Academic literature on the topic 'Supersonic spray deposition'
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Journal articles on the topic "Supersonic spray deposition"
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Singh, Harvinder, and Rajdeep Singh. "A Review Study of Cold Spray Coating Process." Asian Review of Mechanical Engineering 8, no. 1 (May 5, 2019): 28–30. http://dx.doi.org/10.51983/arme-2019.8.1.2463.
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Cold Spray coatings is a material deposition technique from the broad family of thermal spray coatings with the difference of depositing spray particles at the temperature below melting point as it is a solid state process. The spray particles are impinged on the substrate with supersonic velocities. This paper imparts some light on application of this emerging technique with pros and cons. As this technique come up from last 20 years yet practical area is limited and confined to some research only. As this is a quite beneficial technique and help require from public/private sector to commercialize this technique and hope in coming years it comes up with a good growth in this area.
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Ren, Zhi Qiang, Xiao Ming Wang, Qi Wei Wang, Chao Ji Zhou, and Yao Zhang. "Study on Anti-Corrosion Property of Nickel-Based Coatings on Copper Surface in Supersonic Particles Deposition." Applied Mechanics and Materials 778 (July 2015): 164–67. http://dx.doi.org/10.4028/www.scientific.net/amm.778.164.
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In this study, the anti-corrosion properties of nickel-based coatings on the surface of copper alloy were investigated, and damages caused by corrosion on the copper surface were resolved. Researchers prepared nickel-based coatings by supersonic particles deposition, and tested the anti-corrosion properties of brass substrate and nickel-based coating by electrochemical technology and neutral salt spray. The results show that, the corrosion current of coating decreased 35 times than that of matrix. The successive and pyknotic oxide film on the surface of coating prevented reaction of corrosion further. When it reached 500 hours, the corrosion rate closed to 0. Nickel-based coatings prepared by supersonic particles deposition contribute to the increase of corrosion resistance significantly, which verifies that it is feasible to prepare outstanding corrosion resisting nickel-based coating by supersonic particles deposition.
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Lee, Jae Chul, Doo Man Chun, Sung Hoon Ahn, and Caroline S. Lee. "Material Properties of Thick Aluminum Coating Made by Cold Gas Dynamic Spray Deposition." Key Engineering Materials 345-346 (August 2007): 1097–100. http://dx.doi.org/10.4028/www.scientific.net/kem.345-346.1097.
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Cold gas dynamic spray is a relatively new coating process by which coatings can be produced without significant heating during the process. Cold gas dynamic spray is conducted by powder sprayed using supersonic gas jet, and generally called the kinetic spray or cold spray. Its low process temperature can minimize the thermal stress and also reduce the deformation of the substrate. In this study, thick or macro scale deposition was studied while most researches on cold-spray have focused on micro scale coating. Measured material properties of macro scale deposition layer showed that elastic modulus and hardness were lower and electrical resistivity was higher than those of reference substrate material. The main causes of changed material properties were investigated by FE-SEM (Field Emission Scanning Electron Microscope) and EDS (Energy Dispersive X-ray Spectrometer) data. In this result, porous micro structure generated by imperfect plastic deformation might cause decrease in elastic modulus and hardness of the deposition layer by cold spray, and oxidized Al particles increased the electrical resistivity.
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SONG, WOOJIN, KYUBONG JUNG, DOO-MAN CHUN, SUNG-HOON AHN, and CAROLINE SUNYONG LEE. "DEPOSITION OF Al2O3 POWDERS USING NANO-PARTICLE DEPOSITION SYSTEM." Surface Review and Letters 17, no. 02 (April 2010): 189–93. http://dx.doi.org/10.1142/s0218625x10013710.
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In this paper, alumina film was deposited using supersonic micronozzle in nano-particle deposition System (NPDS). Powder deposition at room temperature is important in the field of film deposition since high processing temperature can be a serious limitation for the deposition on flexible substrate. Previously, many studies have been reported on particle deposition, such as aerosol deposition method (ADM) or cold spray method. However, these deposition methods cannot be applied to various types of powders. Recently, NPDS using aluminum nozzle was designed to resolve these problems but it cannot deposit precise patterns less than 1 mm. In this study, alumina particles were deposited using Silicon-based micronozzle in NPDS. Three-dimensional silicon micronozzle was fabricated using semiconductor processing method, specifically deep reactive ion etching (DRIE) method. The silicon micronozzle fabricated by Bosch process is advantageous over the conventionally used nozzle, since the hardness of silicon is higher than that of aluminum and the lifetime can be increased. In this study, alumina nano-particles were accelerated to supersonic level at the neck of micronozzle and deposited on the substrate in a low vacuum condition. The film characteristics were evaluated using field-emission scanning electronic microscope (FE-SEM) and alpha step to measure its thickness of the deposited layer. The deposition result showed that alumina powders were successfully deposited using the fabricated micronozzle by means of NPDS.
