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Effects of Spray Parameters on the YSZ-Alumina Splat Formation During Solution Precursor High Velocity Flame Spraying

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Abstract

Solution precursor thermal Spraying (SPTS) processes that have been successfully developed, are suitable methods for producing nanostructured coatings. In the SPTS coatings, important features are splat, porosity, un-melted particles and un-pyrolysed precursor. Such features can be studied by observing deposit collected by spraying only a single pass on to the substrate. In the present study, deposition of YSZ-40 wt% Al2O3 on glass substrates by solution precursor high velocity flame spraying (SP-HVFS) of zirconium oxy nitrate, yttrium nitrate and aluminum nitrate solutions mixed with suitable percentage to result YSZ-40 wt% Al2O3 in single scan experiment has been studied/for the first time. In order to investigate the SP-HVFS process, all spraying parameters including the fuel-oxygen ratio, the spraying distance and the feed rate of solution precursor were varied. The results of thermal analysis showed that precursor decomposition is an exothermic reaction that mainly occurs at temperatures above 250 °C. Also, the phase compositions of the YSZ-40 wt% Al2O3 powders resulted from pyrolysation of the precursor in furnace at different temperatures were investigated by X-ray diffraction, which confirmed that with increasing heat treatment temperature, the degree of crystallinity and grain size of YSZ-40 wt% Al2O3 powder increases. The morphology of the deposits formed on the glass substrates and their structural characteristics were studied using Field Emission Scanning Electron Microscope. Structural comparison of deposits formed on glass substrates in the single scan experiment showed that at low fuel and oxygen flow rates (30 and 300 l/min respectively), solution precursor injection rate of 20 cm3/min and spray distance of 5 cm, the amount of splats increased. Also, high fuel and oxygen flow rates (50 and 450 l/min respectively), the solution precursor feed rate of 40 cm3/min and spray distance of 5 cm was introduced as the optimal parameter due to higher splats observed.

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  1. Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran

    Saeid Taghi-Ramezani & Zia Valefi

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  1. Saeid Taghi-Ramezani
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Taghi-Ramezani, S., Valefi, Z. Effects of Spray Parameters on the YSZ-Alumina Splat Formation During Solution Precursor High Velocity Flame Spraying. Met. Mater. Int. 30, 928–940 (2024). https://doi.org/10.1007/s12540-023-01548-x

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