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The Role of Substrate Surface Chemistry on Splat Formation During Plasma Spray Deposition by Experiments and Simulations

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Abstract

NiCr single splats were plasma-sprayed on aluminum and stainless steel substrates, which were modified by immersion in boiling water, to grow specific types of oxide/oxyhydroxide on the surface. It was observed that there was no splat formation on aluminum substrate. In contrast, a significant number of splats were formed on stainless steel substrate. The differences in splat formation on aluminum and stainless steel surfaces corresponded to the variations of thickness and proportions of the oxide/oxyhydroxide layer on the surfaces. A three-dimensional numerical model was developed to simulate the impact of a droplet onto the substrate. The simulation illustrated good agreement with experimental observations. The effect of the oxide layer on the splat morphology was also examined. It was suggested that the splat morphology was more strongly influenced by water release from the dehydration of oxyhydroxide to oxide rather than by simple presence of the oxide layer on the substrate surface.

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Abbreviations

B :

body force

C p :

specific heat capacity

f :

mass fraction

F :

volume of fraction of the droplet

k :

thermal conductivity

L :

latent heat of fusion

n :

interface normal vector pointing from the droplet to air

R c :

thermal contact resistance at the droplet-substrate interface

T :

temperature

T 0 :

substrate initial temperature

T m :

equilibrium melting temperature

p :

pressure

t :

time

u :

velocity vector

α:

thermal diffusivity

ρ:

density

μ:

effective viscosity

σ:

surface tension coefficient

κ:

surface curvature

δ:

interface delta function

l:

liquid phase

m:

equilibrium melting temperature

ox:

oxide

s:

solid

sub:

substrate

α:

droplet

β:

air

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Acknowledgments

The author would like to acknowledge Tertiary Education Commission of New Zealand for Top Achiever Doctoral scholarship.

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Authors and Affiliations

  1. Chemical & Materials Engineering Department, The University of Auckland, Private Bag 92019, Auckland, New Zealand

    A. T. T. Tran & M. M. Hyland

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  1. A. T. T. Tran
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Correspondence to A. T. T. Tran.

Additional information

This article is an invited paper selected from presentations at the 2009 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Expanding Thermal Spray Performance to New Markets and Applications: Proceedings of the 2009 International Thermal Spray Conference, Las Vegas, Nevada, USA, May 4-7, 2009, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2009.

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Tran, A.T.T., Hyland, M.M. The Role of Substrate Surface Chemistry on Splat Formation During Plasma Spray Deposition by Experiments and Simulations. J Therm Spray Tech 19, 11–23 (2010). https://doi.org/10.1007/s11666-009-9414-2

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  • DOI: https://doi.org/10.1007/s11666-009-9414-2

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