Abstract
This study aims to investigate the advantage of using flash boiling atomization as a new method of feedstock injection in suspension plasma spraying (SPS) and compare the results with continuous jet injection at ambient temperature that is currently used in SPS. In conventional methods, clogging is the main obstacle for the injection of suspension with concentrations beyond 40 wt.%. In this work, we demonstrate that flash boiling atomization enables the injection of suspensions with solid concentrations up to 70 wt.%. The chosen suspension was water based, and the average diameter for the dispersed titania particles was 500 nm. Coating characterization, phase composition, deposition efficiency, deposition rate and thickness per pass were investigated for different suspension concentrations. It was shown that using suspensions with high solid contents leads to a significantly higher deposition weight per pass and thickness per pass and results in a different coating microstructure.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig3_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig4_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig6_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig7_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig8_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig9_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig10_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig11_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs11666-023-01679-y/MediaObjects/11666_2023_1679_Fig12_HTML.png)
Similar content being viewed by others
References
P. Fauchais, G. Montavon, R.S. Lima, and B.R. Marple, Engineering a New Class of Thermal Spray Nano-Based Microstructures from Agglomerated Nanostructured Particles, Suspensions and Solutions: An Invited Review, J. Phys. D Appl. Phys., 2011, 44(9), p 093001.
M. Aghasibeig, F. Tarasi, R.S. Lima, A. Dolatabadi, and C. Moreau, A Review on Suspension Thermal Spray Patented Technology Evolution, J. Therm. Spray Technol., 2019, 28, p 1579–1605.
E. Aubignat, M.P. Planche, D. Billieres, A. Allimant, L. Girardot, Y. Bailly, and G. Montavon, Optimization of the Injection with a Twin-Fluid Atomizer for Suspension Plasma Spray Process using Three Non-Intrusive Diagnostic Tools, J. Vis., 2016, 19(1), p 21–36.
O. Marchand, L. Girardot, M.P. Planche, P. Bertrand, Y. Bailly, and G. Bertrand, An Insight into Suspension Plasma Spray: Injection of the Suspension and its Interaction with the Plasma Flow, J. Therm. Spray Technol., 2011, 20(6), p 1310–1320.
F.L. Toma, L.M. Berger, D. Jacquet, D. Wicky, I. Villaluenga, Y.R. De Miguel, and J.S. Lindeløv, Comparative Study on the Photocatalytic Behaviour of Titanium Oxide Thermal Sprayed Coatings from Powders and Suspensions, Surf. Coat. Technol., 2009, 203(15), p 2150–2156.
D. Waldbillig and O. Kesler, The Effect of Solids and Dispersant Loadings on the Suspension Viscosities and Deposition Rates of Suspension Plasma Sprayed YSZ Coatings, Surf. Coat. Technol., 2009, 203(15), p 2098–2101.
E. Cañas, E. Rosado, C. Alcázar, M.J. Orts, R. Moreno, and E. Sánchez, Challenging Zircon Deposits by Suspension Plasma Spraying, J. Eur. Ceram. Soc., 2022, 42(10), p 4369–4376.
X. Li, S. Yang, T. Li, D.L. Hung, and M. Xu, Investigations on Near-Field Atomization of Flash Boiling Sprays for Gasoline Direct Injection Related Applications, Fuel, 2019, 257, p 116097.
Ivey, J. (2018). Particle Formation from Evaporating Microdroplets for Inhaled Drug Delivery [Doctoral thesis, University of Alberta]
W. Gao, J. Qi, J. Zhang, G. Chen, and D. Wu, An Experimental Study on Explosive Boiling of Superheated Droplets in Vacuum Spray Flash Evaporation, Int. J. Heat Mass Transf., 2019, 144, p 118552.
Y. Feng, W. Qi, M.H. Baghaei, Y. Zhang, and D. Zhao, Investigation on a Novel Type of Tubular Flame Burner with Multi-Stage Partially-Premixing Features for Liquid-Fueled Gas Turbine, Combust. Sci. Technol., 2021, 193(1), p 110–125.
R. Vaßen, H. Kaßner, G. Mauer, and D. Stöver, Suspension Plasma Spraying: Process Characteristics and Applications, J. Therm. Spray Technol., 2010, 19(1), p 219–225.
J. Château and H. Lhuissier, Breakup of a Particulate Suspension Jet, Phys. Rev. Fluids, 2019, 4(1), p 012001.
B.S. Park and S.Y. Lee, An Experimental Investigation of the Flash Atomization Mechanism, Atomizat. Sprays, 1994, 4(2), p 159–179.
E. Alebrahim, M.S. Rahaman, and C. Moreau, TiO2 Photocatalytic Ultrafiltration Membrane Developed with Suspension Plasma Spray Process, Coatings, 2022, 12(11), p 1764.
P. Fauchais, M. Vardelle, A. Vardelle, and S. Goutier, What Do We Know, What are the Current Limitations of Suspension Plasma Spraying?, J. Therm. Spray Technol., 2015, 24(7), p 1120–1129.
Garmeh, S. (2019). Transportation of high concentration suspension using visco-plastic lubrication [Master’s thesis, Concordia University]
T. Yiamsawas, O. Mahian, A.S. Dalkilic, S. Kaewnai, and S. Wongwises, Experimental Studies on the Viscosity of TiO2 and Al2O3 Nanoparticles Suspended in a Mixture of Ethylene Glycol and Water for High Temperature Applications, Appl. Energy, 2013, 111, p 40–45.
Günther, A., Wirth, K. E. (2016). Superheated Atomization. Process-Spray: Functional Particles Produced in Spray Processes. Springer, 1st ed, 609-645
C. Lee, H. Choi, C. Lee, and H. Kim, Photocatalytic Properties of Nano-Structured TiO2 Plasma Sprayed Coating, Surf. Coat. Technol., 2003, 173(2–3), p 192–200.
A. Fujishima and X. Zhang, Titanium Dioxide Photocatalysis: Present Situation and Future Approaches, C. R. Chim., 2006, 9(5–6), p 750–760.
Acknowledgments
The authors would like to thank the financial support of the Natural Sciences and Engineering Research Council Canada (NSERC) and the Canada Research Chairs Program.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Amrollahy Biouki, S., Ben Ettouil, F., Liberati, A.C. et al. Flash Boiling Atomization of High-Concentration Suspensions in Suspension Plasma Spraying. J Therm Spray Tech 33, 122–133 (2024). https://doi.org/10.1007/s11666-023-01679-y
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-023-01679-y