Abstract
Plasma spraying in controlled atmosphere as very-low-pressure plasma spraying (VLPPS) allows to work with different states of matter, particularly vapor. As a result, the coating microstructure is unique (lower-scale elements, pore architecture) and the properties are improved. Another benefit of VLPPS process is the mold filling. Unlike other thermal spray processes, the vapor mode can follow the gas flow and reach the mold walls to fill. The vapor mode deposition is very soft and protects the surface state of the mold/substrate. The coating microstructure is homogeneous on all the geometry. The choice of a soluble salt mold permits to easily get back the coating and use it as a functional part. The objective is to demonstrate that VLPPS process can be used as an additive manufacturing device to create well-defined objects/pieces.
Similar content being viewed by others
References
A. Vardelle, C. Moreau, J. Akedo, H. Ashrafizadeh, C.C. Berndt, J. Oberste Berghaus, M. Boulos, J. Brogan, A.C. Bourtsalas, A. Dolatabadi, M. Dorfman, T.J. Eden, P. Fauchais, G. Fisher, F. Gaertner, M. Gindrat, R. Henne, M. Hyland, E. Irissou, E.H. Jordan, K.A. Khor, A. Killinger, Y.-C. Lau, C.-J. Li, L. Li, J. Longtin, N. Markocsan, P.J. Masset, J. Matejicek, G. Mauer, A. McDonald, J. Mostaghimi, S. Sampath, G. Schiller, K. Shinoda, M.F. Smith, A. Ansar Syed, N.J. Themelis, F.-L. Toma, J.P. Trelles, R. Vassen, and P. Vuoristo, The 2016 Thermal Spray Roadmap, J. Therm. Spray Technol., 2016, 25(8), p 1376-1440
F.L. Toma, A. Potthoff, L.M. Berger, and C. Leyens, Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review, J. Therm. Spray Technol., 2015, 24(7), p 1143-1152
G. Mauer, M.O. Jarligo, S. Rezanka, A. Hospach, and R. Vaßen, Novel Opportunities for Thermal Spray by PS-PVD, Surf. Coat. Technol., 2015, 268, p 52-57
S. Rezanka, G. Mauer, and R. Vaßen, Improved Thermal Cycling Durability of Thermal Barrier Coatings Manufactured by PS-PVD, J. Therm. Spray Technol., 2014, 23(1-2), p 182-189
M. Gindrat, J.-L. Dorier, C. Hollenstein, A. Refke, and G. Barbezat, Characterization of Supersonic Low Pressure Plasma Jets with Electrostatic Probes, Plasma Sources Sci. Technol., 2004, 13(3), p 484-500
J.-L. Dorier, M. Gindrat, C. Hollenstein, M. Refke, A. Salito, and G. Barbezat, Plasma Jet Properties in a New Spraying Process at Low Pressure for Large Area Thin Film Deposition, Thermal Spray 2001: New Surfaces for A New Millennium, C.C. Berndt, K.A. Khor and E.F. Lugscheider, Ed., May 28-30, 2001 (Singapore, Singapore), ASM International, 2001
K. von Niessen, M. Gindrat, and A. Refke, Vapor Phase Deposition Using Plasma Spray-PVD, J. Therm. Spray Technol., 2010, 19(1-2), p 502-509
A. Barth, M. Gindrat, and S. Usai, High Productivity PS-PVD Process, Thermal Spray 2013: Innovative Coating Solutions for the Global Economy, R.S. Lima, A. Agarwal, M.M. Hyland, Y.-C. Lau, G. Mauer, A. McDonald, F.-L. Toma, Ed., May 13-15, 2013 (Busan, South Korea), ASM International, 2013
P. Fauchais, J.V.R. Heberlein, and M. Boulos, Thermal Spray Fundamentals: From Powder to Part, Springer, NewYork, 2014, p 24
