Abstract
Instabilities and fluctuations of the plasma jet in a thermal spray process can have a significant influence on the particle in-flight temperatures and velocities, affecting the properties of resulting plasma-sprayed coatings. Presented in this paper is a novel method for capturing the effects particles are exposed to in the plasma spraying process. High-speed camera images of a plasma jet generated by a cascaded three-cathode plasma generator (TriplexPro-210) were recorded for varying operating conditions. The images are processed using the inverse Abel transform. This transformation accounts for the fact that the images represent a 2D projection of the 3D jet and generates more accurate intensity values that the sprayed particles would experience. These images are then combined with particle tracks resulting from CFD simulations of the plasma jet to match the particles path with the recorded plasma jet. This new method allows a precise description of the plasma intensity experienced by individual particles with a high temporal resolution. The results show a high sensitivity of the method, even detecting the influence on the particles of the plasma jet originating from the cascaded triple arc plasma generator, which is considered as rather stable.
Highlights
First developed in the 1910s and 1920s (Ref 1), thermal spraying is a coating process in which particles are deposited onto a substrate in molten, semi-molten or solid state
High-speed camera images of a plasma jet generated by a cascaded three-cathode plasma generator (TriplexPro-210) were recorded for varying operating conditions
The results show a high sensitivity of the method, even detecting the influence on the particles of the plasma jet originating from the cascaded triple arc plasma generator, which is considered as rather stable
Summary
First developed in the 1910s and 1920s (Ref 1), thermal spraying is a coating process in which particles are deposited onto a substrate in molten, semi-molten or solid state. With this technique, coatings ranging in thickness from microns to millimeters can be applied over a large area and at a fast deposition rate compared to other similar methods. The specific material(s) chosen are mainly dependent on the desired function of the coating, allowing for application-specific tailoring of the coating to withstand chemical/mechanical attack, be a thermal barrier, act as functional coatings or for aesthetic effects This has allowed thermal spray coatings to find application in several areas in industry, including transport, energy and manufacturing. Thermalsprayed coatings have been used in advanced gas turbine components which has driven much of the research (Ref 2)
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