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Caliari, F. R., F. S. Miranda, D. A. P. Reis, A. M. Essiptchouk, and G. P. Filho. "Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy." Journal of Thermal Spray Technology 26, no. 5 (May 19, 2017): 880–89. http://dx.doi.org/10.1007/s11666-017-0563-4.
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Gulizia, Stefan, A. Trentin, S. Vezzù, Silvano Rech, Peter King, Mahnaz Z. Jahedi, and Mario Guagliano. "Characterisation of Cold Spray Titanium Coatings." Materials Science Forum 654-656 (June 2010): 898–901. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.898.
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Cold spray is a solid state spray deposition process utilizing a supersonic De Laval nozzle to accelerate fine particles to high velocities. Particles plastically deform on impact to the substrate and to each other to create dense well adhered structures. In this study, the microstructure and mechanical properties of cold spray Titanium coatings deposited using nitrogen gas at different gas temperature and pressure were examined. In general, it was found that gas-atomised CP-titanium powder is capable of producing dense coating structures on aluminium alloy (Al6061) substrates. The micro-hardness, oxygen and nitrogen content of the coatings were found to be slightly higher than powder in the as-received condition. It was also found the coating residual stress was purely compressive when cold spray is conducted at high gas pressure and temperature.
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Peng, Daren, Caixian Tang, Neil Matthews, Rhys Jones, Sudip Kundu, R. K. Singh Raman, and Alankar Alankar. "Computing the Fatigue Life of Cold Spray Repairs to Simulated Corrosion Damage." Materials 14, no. 16 (August 9, 2021): 4451. http://dx.doi.org/10.3390/ma14164451.
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This paper summarises the findings of an investigation into the durability of cold spray repairs, also known as supersonic particle deposition or SPD repairs, to simulated corrosion damage in AA7075-T7351 aluminium alloy specimens. A feature of this paper is that it is the first to show how to perform the mandatory durability analysis of repaired corroded structures, where the corroded material is first removed by machining and then repaired using cold spray, in a fashion consistent with the requirements delineated in USAF Structures Bulletin EZ-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006.
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Garmeh, Saeed, Mehdi Jadidi, and Ali Dolatabadi. "Cold Spray for Additive Manufacturing: Possibilities and Challenges." Key Engineering Materials 813 (July 2019): 423–28. http://dx.doi.org/10.4028/www.scientific.net/kem.813.423.
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Cold spray (CS) is a deposition technique to form a coating from the particles with temperature lower than their melting point. In this technique, particles are accelerated by a supersonic flow of a carrier gas such as air or nitrogen. Upon impact, particles undergo significant plastic deformation that bonds them to the substrate. Since the particles are not molten, this deposition method does not apply a lot of heat to the substrate and this makes CS the best candidate for temperature sensitive and oxygen sensitive materials. CS can be adapted to form 3D objects following layer-by-layer approach. This is called cold gas dynamic manufacturing (CGDM) or cold spray as additive manufacturing. Developing complex shapes by CGDM may result in formation of inclined surfaces, corners and sharp edges. Deposition in those regions is often accompanied with challenges that affect the accuracy and efficiency of the manufacturing. In this study, CGDM for two typical shapes such as cylinder and frustum on a flat substrate has been simulated to represent the additively manufactured parts. Particle trajectories and impact conditions i.e. velocity and size distributions have been compared. The results of numerical modelling provided useful information for understanding the limitations and challenges associated with CGDM that can help us to improve the quality and precision of particle deposition.
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Klarić, Štefanija, Zlatko Botak, Damien J. Hill, Matthew Harbidge, and Rebecca Murray. "Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes." Tehnički glasnik 14, no. 1 (March 20, 2020): 27–31. http://dx.doi.org/10.31803/tg-20190719094329.
