High Velocity Atmospheric Plasma Spraying Research Articles

Структура и свойства покрытий WC-10Co4Cr, полученных высокоскоростным плазменным напылением

Introduction. Carbon steel is often used for the manufacture of various machine parts, but its operation in aggressive conditions (operation of steel parts under conditions of wear, high temperatures and aggressive corrosive environments) contributes to an extreme decline in properties, up to failure. To solve this problem the modification of the working surfaces of steel parts can be used. It increases its wear resistance, corrosion resistance, and service life. Metal-ceramic coatings based on WC are often used to improve the hardness, wear resistance and corrosion resistance of steel parts. The work purpose is to study the effect of high velocity atmospheric plasma spraying (HV-APS) modes on the structure, phase composition and properties of WC-Co coatings. Materials and methods. 86% WC-10% Co-4% Cr coatings were deposited on a mild steel substrate with help of the HV-APS method. The structure and phase composition of the coatings were analyzed using optical microscopy, scanning electron microscopy, and X-ray phase analysis. In addition, the results of measurements of porosity, microhardness, wear resistance, as well as a qualitative assessment of the adhesion are shown in this paper. Results and discussion. It is shown that all coatings are characterized by high density, absence of cracks and oxide films. Using the SEM and XRD methods, it is found that the coatings contain WC and W2C particles uniformly distributed in the metal matrix. The matrix is an amorphous or nanocrystalline supersaturated Co(W,C) solid solution. The maximum amount of carbides (49%) is observed in coatings obtained by deposition from a distance of 170 mm, arc current — 140 A; the minimum (25%) is observed in coatings obtained by deposition from a distance of 250 mm, arc current — 200 A. The coatings with the maximum amount of carbides have the maximum values of microhardness (1,284 HV0.1) and wear resistance. It is established that all coatings are characterized by high adhesion.

Microstructure and properties of Ni-Al coatings obtained by conventional and high-velocity atmospheric plasma spraying

In this paper, we report on the microstructure and properties study of the Ni-Al system (75/25 at. %) coatings obtained by atmospheric plasma spraying (APS) and high-velocity plasma spraying (HV-APS) methods which differ in the speed of the sprayed particles. The structure and phase composition were investigated using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray phase analysis (XRD). The paper presents the measurements results of porosity and microhardness, as well as the resistance of coatings to high-temperature oxidation. Additionally, we propose a phase transformations model that explains the difference in structure formation. For HV-APS and APS coatings, the difference in structure is shown to be due to different residence conditions of the sprayed particles in the plasma jet. Particles in the HV-APS coatings were completely melted, while a significant proportion of unmelted particles was observed in the APS coatings. HV-APS coatings have better high-temperature oxidation resistance compared to APS coatings, which is explained by a decrease in their porosity to ∼2 %.

Cr2AlC MAX phase as bond coat for thermal barrier coatings: Processing, testing under thermal gradient loading, and future challenges

AbstractCr2AlC layers with thickness up to 100 µm were deposited by high‐velocity‐atmospheric plasma spray (HV‐APS) on Inconel 738 substrates to analyze the potential of MAX phases as bond coat in thermal barrier coating systems (TBCs). The deposited Cr2AlC layers showed high purity with theoretical densities up to 93%, although some secondary phases were detected after the deposition process. On top of this MAX phase layer, a porous yttria‐stabilized zirconia (YSZ) was deposited by atmospheric plasma spraying. The system was tested under realistic thermal loading conditions using a burner rig facility, achieving surface and substrate temperatures of 1400°C and 1050°C, respectively. The system failed after 745 cycles mainly for three reasons: (i) open porosity of the bond coat layer, (ii) oxidation of secondary phases, and (iii) inter‐diffusion. Nevertheless, these results show a high potential of Cr2AlC and other Al‐based MAX phases as bond coat material for high‐temperature applications. Furthermore, future challenges to transfer MAX phases as eventual bond coat or protective layer are discussed.

Recent developments in plasma spray processes for applications in energy technology

This work focuses on recent developments of plasma spray processes with respect to specific demands in energy technology. High Velocity Atmospheric Plasma Spraying (HV-APS) is a novel variant of plasma spraying devoted to materials which are prone to oxidation or decomposition. It is shown how this process can be used for metallic bondcoats in thermal barrier coating systems. Furthermore, Suspension Plasma Spraying (SPS) is a new method to process submicron-sized feedstock powders which are not sufficiently flowable to feed them in dry state. SPS is presently promoted by the development of novel torch concepts with axial feedstock injection. An example for a columnar structured double layer thermal barrier coating is given. Finally, Plasma Spray-Physical Vapor Deposition (PS-PVD) is a novel technology operating in controlled atmosphere at low pressure and high plasma power. At such condition, vaporization even of high-melting oxide ceramics is possible enabling the formation of columnar structured, strain tolerant coatings with low thermal conductivity. Applying different conditions, the deposition is still dominated by liquid splats. Such process is termed Low Pressure Plasma Spraying-Thin Film (LPPS-TF). Two examples of applications are gas-tight and highly ionic and electronic conductive electrolyte and membrane layers which were deposited on porous metallic substrates.

