Partnership for accelerated insertion of new technology: case study for thermal spray technology

Sanjay Sampath,Alfredo Valarezo,Gopal Dwivedi,Brian Choi

doi:10.1186/2193-9772-2-1

Abstract

Abstract Introduction Materials and manufacturing innovation in complex engineering systems such as those in aerospace, energy, heavy machinery is extremely challenging as they typically involve lengthy and costly development cycles and generally follow stringent guidelines and defined road maps. Incorporating academic science and disruptive advances into this product development cycle is challenging. Effective partnerships via integrated academic-industry study groups and joint value proposition of scientific advances and models, can accelerate insertion of new knowledge/technologies in this class of materials and manufacturing ecosystems. Case Description This paper describes such a partnership and integration framework through exemplary case studies in thermal spray materials processing. Thermal spray is a platform materials manufacturing technology enabling deposition of advanced coatings for wide range of materials applications in aerospace, energy, heavy machinery, electronics and biomedical devices. It is a complex process involving many facets of engineering sciences including thermo-fluids, heat transfer, materials science and mechanics, incorporating non-equilibrium phenomena and multi-scale structure/behavior. The required breadth and depth of process and materials knowledge for advancing the technology is very significant, resulting in lengthy, trial and error based developments. Specific case studies illustrate knowledge advancement through science and models, development of measurement tools and simulations, along with industrial demonstration studies, addressing the utility in the manufacturing enterprise. Together, they represent a framework for establishing integrated computational and experimental materials engineering concepts and serve as a model ecosystem for accelerating innovation in complex industrial manufacturing processes.

Highlights

Materials and manufacturing innovation in complex engineering systems such as those in aerospace, energy, heavy machinery is extremely challenging as they typically involve lengthy and costly development cycles and generally follow stringent guidelines and defined road maps
The results present both first and second order maps for the zirconia systems applied under industrially relevant conditions but using the diagnostics tools and methodologies emerging from academic work
From an OEM point of view, the property data can be used for design and can use the maps to guide the supplier with respect to process loci of interest while the supplier has the opportunity to engineer the process for reliability and efficiency providing the flexibility in terms of performance space to the OEMs

Summary

Introduction

Materials and manufacturing innovation in complex engineering systems such as those in aerospace, energy, heavy machinery is extremely challenging as they typically involve lengthy and costly development cycles and generally follow stringent guidelines and defined road maps. Process maps: synthesis of process diagnostics and models for reliable manufacturing Defined the innovation scenario described in Figure 1; in a traditional system driven design and manufacturing methodologies applied to spray coatings, OEMs will typically conduct optimization studies to enhance performance and durability of spray coatings, and identify the resultant microstructural character as a target specification for supply chain adaptation.

Results

Conclusion