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Cold spray process principles allow the production of near-net-shape metal parts with a fast layer deposition by using 3D printing techniques via supersonic 3D deposition (SP3D). This innovative additive manufacturing process allows an easy and quick production of copper and aluminium parts with future possibilities to expand materials and alloys. The speed and materials enable the application of this cold spray based 3D printing process for the production of tools. In this paper, Electrical Discharge Machining (EDM) electrodes were fabricated by using SP3D to investigate its application in tool production. Requirements for the materials of electrodes and some existing solutions for the production of EDM electrodes with additive manufacturing methods are described first. The fabrication and experimental results are then presented for 3D printed copper EDM electrodes that were tested by using St 37-2 (DIN 17100) steel as the workpiece.
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Harihara Sudhan, K., G. Krishna Prasad, Nikhil K. Kothurkar, and A. R. Srikrishnan. "Studies on supersonic cold spray deposition of microparticles using a bell-type nozzle." Surface and Coatings Technology 383 (February 2020): 125244. http://dx.doi.org/10.1016/j.surfcoat.2019.125244.
Full textDissertations / Theses on the topic "Supersonic spray deposition"
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Akhtar, Kareem. "A Numerical Study of Supersonic Rectangular Jet Impingement and Applications to Cold Spray Technology." Diss., Virginia Tech, 2015. http://hdl.handle.net/10919/71711.
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Particle-laden supersonic jets impinging on a flat surface are of interest to cold gas-dynamic spray technology. Solid particles are propelled to a high velocity through a convergent-divergent nozzle, and upon impact on a substrate surface, they undergo plastic deformation and adhere to the surface. For given particle and substrate materials, particle velocity and temperature at impact are the primary parameters that determine the success of particle deposition. Depending on the particle diameter and density, interactions of particles with the turbulent supersonic jet and the compressed gas region near the substrate surface can have significant effects on particle velocity and temperature. Unlike previous numerical simulations of cold spray, in this dissertation we track solid particles in the instantaneous turbulent fluctuating flow field from the nozzle exit to the substrate surface. Thus, we capture the effects of particle-turbulence interactions on particle velocity and temperature at impact.
The flow field is obtained by direct numerical simulations of a supersonic rectangular particle-laden air jet impinging on a flat substrate. An Eulerian-Lagrangian approach with two-way coupling between solid particles and gas phase is used. Unsteady three-dimensional Navier-Stokes equations are solved using a six-order compact scheme with a tenth-order compact filter combined with WENO dissipation, almost everywhere except in a region around the bow shock where a fifth-order WENO scheme is used. A fourth-order low-storage Runge-Kutta scheme is used for time integration of gas dynamics equations simultaneously with solid particles equations of motion and energy equation for particle temperature. Particles are tracked in instantaneous turbulent jet flow rather than in a mean flow that is commonly used in the previous studies. Supersonic jets for air and helium at Mach number 2.5 and 2.8, respectively, are simulated for two cases for the standoff distance between the nozzle exit and the substrate. Flow structures, mean flow properties, particles impact velocity and particles deposition efficiency on a flat substrate surface are presented. Different grid resolutions are tested using 2, 4 and 8 million points. Good agreement between DNS results and experimental data is obtained for the pressure distribution on the wall and the maximum Mach number profile in wall jet. Probability density functions for particle velocity and temperature at impact are presented. Deposition efficiency for aluminum and copper particles of diameter in the range 1 micron to 40 microns is calculated.
Instantaneous flow fields for the two standoff distances considered exhibit different flow characteristics. For large standoff distance, the jet is unsteady and flaps both for air (Mach number 2.5) and for helium (Mach number 2.8), in the direction normal to the large cross-section of the jet. Linear stability analysis of the mean jet profile validates the oscillation frequency observed in the present numerical study. Available experimental data also validate oscillation frequency. After impingement, the flow re-expands from the compressed gas region into a supersonic wall jet. The pressure on the wall in the expansion region is locally lower than ambient pressure. Strong bow shock only occurs for small standoff distance. For large standoff distance multiple/oblique shocks are observed due to the flapping of the jet.
The one-dimensional model based on isentropic flow calculations produces reliable results for particle velocity and temperature. It is found that the low efficiency in the low-pressure cold spray (LPCS) compared to high-pressure cold spray (HPCS) is mainly due to low temperature of the particles at the exit of the nozzle. Three-dimensional simulations show that small particles are readily influenced by the large-scale turbulent structures developing on jet shear layers, and they drift sideways. However, large particles are less influenced by the turbulent flow. Particles velocity and temperature are affected by the compressed gas layer and remain fairly constant in the jet region. With a small increase in the particles initial temperature, the deposition efficiency in LPCS can be maximized. There is an optimum particle diameter range for maximum deposition efficiency.Ph. D.