Isothermal and cyclic oxidation behavior of free standing MCrAlY coatings manufactured by high-velocity atmospheric plasma spraying

In the present paper the high temperature oxidation behavior of a free standing NiCoCrAlY coating produced by high-velocity atmospheric plasma spraying (HV-APS) is investigated and compared with that produced by conventional low pressure plasma spraying (LPPS). Isothermal thermogravimetric experiments at 1000 and 1100°C in synthetic air revealed a lower oxidation rate of the HV-APS than the LPPS coating. Both coatings formed oxide scales based on alpha alumina, however, in the LPPS coating incorporation of coarse mixed Y/Al-oxide pegs into the scale occurred, increasing the oxidation rate by providing short circuit paths for oxygen diffusion probably due to higher diffusivities in the mixed oxide and/or along the interfaces between mixed oxide and alumina. In the HV-APS coatings most of the yttrium was tied-up in sub-μm Y-containing oxide particles and only minor amounts of mixed Y/Al oxide precipitates were found in the alumina surface scale. Cyclic air oxidation tests at 1100°C revealed a lower oxidation rate and better scale adherence for the HV-APS coating.The results thus show that HV-APS is a promising method for the processing of MCrAlY coatings. The specific yttrium distribution in form of fine oxide precipitates in the HV-APS material prevents the formation of deleterious Y-rich oxide pegs and promotes formation of a slowly growing, protective alumina scale with excellent adherence.

Impact of processing conditions and feedstock characteristics on thermally sprayed MCrAlY bondcoat properties

One of the options to manufacture MCrAlY bondcoats (M=Co, Ni) for thermal barrier coating systems is High Velocity Oxy-Fuel spraying (HVOF). In this work, particle diagnostics were applied to investigate the impact of processing conditions and feedstock characteristics on the relevant bondcoat properties. The results showed that compromises must be made on the oxygen/fuel ratio, spray distance, and particle size distribution to strike a balance between low oxidation and dense microstructures.These limitations initiated the development of the High Velocity Atmospheric Plasma Spray process (HV-APS) as a further alternative process. In this work, HV-APS process parameters were developed for a three cathode torch in combination with a 5mm diameter high speed nozzle. A one-dimensional calculation of the expansion through this nozzle to atmospheric pressure yielded supersonic conditions with a Mach number of 1.84. The calculated plasma temperatures at the nozzle exit and in the expanded jet are 8400K and slightly above 5200K, respectively, which is low compared to conventional APS processes.A very fine powder with a median particle size of 18μm was identified to be most suitable. Although the spray conditions were relatively cold, reasonable deposition efficiencies up to 61% and rather dense coatings were achieved using this feedstock. The as-sprayed porosity was ≈2% which was reduced by the subsequent vacuum heat treatment to <1%. The oxygen content determined by chemical analysis for a sample sprayed at a spray distance of 100mm was 0.41±0.04wt%.Moreover, reference samples were manufactured by Low Pressure Plasma Spraying (LPPS). The oxidation behavior was compared in isothermal and cyclic oxidation tests. The oxidation rates of the HV-APS coatings were found to be significantly lower than those of LPPS coatings. The thermally grown oxide scale showed less yttrium incorporation and better adherence in case of HV-APS. The latter is suggested to be related to a unique new distribution of Y-rich nano-sized oxide precipitates. The cyclic oxidation test confirmed the better oxidation resistance of the HV-APS coatings.

Thermoelectric Properties of Magnesium Silicide Deposited by Use of an Atmospheric Plasma Thermal Spray

The thermoelectric properties of magnesium silicide (Mg2Si) samples prepared by use of an atmospheric plasma spray (APS) were compared with those of samples prepared from the same feedstock powder by use of the conventional hot-pressing method. The characterization performed included measurement of thermal conductivity, electrical conductivity, Seebeck coefficient, and figure of merit, ZT. X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive x-ray spectroscopy (EDX) were used to assess how phase and microstructure affected the thermoelectric properties of the samples. Hall effect measurements furnished carrier concentration, and measurement of Hall mobility provided further insight into electrical conductivity and Seebeck coefficient. Low temperature and high velocity APS using an internal-powder distribution system achieved a phase of composition similar to that of the feedstock powder. Thermal spraying was demonstrated in this work to be an effective means of reducing the thermal conductivity of Mg2Si; this may be because of pores and cracks in the sprayed sample. Vacuum-annealed APS samples were found to have very high Seebeck coefficients. To further improve the figure of merit, carrier concentration must be adjusted and carrier mobility must be enhanced.

MCrAlY Bondcoats by High-Velocity Atmospheric Plasma Spraying

MCrAlY bondcoats (M = Co, Ni) are used to protect metallic substrates from oxidation and to improve adhesion of ceramic thermal barrier coatings for high temperature applications, such as in land-based and aviation turbines. Since MCrAlYs are prone to take up oxygen during thermal spraying, bondcoats often are manufactured under inert gas conditions at low pressure. Plasma spraying at atmospheric conditions is a cost-effective alternative if it would be possible to limit the oxygen uptake as well as to obtain sufficiently dense microstructures. In the present work, high-velocity spray parameters were developed for the TriplexPro 210 three-cathode plasma torch using MCrAlY powders of different particle size fractions to achieve these objectives. The aims are conflictive since the former requires cold conditions, whereas the latter is obtained by more elevated particle temperatures. High particle velocities can solve this divergence as they imply shorter time for oxidation during flight and contribute to coating densification by kinetic rather than thermal energy. Further aims of the experimental work were high deposition efficiencies as well as sufficient surface roughness. The oxidation behavior of the sprayed coatings was characterized by thermal gravimetric analyses and isothermal heat treatments.