Abstract
When nanostructured material is thermally sprayed to produce coatings, the retention of the original nanostructure that is engineered into the raw stock is a principal objective, along with production of some molten material in order to adhere the sprayed material to the surface being coated. Therefore, in contrast to spraying conventional material, complete melting of the nanostructured raw stock is to be avoided. In this study, the melting and re-solidification of sprayed material is correlated to a spray process parameter that has been introduced in the literature by others. Using computer modeling, processing of zirconia agglomerates with plasma spraying has been simulated. Transition regions of the phase change response of the material to the thermal processing conditions are identified. The retained nanostructure content and liquid fraction of the sprayed material is correlated to the particle diameters, as well as the thermal processing parameter. Finally, a novel method to produce desired coatings composed of partially molten sprayed material, by using a bimodal particle size distribution of the sprayed powder, is presented and discussed.
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