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Bush, Trenton. "Cold Gas Dynamic Spray – Characterization of Polymeric Deposition." 2016. https://scholarworks.umass.edu/masters_theses_2/413.
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When a solid, ductile particle impacts a substrate at sufficient velocity, the resulting heat, pressure, and plastic deformation can produce bonding at the interface. The use of a supersonic gas flow to accelerate such particles is known as Cold Spray deposition. The Cold Spray process has been commercialized for some metallic materials, but further research is required to unlock the exciting material properties possible with polymeric compounds. In this work, a combined computational and experimental study a) simulated and optimized the nozzle flow conditions necessary to produce bonding in a polyethylene particle, b) developed and fabricated an experimental device, and c) explored temperature-pressure space across a range of substrate materials, resolving a material dependent ‘window of deposition’ where successful coatings form. Insights into bonding mechanisms are discussed, and paths forward proposed.
Book chapters on the topic "Supersonic spray deposition"
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A. R., Srikrishnan. "Cold Spray Method for Wear-Resistant Surface Coating." In Handbook of Research on Tribology in Coatings and Surface Treatment, 118–37. IGI Global, 2022. http://dx.doi.org/10.4018/978-1-7998-9683-8.ch006.
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This chapter is focused on cold spray deposition of particles for surface modification. The method, which has been recently proven to have wide applicability in the domain of tribology and wear-resistant coatings, relies on supersonic gaseous jets to deposit the particle without phase change. The chapter aims at examining the influence of the unique gas dynamic characteristics of the high-speed jets on the deposition process. The general structure of the supersonic jets, including the velocity field, pressure gradients, and the impingement behaviour, is discussed with specific attention to the requirements of the sprays for tribological coatings. Results of detailed numerical simulation of the impingement process are made use of to demonstrate the parametric influence of the supersonic jet structure on critical spray characteristics, like the particle velocity. The study also examines various aspects of the energy conversion as applied to the basic nature of the supersonic jet as well as its interaction with the microparticles.
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Papyrin, A., S. Klinkov, and V. Kosarev. "Supersonic jet/substrate interaction in the cold spray process." In The Cold Spray Materials Deposition Process. CRC Press, 2007. http://dx.doi.org/10.1201/9781439824122.ch10.
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KOSAREV, V. F., S. V. KLINKOV, and A. N. PAPYRIN. "Supersonic jet/substrate interaction in the cold spray process." In The Cold Spray Materials Deposition Process, 178–216. Elsevier, 2007. http://dx.doi.org/10.1533/9781845693787.2.178.
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Tlotleng, Monnamme, Esther T. Akinlabi, Mukul Shukla, and Sisa Pityana. "Application of Laser Assisted Cold Spraying Process for Materials Deposition." In Surface Engineering Techniques and Applications, 177–221. IGI Global, 2014. http://dx.doi.org/10.4018/978-1-4666-5141-8.ch006.
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The Laser-Assisted Cold Spraying (LACS) process is a hybrid technique that uses laser and cold spray mechanism to deposit solid powders on metal substrates. For bonding to occur, the particle velocities must be supersonic. The supersonic effects can be achieved by passing a highly compressed Nitrogen gas (˜30 bars) through de Laval supersonic nozzle. LACS is a surface coating technique that is desirable in rapid prototyping and manufacturing, particularly for biomedical applications. Current world research reveals that the capability of the LACS regarding the enhancement of surface properties of coating titanium alloys with hydroxyapatite will be essential for fabricating scaffolds for bone implants using Laser Engineered Net Shaping (LENS) technique. In this chapter, coatings of composite powders made of titanium and hydroxyapatite deposited on Ti-6Al-4V substrate by LACS technology are presented. These coatings were successfully characterised by means of X-Ray Diffraction (XRD) and optical microscopy for their phases, composition, and microstructure, respectively. The results of the produced LACS coatings compare well with those obtained with traditional thermal spray and cold spray techniques, respectively. In addition, the XRD results were found to be similar to the precursor powders, which indicated that no phase transformation occurred to HAP. Coatings comprising of other crystalline phases of HAP are less bio-integrable and fail quicker within the human body fluids environments.
