Tailoring the Spray Conditions for Suspension Plasma Spraying

Joulia, Aurélien; Duarte, William; Goutier, Simon; Vardelle, Michel; Vardelle, Armelle; Rossignol, Sylvie

doi:10.1007/s11666-014-0184-0

Cited by 13 publications

(18 citation statements)

References 15 publications

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“…Rather, coating activity has been observed to be affected by a number of factors including phase composition, TiOx concentration and surface roughness/area in these results alone, with more reported in the literature. [24] A challenge in suspension spray is therefore, to observe the effect of each of these aspects separately, with spray parameters having far reaching effects on coating properties. Similar observations of more complex coating parameters affecting coating activity have been reported previously.…”

Section: Figure 7 Sem Images Of Sfs Sps and Hvsfs Coating Surfaces Smentioning

confidence: 99%

“…Other researchers have managed substrate temperature through the use of proprietary gas cooling technology. [24] As such, it is clear that thermal loading is a significant challenge in suspension spraying. Of the three processes, SFS, while having the shortest stand-off distance, transfers the least heat into the substrate/jigging due to the lower temperature and kinetic force of the jet relative to SPS and HVSFS respectively.…”

Section: Scale-up Cost and Technical Challengesmentioning

confidence: 99%

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A Comparison of the Potential Capability of SFS, SPS and HVSFS for the Production of Photocatalytic Titania Coatings

et al. 2016

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The photocatalytic capabilities of titanium dioxide are widely published. Reported applications of titania coatings include air purification, water purification and self-cleaning. Suspension spray has been highlighted as a possible route for the deposition of highly active nanostructured TiO2 coatings. Published work has demonstrated the capabilities of suspension plasma spray (SPS) and high velocity suspension flame spray (HVSFS), however, little work exists for suspension flame spray (SFS). Herein, these three suspension spray processes are compared as regards their capability to produce photocatalytic TiO2 coatings and their potential for industrial scale up. A range of coatings were produced for each process, manipulating coating parameters in order to vary phase composition and other coating characteristics to effect activity. Coatings produced were found to vary significantly between the processes with SFS highlighted as the most effective technique with regards to future scale-up and coating photoactivity. SFS coatings were found to be up to 5 times more active than analogous coating produced by CVD.

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Section: Figure 7 Sem Images Of Sfs Sps and Hvsfs Coating Surfaces Smentioning

confidence: 99%

Section: Scale-up Cost and Technical Challengesmentioning

confidence: 99%

A Comparison of the Potential Capability of SFS, SPS and HVSFS for the Production of Photocatalytic Titania Coatings

et al. 2016

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“…[26][27][28][29][30] VanEvery et al's studies indicated that the finer YSZ powder like nanometer sized and lower suspension concentration (less than 10 wt%) could facilitate a columnar SPS coating formation. It is important that both DVC and columnar-structured YSZ coatings can be prepared by SPS as reported in previous studies, which might result in substantial improvements in YSZ TBCs' durability.…”

Section: Introductionmentioning

confidence: 99%

“…31 Pawlowski et al also carried out a series of studies on SPS YSZ coatings with various microstructures in terms of suspension concentration and substrate roughness using two types of commercial plasma spray torches with radial feedstock injection, i.e., SG-100 Ò (Praxair S.T., Indianapolis, IN) and Triplex Ò (Sulzer Metco AG, Wohlen, Switzerland). 26,29,31 Therefore, this study aims to acquire some new insights to understand the formation of both columnar and DVC-structured SPS YSZ coatings deposited using an ethanol-based suspension through varying some key processing parameters such as the plasma power, plasma gas composition, plasma jet velocity, and substrate roughness, and to investigate how these changes are reflected in the intermediate products such as the in-flight particles and splats as described above. 32, 33 Guignard et al showed that the DVC YSZ coating prepared by SPS with a crack density of 6.5 cracks/mm exhibited a poorer thermal cycling lifetime compared to the conventional APS YSZ coating due to the presences of unmelted or spherical particles in the SPS coating leading to poorer adhesive strength.…”

Section: Introductionmentioning

confidence: 99%

Effects of Processing Parameters on the Deposition of Yttria Partially Stabilized Zirconia Coating During Suspension Plasma Spray

et al. 2016

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The process–microstructure relationship in suspension plasma spray (SPS) of yttria partially stabilized zirconia (YSZ) has been studied experimentally. An ethanol‐based suspension with a powder loading of 25 wt% was plasma sprayed with radial injection under four different plasma conditions, to examine the effects of plasma gas composition (Ar/He ratio), secondary gas (Ar/He and Ar/H2), and the nozzle diameter of the plasma gun. The suspension feeding rate was optimized firstly and coatings were prepared for microstructural observation. Capturing of in‐flight particles into water as well as collection of splats formed on heated flat metal substrates were utilized in order to better understand the more complicated intermediate process steps in SPS. It was found that a plasma jet with higher momentum allowed a higher suspension flow rate and both columnar and deep vertically cracked structure could be created depending on the plasma parameters as well as the substrate surface roughness.

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“…For this reason, thermal spraying with suspensions is primarily seen as a technology for the preparation of ceramic oxide coatings. Except oxides (Al 2 O 3 , TiO 2 , Cr 2 O 3 , YSZ), biomaterials (hydroxyapatite, bioglasses) and perovskites were studied to produce suspensions for spraying (i.e., Ref 4,[7][8][9][10][11][12][13][14][15][16][17][18]. In the case of metals, only the chemically prepared metallic powders are good candidates for suspensions.…”

Section: Introductionmentioning

confidence: 99%

Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review

et al. 2015

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Research and development work for about one decade have demonstrated many unique thermal spray coating properties, particularly for oxide ceramic coatings by using suspensions of fine powders as feedstock in APS and HVOF processes. Some particular advantages are direct feeding of fine nano-and submicron-scale particles avoiding special feedstock powder preparation, ability to produce coating thicknesses ranging from 10 to 50 lm, homogeneous microstructure with less anisotropy and lower surface roughness compared to conventional coatings, possibility of retention of the initial crystalline phases, and others. This paper discusses the main aspects of thermal spraying with suspensions which have been taken into account in order to produce these coatings on an economical way. The economic efficiency of the process depends on the availability of suitable additional system components (suspension feeder, injectors), on the development and handling of stable suspensions, as well as on the high process stability for acceptance at industrial scale. Special focus is made on the development and processability of highly concentrated water-based suspensions. While costs and operational safety clearly speak for use of water as a liquid media for preparing suspensions on an industrial scale, its use is often critically discussed due to the required higher heat input during spraying compared to alcoholic suspensions.

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Tailoring the Spray Conditions for Suspension Plasma Spraying

Abstract: International audienc

Cited by 13 publications

References 15 publications

A Comparison of the Potential Capability of SFS, SPS and HVSFS for the Production of Photocatalytic Titania Coatings

A Comparison of the Potential Capability of SFS, SPS and HVSFS for the Production of Photocatalytic Titania Coatings

Effects of Processing Parameters on the Deposition of Yttria Partially Stabilized Zirconia Coating During Suspension Plasma Spray

Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review

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