F.W. Baumann and D. Roller, Additive Manufacturing, Cloud-Based 3D Printing and Associated Services—Overview, J. Manuf. Mater. Process, 2017, 15(1), p 1-15
W.E. Frazier, Metal Additive Manufacturing, Rev. J. Mater. Eng. Perform., 2014, 23(6), p 1917-1928
I. Gibson, D. Rosen, and B. Stucker, Additive Manufacturing Technologies, Springer, New York, 2015
E.O. Olakanmi, R.F. Cochrane, and K.W. Dalgarno, A Review on Selective Laser Sintering/Melting (SLS/SLM) of Aluminium Alloy Powders: Processing, Microstructure, and Properties, Prog. Mater. Sci., 2015, 74, p 401-477
R.N. Raoelison, C. Verdy, and H. Liao, Cold Gas Dynamic Spray Additive Manufacturing Today: Deposit Possibilities, Technological Solutions and Viable Applications, Mater. Des., 2017, 133, p 266-287
A. Astarita, F. Coticelli, and U. Prisco, Repairing of an Engine Block Through the Cold Gas Dynamic Spray Technology, Mater. Res., 2016, 19(6), p 1226-1231
A. Villafuerte, Modern Cold Spray: Materials, Process and Applications, Springer, New York, 2015, p 341-358
E. Bannier, G. Darut, E. Sánchez, A. Denoirjean, M.C. Bordes, M.D. Salvador, E. Rayón, and H. Ageorges, Microstructure and Photocatalytic Activity of Suspension Plasma Sprayed TiO2 Coatings on Steel and Glass Substrates, Surf. Coat. Technol., 2011, 206(2-3), p 378-386
S. Guanhong, H. Xiaodong, J. Jiuxing, and S. Yue, Parametric Study of Al and Al2O3 Ceramic Coatings Deposited by Air Plasma Spray onto Polymer Substrate, Appl. Surf. Sci., 2011, 257(17), p 7864-7870
K.J. Klabunde, Thin Films From Free Atoms and Particles, Academic Press Inc, Orlando, 2012, p 8
G. Reisel and R.B. Heimann, Correlation Between Surface Roughness of Plasma-Sprayed Chromium Oxide Coatings and Powder Grain Size Distribution: A Fractal Approach, Surf. Coat. Technol., 2004, 185(2-3), p 215-221
Y. Wang, G. Darut, T. Poirier, J. Stella, H. Liao, and MP. Planche, Ultrasonic Cavitation Erosion of Vacuum Plasma sprayed Yttria Stabilized Zirconia Coatings, 8th RIPT2017, December 6-8, 2017 (Limoges, France)
J. Ilavsky, A.J. Allen, G.G. Long, S. Krueger, C.C. Berndt, and H. Herman, Influence of Spray Angle on the Pore and Crack Microstructure of Plasma-Sprayed Deposits, J. Am. Ceram. Soc., 1997, 80(3), p 733-742
S.H. Leigh and C.C. Berndt, Evaluation of Off-Angle Thermal Spray, Surf. Coat. Technol., 1997, 89(3), p 213-224
P. Fauchais, A. Vardelle, M. Vardelle, and M. Fukumoto, Knowledge Concerning Splat Formation: An Invited Review, J. Therm. Spray Technol., 2004, 13(3), p 337-360
Acknowledgments
The authors gratefully acknowledge Creaholic Company which supported the project.
Author information
Authors and Affiliations
Corresponding author
Additional information
This article is an invited paper selected from presentations at the 2018 International Thermal Spray Conference, held May 7-10, 2018, in Orlando, Florida, USA, and has been expanded from the original presentation.
Rights and permissions
About this article
Cite this article
Darut, G., Niederhauser, A., Jaccoud, B. et al. VLPPS: An Emerging Process to Create Well-Defined Components by Additive Manufacturing. J Therm Spray Tech 28, 255–264 (2019). https://doi.org/10.1007/s11666-018-0792-1
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-018-0792-1