RESUMEN
Thermal spray deposition (specifically Atmospheric Plasma Spraying, APS) is a well-established surface coating technology with a broad scope of applications (i.e., insulative coatings, tribological coatings, anti-corrosion coatings, etc.). In addition, there is a constant drive to introduce the APS process into new and emerging fields. One such niche application for APS would be sub-stoichiometric TiO2-x coatings with enhanced thermoelectric performance (compared to the bulk material). The APS process in this context has a unique ability-given the use of hydrogen as a plasma gas-to reduce TiO2-x material during processing. However, to this point, there is neither a reliable nor self-consistent method to assess (nor control by parametric optimization) the inflight reduction of molten oxide particles during processing. This study shows that using Optical Emission Spectroscopy (OES), it can be possible-even in atmospheric conditions-to identify characteristic emission peaks associated with the inflight reduction of TiO2 during APS. Using this OES data, the input spray processing parameters and their influence on coating microstructure and the degree of inflight reduction of the material will be shown. Results suggest under equilibrium conditions only a minimal amount of hydrogen gas is needed in the plasma to fulfill the TiO2 reduction.
RESUMEN
The TriplexPro™-210 plasma spray torch (Oerlikon Metco) is a three-cathode plasma generator. It became a kind of workhorse for the wide range of tasks handled at the Jülich Thermal Spray Center (JTSC). Compared to conventional single-cathode torches, the cascaded design of the nozzle suggests low fluctuations of the arc and thus high stability. However, after a certain time, degradation sets in even with such a torch, impairing the reliability of the process. It is therefore important to detect indications of performance loss in time and not only during the inspection of the deposited layer. In this study, standard samples of YSZ thermal barrier coatings were sprayed regularly over a period of two years. Operational data and feedstock characteristics were collected and correlated with the area-specific mass deposition. It turned out that the measured substrate surface temperature showed a distinct correlation. Searching for the reasons for the temperature variations, several process parameters could be ruled out as they are monitored by calibrated sensors, controlled, and their time course is recorded by the control unit. Moreover, there are other parameters, which can have a considerable impact such as the robot alignment or the substrate cooling conditions. However, the purposeful experimental variation of such variables resulted in a variability of the mass deposition being considerably smaller than observed over the two years. Thus, it can be concluded that torch degradation had a pronounced effect, too. The substrate surface temperature can be used as indicator for the torch status and the reliability of the spray process.
RESUMEN
Cavitation erosion is a sever wear mechanism that takes place in hydrodynamic systems. Examples are turbine vanes of hydropower plants or components of valves and pumps in hydraulic systems. Nickel-titanium shape memory alloys (NiTi) are attractive materials for cavitation-resistant coatings because of their pronounced intrinsic damping mitigating cavitation-induced erosion. In this work, NiTi coatings were produced by cold gas spraying. The phase transformation behaviors of the powder feedstock and the as-sprayed coatings were investigated. Regarding the obtained transformation temperatures, the measured substrate temperatures during spraying rule out that either the shape memory effect or the pseudoelasticity of NiTi could affect the deposition efficiency under the applied conditions of cold gas spraying. Another potential effect is stress-induced amorphization which could occur at the particle-substrate interfaces and impair particle bonding by stress relaxation. Moreover, also oxide formation can be significant. Thus, the presence of amorphous phases and oxides in the near-surface zone of particles bounced off after impact was investigated. Oxidation could be confirmed, but no indication of amorphous phase was found. Besides, also the evolution of local microstrains implies that the substrate temperatures affect the deposition efficiency. These temperatures were significantly influenced by the spray gun travel speed.