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Cockburn, Andrew, Nicholas Soane, Martin Sparkes, and William O’Neill. "Supersonic Laser Deposition of Self-Lubricating Coatings." In Advances in Transdisciplinary Engineering. IOS Press, 2021. http://dx.doi.org/10.3233/atde210054.
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Supersonic Laser Deposition (SLD) is a coating and fabrication process combining cold spray (CS) with laser heating of the deposition zone. Laser heating increases deformation on impact, improving bonding for a given particle velocity, eliminating the need to use helium while retaining the advantages of CS; solid-state deposition, low oxidation and high build rate (≤ 10 kg/hr). Although solid lubricants offer advantages over liquid lubrication, remaining effective over a wide range of operating temperatures and loads, while simplifying sealing, their use is limited by current application methods. SLD enables the deposition of metallic coatings which incorporate solid lubricants into metallic coatings, onto a range of substrates. This paper details the powders and conditions used to deposit nickel/graphite using SLD, and the structure and tribological properties of the coatings produced. Co-efficients of friction below 0.14 were demonstrated for nickel/graphite coatings on aluminium substrates.
Conference papers on the topic "Supersonic spray deposition"
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Niessen, K. von, and M. Gindrat. "Vapor Phase Deposition Using a Plasma Spray Process." In ITSC2010, edited by B. R. Marple, A. Agarwal, M. M. Hyland, Y. C. Lau, C. J. Li, R. S. Lima, and G. Montavon. DVS Media GmbH, 2010. http://dx.doi.org/10.31399/asm.cp.itsc2010p0219.
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Abstract Plasma spray – physical vapor deposition (PS-PVD) is a low pressure plasma spray technology to deposit coatings out of the vapor phase. PS-PVD is part of the family of new hybrid processes recently developed by Sulzer Metco AG (Switzerland) on the basis of the well established low pressure plasma spraying (LPPS) technology. Included in this new process family are plasma spray - chemical vapor deposition (PS-CVD) and plasma spray - thin film (PS-TF) processes. In comparison to conventional vacuum plasma spraying (VPS) and low pressure plasma spraying (LPPS), these new processes use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and EB-PVD coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Due to the forced gas stream of the plasma jet, complex shaped parts like multi-airfoil turbine vanes can be coated homogeneously with columnar thermal barrier coatings using PS-PVD. This paper reports on the progress made by Sulzer Metco to develop a thermal spray process to produce coatings out of the vapor phase.
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von Niessen, Konstantin, and Malko Gindrat. "Vapor Phase Deposition Using a Plasma Spray Process." In ASME Turbo Expo 2010: Power for Land, Sea, and Air. ASMEDC, 2010. http://dx.doi.org/10.1115/gt2010-22640.
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Plasma spray - physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland) to deposit coatings out of the vapor phase. PS-PVD is developed on the basis of the well established low pressure plasma spraying (LPPS) technology. In comparison to conventional vacuum plasma spraying (VPS) and low pressure plasma spraying (LPPS), these new process use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam - physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Due to the forced gas stream of the plasma jet, complex shaped parts like multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight to the coating source can be coated homogeneously. This paper reports on the progress made by Sulzer Metco to develop a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This includes coating properties like strain tolerance and erosion resistance but also the coverage of multiple air foils.
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Han, Taeyoung, Zhibo Zhao, Bryan A. Gillispie, and John R. Smith. "A Fundamental Study of the Kinetic Spray Process." In ITSC2004, edited by Basil R. Marple and Christian Moreau. ASM International, 2004. http://dx.doi.org/10.31399/asm.cp.itsc2004p0363.
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Abstract In the kinetic spray process, metallic particles are injected into a supersonic gas stream and accelerated to high velocities. When the particles impinge upon a substrate, they are plastically deformed and they bond to the substrate and to one another. In this process, a number of process parameters may affect the particle velocities and particle temperatures, and thus, affect coating formation. In the present study, various spray variables for the large particle sizes are systematically investigated through computational modeling and experiments. The relatively large size aluminum particles (63-90 µm) are used in this study. Effects on coating deposition are discussed in terms of loading behavior, deposition rate and deposition efficiency of the coatings. It was found that the coating formation is critically controlled by particle temperature, in addition to particle velocity.
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Barykin, G., and M. Parco. "The Oxy-Fuel Ionisation (OFI) Spray Processes." In ITSC2007, edited by B. R. Marple, M. M. Hyland, Y. C. Lau, C. J. Li, R. S. Lima, and G. Montavon. ASM International, 2007. http://dx.doi.org/10.31399/asm.cp.itsc2007p0594.
