Effect of plasma spray parameters on porosity of fly ash deposited coatings

Muhammad, M. M.; Jalar, Azman; Shamsudin, Roslinda; Isa, M. C.

doi:10.1063/1.4895182

Cited by 7 publications

(3 citation statements)

References 7 publications

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“…All deposited Al 2 O 3 coatings demonstrated good adhesion to the steel substrate. There is a minimal number of microcracks and pores between the substrate and the coating; however, over the entire coating width, there are a lot more cavities, which are common for plasma-sprayed coatings [30,31]. The coating thickness was similar for all samples (around 40 µm).…”

Section: Resultsmentioning

confidence: 89%

Influence of Plasma Torch Power on the Plasma Jet Properties and Microstructure of Alumina Coatings

et al. 2022

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In this study, alumina coatings were formed using atmospheric plasma spraying, increasing the torch power from 29.4 to 45.1 kW. The surface morphology of the coatings was determined using scanning electron microscopy; the elemental composition was examined using energy-dispersive X-ray spectroscopy (EDS); phase composition was investigated using X-ray diffraction; and surface roughness was determined using a profilometer. The steel surface temperature was measured using a type-K thermocouple, and the plasma jet temperature, at a distance of 70 mm, using a type-B thermocouple. Alumina particle velocity was calculated by analyzing high-speed camera footage using ImageJ software. The results indicate that plasma jet temperature, speed, and in-flight particle velocity increased with plasma torch power. Furthermore, the amount of γ-Al2O3 phase in the coating increased, and the α-Al2O3 decreased with increasing plasma power. The surface roughness (Rq) of the Al2O3 coatings decreased from 7.13 to 5.54 μm, with an increase in torch power. The EDS measurements indicate that the increase in torch power did not affect the elemental composition of as-sprayed coatings. The results provide a wider understanding of an atmospheric plasma spray technique, optimizing and controlling the parameters using air as a primary gas.

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Section: Resultsmentioning

confidence: 89%

Influence of Plasma Torch Power on the Plasma Jet Properties and Microstructure of Alumina Coatings

et al. 2022

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“…An analysis of plasma-spraying characteristics allows adjusting the porosity of coatings and the pore size [28,29]. A number of studies have focused on the theoretical [30,31] and experimental [32][33][34][35][36][37][38][39] research of the relationship between the parameters of the plasma jet and pore-size distribution of the coated material. On the basis of the empirical results obtained in [33], it is possible to figure out that the porosity is a function of the plasma powder particles' dimension:…”

Section: Analysis Of Structural Defectsmentioning

confidence: 99%

“…Therefore, the porosity of the coating layer can be determined using the characteristics of the plasma spraying process. This relationship enables defining the key feature of the coating material, as the porosity has an important impact on the thermal characteristics and microhardness of plasma coatings [37,38].…”

Section: Analysis Of Structural Defectsmentioning

confidence: 99%

Modelling of Temperature Field and Stress–Strain State of the Workpiece with Plasma Coatings during Surface Grinding

Usov

Tonkonogyi

Dašić³

et al. 2019

Machines

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Plasma coatings play a key role in surface tailoring through providing important advantages for tools during their further application. However, grinding these coatings may cause different defects such as grinding burns and cracks, structural changes to the coating material, and the destruction of adhesive contacts between the coating layer and the substrate. The reason for that is the high heat flux generated in the process of abrasive material removal due to the high friction and stresses. In order to define the optimal conditions for grinding plasma coatings, the mathematical model of the temperature thermal field and the stress–strain state during the grinding process is developed. Based on the temperature, strength, and fracture criteria, this mathematical model makes it possible to define the functional relationship between the technological characteristics of the grinding process and the conditions that provide the required quality of surface processing. The role of the structural defects that are generated while coatings are being sprayed, as well as during coating adhesion, is also considered. An algorithm developed to present the results of the modelling process enables checking if the input parameters meet the condition of zero-defect grinding of a workpiece, and determining an expected surface roughness. Input parameters include the grinding wheel geometry, its abrasive properties, the wheel speed, longitudinal and transverse motion, grinding depth, and the use of the cutting fluid. Experimental testing of this study shows the way in which the regime of the grinding process and different grinding wheel parameters influence the physical and mechanical properties of the surface layer.

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