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Effect of Solid Shield on Coating Properties in Atmospheric Plasma Spray Process

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Abstract

This paper investigates the impact of shrouded shield structure on plasma spray processes and the selection of optimal shield structure. Response of plasma flame characteristics to solid shield structures is studied first, and experimental investigations are then performed for both atmospheric (APS) and shrouded (SPS) plasma spray processes. It is found that the usage of conical shield (divergence angle 5.5°) with 90 mm in length is effective to form a low-oxygen (<2%) and high-temperature (>3000 K) region in the plasma flame and this region can cover the majority area for particles passing by. The average particle temperature is higher in SPS than in APS with the given conditions, and such behavior is intensified as solid shield length increases. Using the SPS process, more disk-shaped splats are obtained, and the oxygen concentration in coating is significantly reduced. The degree of the oxidation in the coatings is further reduced as the length of the solid shield increases from 50 to 90 mm. Applying solid shield will lead to high flame temperature and low oxidation; however, the substrate overheating and velocity reduction may occur. For the cases studied, the optimal shield length is around 90 mm.

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Abbreviations

Cp :

Specific heat, J/(kg K)

h :

Convective heat transfer coefficient, W/(m2 K)

k :

Thermal conductivity, W/(m K)

r, R i :

Radial coordinate, m

t :

Time, s

T :

Temperature, K

\(\vec{v}\) :

Velocity vector, m/s

x :

Axial coordinate, m

H :

Specific enthalpy, J

\(\upmu\) :

Viscosity, kg/(s m)

\(\uprho\) :

Density, kg/m3

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Acknowledgments

The authors are grateful to Professor Guanzhong Zhang for his assistance in preparing plasma spray coatings. This work is partially supported by the Civil Aviation Science and Technology Project of China (Grant No. 20150215), by the National Natural Science Foundation of China (Grant No. 91224008) and by the National Basic Research Program of China (973 Program No. 2012CB719705).

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Authors and Affiliations

  1. School of Aerospace Engineering, Tsinghua University, Beijing, 100084, China

    Ting Liu & Lili Zheng

  2. Department of Engineering Physics, Tsinghua University, Beijing, 100084, China

    Hui Zhang

Authors
  1. Ting Liu
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  2. Lili Zheng
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  3. Hui Zhang
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Corresponding author

Correspondence to Lili Zheng.

Additional information

This article is an invited paper selected from presentations at the 7th Asian Thermal Spray Conference (ATSC 2015) and has been expanded from the original presentation. ATSC 2015 was held in Xi’an, China, September 23–25, 2015, and was organized by the Asian Thermal Spray Society in association with Xi’an Jiaotong University, State Key Laboratory for Mechanical Behavior of Materials.

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Liu, T., Zheng, L. & Zhang, H. Effect of Solid Shield on Coating Properties in Atmospheric Plasma Spray Process. J Therm Spray Tech 25, 1502–1515 (2016). https://doi.org/10.1007/s11666-016-0442-4

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