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Abstract Owing to gas velocities in the super-sonic regimen in combination with moderate flame temperatures, the HVOF processes are preferred for the deposition of wear and/or corrosion resistant carbides as well as Hastelloy, Triaballoy and Inconel alloys. The resulting coatings have usually very high bond strengths, fine as-sprayed surface finishes and low oxide levels. However, the generation of a supersonic flow of combustion products supposes the implementation of relatively high gas flow rates and high energetic gas mixtures, which are intrinsically associated with high production costs, limiting the application of this technology in some industrial fields. This work summarises the first results in the development of a prototype aimed to show the potential of a new thermal spray technology named Oxy-Fuel Ionisation spraying for the development of high quality carbide base coatings. The OFI process is a supersonic combustion process as well, enhanced by the addition of ionised gas specimens. The arising combustion process is characterised by its stability within a broader range of the “fuel/oxidant” correlation in comparison to conventional HVOF systems, because of the presence of ionised gas specimens which are acting as a catalyst. It has been proved that this developed prototype allows the thermal spray deposition of carbide based materials with relatively low oxygen flow rates. For comparison two different coating materials were investigated, WC-17Co and Cr3C2-NiCr. The process parameters were optimised in terms of the micro hardness, the porosity and the decarburization of the resulting coatings.
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Sonoda, T., T. Kuwashima, M. Nakamura, and T. Saito. "Effect of Powder Compressive Strength on Deposition Characteristics in Cold Spraying." In ITSC2010, edited by B. R. Marple, A. Agarwal, M. M. Hyland, Y. C. Lau, C. J. Li, R. S. Lima, and G. Montavon. DVS Media GmbH, 2010. http://dx.doi.org/10.31399/asm.cp.itsc2010p0865.
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Abstract In cold spray, feedstock powders are accelerated by supersonic jet with solid phase and deposited onto substrate. Compare with the conventional thermal spray, the coatings have low porosity without oxidation and decomposition. This study examines the effect of the powder compressive strength of each particle on coating deposition characteristics using two types of Ni powders, manufactured in a different process, in cold spray. The result indicated that heat treatment reduced the powder compressive strength, and the decrease of the powder compressive strength was related to the increase of bond strength of particles and deposition efficiency. In addition, it was shown that the powder compressive strength has an influence of deposition mechanism.
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Richer, P., B. Jodoin, E. Sansoucy, L. Ajdelsztajn, and G. E. Kim. "Properties of Cold Spray Nickel Based Coatings." In ITSC2006, edited by B. R. Marple, M. M. Hyland, Y. C. Lau, R. S. Lima, and J. Voyer. ASM International, 2006. http://dx.doi.org/10.31399/asm.cp.itsc2006p0227.
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Abstract Nickel based alloys used in coating applications have been the focus of many studies, particularly in the aerospace industry. Their inherent corrosion and oxidation resistant properties have made them especially attractive for use as the metallic bond coat found in thermal barrier coating systems. Cold Spray is an emerging coating technology in which fine powder particles are accelerated in a supersonic flow and then deposited onto a substrate by means of plastic deformation. In this study, conventional CoNiCrAlY coatings and nanocrystalline nickel coatings are produced using the Cold Spray deposition technique. The coating quality is evaluated using scanning electron microscopy as well as porosity and microhardness measurements.
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Gabor, Ted, Semih Akin, Jung-Ting Tsai, Seunghwan Jo, Feraas Al-Najjar, and Martin Byung-Guk Jun. "Numerical Studies on Cold Spray Particle Deposition Using a Rectangular Nozzle." In ASME 2022 17th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/msec2022-85673.
