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Rapid solidification in thermal spray deposition: Microstructure and modelling

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Abstract

Mechanical thermal and adhesive properties of thermal spray coating are primarily determined by the phase and microstructure of single splats, which ultimately depend on rapid solidification of each splat and on the interactions between the splats and between the splat and the substrate. Significant efforts are being made to develop a better understanding of the physical mechanisms underlying these phenomena. This paper reviews a series of work in the area of mathematical modeling of phase and microstructure formation during the rapid solidification of single splats and coatings. The model development has been complimented by special experiments. Conditions under which plantar interface solidification occurs, columnar celluar or dendritic growth takes place, or banded structure forms, have been identified. A microstructure map can therefore built using the model presented here. The process parameters that promote crystalline nucleation and grain structure formation can be isolated and the effect of interfacial heat transfer, splat substrate temperature difference, and substrate melting and resolidification can be examined using the model. The model prediction agree qualitatively well with the experimental data for alumina, yttria, partially-stabilized zirconia, and molybdenum.

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Authors and Affiliations

  1. Department of Mechanical Engineering, The University of Akron, 44325-3903, Akron, OH, USA

    Guo-Xiang Wang

  2. Center for Thermal Spray Research, College of Engineering and Applied Sciences, Suite University of New York at Stony Brook, 11794-2300, Stony Brook, NY, USA

    V. Prasad & S. Sampath

Authors
  1. Guo-Xiang Wang
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  2. V. Prasad
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  3. S. Sampath
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Wang, GX., Prasad, V. & Sampath, S. Rapid solidification in thermal spray deposition: Microstructure and modelling. Sadhana 26, 35–57 (2001). https://doi.org/10.1007/BF02728478

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