostructures or do not have the capacity for large-scale deposition applications. In this study, we introduce a novel spray system that uses supercritical CO2 to assist the atomization process and create uniform micron-size water droplets that are used as cellulose nanocrystal (CNC) carriers. CNCs are selected in this study as they are abundant, possess superior mechanical properties, and contain hydroxyl groups that facilitate interaction with neighboring materials. We fundamentally investigate the effect of different process parameters, such as injection pressure, gas-to-liquid ratio, the axial distance between the nozzle and substrate, and CNC concentration on the final patterns left on the substrate upon evaporation of water droplets. To this end, we show how tuning process parameters control the size of carrier droplets, dynamics of evaporation, and self-assembly of CNCs, which in turn dictate the final architecture of the deposited nanostructures. We will particularly investigate the morphology of the nanostructures deposited after evaporation of micron-size droplets that has not been fully disclosed to date. Different characterization techniques such as laser diffraction, polarized microscopy, and high-resolution profilometry are employed to visualize and quantify the effect of each process parameter. Numerical simulations are employed to inform the design of experiments. Finally, it is shown that the fabricated nanostructures can be engineered based on the size of the carrier droplets controlled by adjusting spray parameters and the concentration of nanoparticles in the injected mixture. Process parameters can be selected such that nanoparticles form a ring, disk, or dome-shaped structure. Moderate operational conditions, simplicity and time efficiency of the process, and use of abundant and biodegradable materials, i.e., water, CNC, and CO2 promote the scalability and sustainability of this method.


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