Properties of coatings and applications of low pressure plasma spray

Warm spray (WS) is a modification of high-velocity oxy-fuel spraying, in which the temperature of the supersonic gas flow generated by the combustion of kerosene and oxygen is controlled by diluting the combustion flame with an inert gas such as nitrogen. The inert gas is injected into the mixing chamber placed between the combustion chamber and the powder feed ports, thus the temperature of the propellant gas can be controlled from~700 to 2,000 K. Since WS allows for higher particle temperatures in comparison to cold spray, warm sprayed particles are more softened upon impact, thus resulting in greater deformation facilitating the formation of shear instability for bonding. Recently, the combustion pressure of WS has been increased from 1 (low-pressure warm spray) to 4 MPa (high-pressure warm spray) in order to increase the velocity of sprayed particles. Effects of spray parameters on microstructure, mechanical properties, and splats formation of Ti-6Al-4V were systematically studied. Obtained coatings were examined by analyzing the coating cross-section images, microhardness as well as oxygen content. In addition, flattening ratio of splats was calculated as a function of nitrogen flow rate. It was found that the increased particle velocity caused by the increased combustion pressure had significant beneficial effects in terms of improving density and controlling the oxygen level in the sprayed Ti-6Al-4V coatings.

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“…[1][2][3][4][5][6][7][8][9][10]. The mixture ratio of kerosene to oxygen was fixed at the stoichiometric ratio for complete combustion.…”

Section: Warm Spray Conditionsmentioning

confidence: 99%

Warm Spray Forming of Ti-6Al-4V

et al. 2013

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“…Sanz reported that high velocity oxygen fuel (HVOF) sprayed WC‐17%Co coatings showed superior wear resistance and lower abrasion rates as compared to a new generation weld overlay coating. Other thermal spray coating materials used on process rolls involve Cr3C2‐NiCr and ZrO2‐MgO‐(WC‐12Co) for guide rolls, WC‐Ni‐Cr for continuous galvanizing lines, and WC‐Co for bridle rolls. Under high operating temperatures, as in the case of stainless steel production, thermal barrier coating (TBC) systems are widely used for oxidation and high temperature resistance.…”

Section: Introductionmentioning

confidence: 99%

Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr₂O₃ and Al₂O₃‐13TiO₂ coatings

Öge

Küçük

Gök

et al. 2019

Int J Applied Ceramic Tech

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The microstructure and dry sliding wear performance of thermally sprayed FeCr slag coating were evaluated in comparison with those of commercially available Al 2 O 3 -13TiO 2 and Cr 2 O 3 ceramic coating powders to assess the applicability of FeCr slag (FS) powder, fabricated from industrial waste, as a ceramic top-coating material against wear. Ceramic top coats and underlying NiCoCrAlY bond coats were deposited on AISI 316L samples via atmospheric plasma spraying (APS), and their tribological properties were assessed using a ball-on-disc test rig at room temperature. As a result, FS coating exhibited the lowest worn volume, although it has the lowest surface hardness. Tribolayer formation was observed on the surface of the samples which were subjected to dry sliding wear tests. Delamination type wear is the dominant wear mechanism for Cr 2 O 3 and FS coatings, whereas local spallation areas arising from plastic deformation were observed on the surface of Al 2 O 3 -13TiO 2 coatings. The results suggested the applicability of FS powder as a candidate ceramic top coating material against wear. K E Y W O R D S Al 2 O 3 -13TiO 2 coatings, Cr 2 O 3 coatings, dry sliding wear, FeCr slag coatings 2284 | ÖGE Et al.

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“…7,8 Also, commercial (Cr and WC based) coating powders with oxide content are mostly preferred for protective coating of caster roll surfaces with APS method. 1,4,5,[16][17][18][19][20][21] In this study, an alternative protective coating material (ferrochromium slag) is introduced for deposition as a top coat layer on the surface of the caster rolls using APS technique, in accordance with TBC principle. Ferrochromium (FeCr) is a metal compound used in stainless and thermalresistant steel production.…”

Section: Introductionmentioning

confidence: 99%

“…However, service life of welded coatings is limited due to formation of thermal cracks and vapor oxidation and these coatings exhibit low toughness as mentioned above . Also, commercial (Cr and WC based) coating powders with oxide content are mostly preferred for protective coating of caster roll surfaces with APS method …”

Section: Introductionmentioning

confidence: 99%

Ferrochromium slag as a protective coating material against oxidation for caster rolls

Küçük

Öge

Gök

et al. 2018

Int J Applied Ceramic Tech

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In this study, ferrochromium (FeCr) slag, which is available as an industrial waste, is proposed as a protective surface coating material particularly for protection of continuous casting rolls against oxidation. FeCr slag was successfully deposited with atmospheric plasma spray (APS) method. Before the coating process, FeCr slag powder prepared in the particle size range of 5‐38 μm, was investigated using conventional characterization methods (XRD, SEM, TGA etc.). Thermal Barrier Coating (TBC) system was used as a basis for deposition processes. Accordingly, NiCoCrAlY (Amdry, −45 + 5 μm) was firstly deposited as metallic bond coat layer onto the surface of AISI 420 substrate, and then FeCr slag layer was deposited as the top coating layer. After the deposition of FeCr slag powder, the resulting coating layer was found to have low porosity with a homogeneous microstructure. The deposited FeCr slag coatings were subjected to isothermal oxidation tests at different temperatures and test durations for determination of their oxidation behavior and upper operating temperature limits. The results obtained from this study indicate that FeCr slag can be considered as an alternative protective coating material for caster rolls which are subjected to high temperatures up to 800°C.

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Properties of coatings and applications of low pressure plasma spray

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Cited by 18 publications

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Warm Spray Forming of Ti-6Al-4V

Warm Spray Forming of Ti-6Al-4V

Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr₂O₃ and Al₂O₃‐13TiO₂ coatings

Ferrochromium slag as a protective coating material against oxidation for caster rolls

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Properties of coatings and applications of low pressure plasma spray

Abstract: Abstract

Cited by 18 publications

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Warm Spray Forming of Ti-6Al-4V

Warm Spray Forming of Ti-6Al-4V

Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr2O3 and Al2O3‐13TiO2 coatings

Ferrochromium slag as a protective coating material against oxidation for caster rolls

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Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr₂O₃ and Al₂O₃‐13TiO₂ coatings