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Abstract Cold spray additive manufacturing (CSAM) is an emerging technique for scalable and rapid deposition of thick metallic coatings on various substrates. Despite great promises, CSAM with no upper limit of coating thickness remains challenging due to the stochastic nature of cold spray (CS) deposition. In particular, using axisymmetric nozzles (i.e., circular supersonic nozzles) lead to a quasi-Gaussian shaped particle distribution on the target surface, which limits the CSAM due to the formation of triangular-shaped (i.e., peak/valley-shaped) coating morphology. Recently, rectangular cold spray nozzles have been applied to CS particle deposition, and found to be promising for CSAM owing to its more uniform particle distribution and wider spray beam. In these studies, however, process-structure properties of cold spray deposition with a rectangular nozzle have not been sufficiently elucidated. Practical expansion of rectangular nozzles in CSAM strictly depends on uncovering process-structure properties of CS deposition phenomenon. To this end, we investigate cold spray deposition of microscale particles using a rectangular nozzle through three-dimensional discrete-phase turbulent flow modeling. The numerical modeling results are experimentally justified using a dual disc anemometer setup. The influence of operating gas conditions on critical particle deposition parameters is studied. An experimental case study of cold spray particle deposition on a polymer (ABS) substrate is also conducted to show the potential of rectangular nozzle in cold-spray based polymer metallization. The results suggest that cold spraying using a rectangular nozzle is beneficial for a more uniform, compact, and higher precision particle distribution on the target surface.
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Taylor, K., B. Jodoin, J. Karov, and P. Richer. "Particle Loading Effect in Cold Spray." In ITSC2005, edited by E. Lugscheider. Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, 2005. http://dx.doi.org/10.31399/asm.cp.itsc2005p0186.
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Abstract Cold Gas Dynamic Spray is a line of sight, high rate material deposition process that uses a supersonic flow to accelerate small particles (micron size powder) above a material dependent critical velocity. When the particles impact the substrate, they plastically deform and bond to form a coating. The objective of this research is to investigate the influence of the particle mass flow rate on the properties of coatings sprayed using the Cold Spray process. Varying the mass flow rate at which the feedstock particles are fed into the carrier gas stream can change the thickness of the coating. It was shown that poor coating quality (peeling) was not a result of flow saturation but instead, excessive particle bombardment per unit area on the substrate. This can be overcome by increasing the relative velocity between the substrate and the spraying nozzle. The results are dense coatings, even at higher powder mass flow rates.
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Hafiz, J., R. Mukherjee, X. Wang, P. H. McMurry, J. V. R. Heberlein, and S. L. Girshick. "Hypersonic Plasma Particle Deposition – A Hybrid between Plasma Spraying and Vapor Deposition." In ITSC2006, edited by B. R. Marple, M. M. Hyland, Y. C. Lau, R. S. Lima, and J. Voyer. ASM International, 2006. http://dx.doi.org/10.31399/asm.cp.itsc2006p1323.
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Abstract In the hypersonic plasma particle deposition process, vapor phase reactants are injected into a plasma and rapidly quenched in a supersonic nozzle, leading to nucleation of nanosize particles. These particles impact a substrate at high velocity, forming a coating with grain sizes of 10 to 40 nm. As previously reported, coatings of a variety of materials have been obtained, including silicon, silicon carbide, titanium carbide and nitride, and composites of these, all deposited at very high rates. Recent studies have shown that slight modifications of the process can result in nanosize structures consisting of single crystal silicon nanowires covered with nanoparticles. These nanowires are believed to grow in a vapor deposition process, catalyzed by the presence of titanium in the underlying nanoparticle film. However, simultaneously nanoparticles are nucleated in the nozzle and deposited on the nanowires, leading to structures that are the result of a plasma CVD process combined with a nanoparticle spray process. The combination of these two process paths opens new dimensions in nanophase materials processing.
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Richer, P., B. Jodoin, K. Taylor, E. Sansoucy, M. Johnson, and L. Ajdelsztajn. "Effect of Particle Geometry and Substrate Preparation in Cold Spray." In ITSC2005, edited by E. Lugscheider. Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, 2005. http://dx.doi.org/10.31399/asm.cp.itsc2005p0193.
Full textAbstract:
Abstract Cold Gas Dynamic Spraying is a relatively new high rate deposition process that uses a supersonic gas flow to accelerate fine powder particles (micron size) above a critical velocity. Upon impact, the particles deform plastically and bond to the substrate to form a coating. In this study, nanocrystalline Al-Mg coatings are produced using the Cold Spray technology. In an attempt to improve the understanding and optimize the process, the effects of substrate preparation and substrates thickness on the overall quality of the coatings are investigated. Two different grit materials are used to prepare the substrates with simple grit-blasting. Results show that the use of different grit sizes leads to changes in the mass deposited on the substrate (deposition efficiency) but has no significant effect on the coating microstructure. Other trials are conducted on samples of different thickness to verify the applicability of the Cold Spray process on thin surfaces. Results show that the Cold Spray process can be used to produce coatings on thin surfaces without noticeable damage to the substrate and with the same coating quality.