Equipment and technologies of air-plasma spraying of functional coatings

Кузьмин, В. С.; Gulyaev, I. P.; Sergachev, D. V.; Vaschenko, S. P.; Kornienko, Elena; Tokarev, Alexander

doi:10.1051/matecconf/201712901052

Cited by 18 publications

(3 citation statements)

References 6 publications

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“…These technologies use both hydrocarbon gases as heat carriers (including plasma mixtures of methane with CO 2 ) to improve the velocity and thermal conductivity of plasma jets and intensification of particle melting in them, and with feeding of particulates or droplets of organic additives to the plasma jet to control the porosity and microstructure of sprayed metal and composite functional coatings, including for thermally resistant blades of gas turbines (in particular, according to the data [6,[9][10][11][12][13][14]). At the same time, in recent years, in particular, in Theoretical and Applied Mechanics Institute (Siberian Branch of the Russian Academy of Sciences), an adjacent promising air plasma spraying technology is being developed for use with new medium-power plasma torches to spray powders from a number of alloys, oxides (including doped alumina) and cermet compositions [8,[15][16]. Moreover, as a variant, this technology is proposed for practical use when air as the plasma gas is combined with feeding of additives of alkane hydrocarbons (liquefied gases (LPG) or natural gas) into the plasma torch.…”

Section: Introduction and Research Tasksmentioning

confidence: 99%

Investigation of Upgraded Technology for Plasma Spraying of Bronze Powder Using the Combined Process with Hydrocarbon Additions

et al. 2023

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The object of the research is thermal spray process for the formation of metal coating from bronze powder in plasma-fuel variant, using direct current (DC) electric arc plasma torch, on steel samples. The aim of the work was to investigate and develop the technology for plasma-fuel spraying of functional coatings (for wear-resistant and antimicrobial applications) on machine-building and medical purpose pieces with increased process capacity and moderate energy consumptions in a comparison with conventional thermal spray technologies with use of inert and oxygen-free gas media. During the study, using experimental and thermodynamic estimation methods, the thermal and chemical parameters of the process under the spraying conditions at ambient pressure were characterized, which made it possible to determine the area of preferred regimes of the developed technology. On the modernized testing unit for plasma spraying of metal powders with power of up to 40 kW, operating using a controlled combination of three types of gases – technical nitrogen and propane-butane (LPG) with compressed air, the measurement and optimization of the operating and constructive/assembling parameters of the system for aluminum bronze coating spraying were established. In this case, the experiments were carried out using the designed fuel intensifier, which is joined with the PP-25 arc plasma torch, as well as additional technological equipment (protective shroud). For samples of the resulting coatings with a thickness of 100 to 450 mm from the bronze material, testing of phase composition and some parameters of the resulting coatings on steel products was carried out. Operating capacity of the proposed process reaches 7–15 kg/h for bronze powder when using a moderate power of the torch – up to 35–40 kW and a limited flow rate of hydrocarbon gas (for example, LPG of the SPBT grade) – 0.1–0.35 kg/h. Analysis of the energy efficiency parameters of the developed technology, as well as its calculated technical characteristics, in a comparison with plasma and combined equipment of a similar purpose, showed that it has an advantage in terms of target indicators, in particular, in terms of energy consumption and total energy efficiency of the spraying unit, not less than 20–30 %. This makes it to proceed later to the stage of application of this technology into production based on a new process for the metal coating formation, in particular with antimicrobial properties, with improved energy efficiency of the process.

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Section: Introduction and Research Tasksmentioning

confidence: 99%

Investigation of Upgraded Technology for Plasma Spraying of Bronze Powder Using the Combined Process with Hydrocarbon Additions

et al. 2023

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“…Variants of schematics of the systems for high temperature processing of metal and ceramic powders, using the polymeric particle additions: a -on the technical description [1] for the process of electric arc plasma spraying of metal/alloy powders; b -analyzed by authors schematic diagram for potential technologies for thermal plasma spraying or spheroidizing of oxide and metal powders with additional feeding of SFA-addition in the processing zone At the same time, it seems acceptable to consider (initially, at a theoretical level) the case of air heat carrier (it acts simultaneously as an oxidizer). It was efficiently used during the recent few years by Russian group [9,10], based on new arc plasma torches with a power of up to 52 kW for powder spraying of some alloys, oxides and cermet compositions, and, as one of the variants, this technology was used with the combination of air with injection of hydrocarbons (propane-butane or methane) additions into the torch. The chosen variant of the process to consider is schematically illustrated in Fig.…”

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confidence: 99%

“…As the simulants of typical thermal treated powders in a high temperature flow, it is suitable to consider a set of three oxide compounds -Al 2 O 3 , TiO 2 , Cr 2 O 3 and two metals -copper and nickel. These substances are widely used in conventional industrial technologies [11] as well as newly developed ones for spheroidizing and plasma spraying of powder materials [1,2,4,[8][9][10]12].…”

mentioning

confidence: 99%

Thermodynamic Estimation of the Parameters for the C–H–O–N–Me-Systems as Operating Fluid Simulants for New Processes of Powder Thermal Spraying and Spheroidizing

et al. 2021

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Over the past few years, a group of new processes was developed for high-temperature, including plasma electric arc spraying (at ambient pressure) and spheroidizing of some ceramic and metal powder materials with the use of gaseous hydrocarbons in the heat carriers as well as with feeding of organic additions into a high-temperature jet, in particular, polymeric ones, to control porosity of sprayed metallic functional coatings. The paper considers the possibility to modify such technological processes by introducing solid fuel additions of a polymer type into the operating fluid of an apparatus for gasthermal (plasma or other) treatment, which provides melting of metal or oxide powders. For this, with the help of thermodynamic analysis, the processes have been evaluated at temperatures (300–3000) K for the set of such reacting five component systems as C–H–O–N–Me (at ambient pressure 0.101 MPa) with five variants of Ме – aluminum, titanium, chrome, copper, nickel. This makes it possible to consider these systems as simulants for potential technologies for the treatment of oxide powders (Al2O3, TiO2, Cr2O3) as well as metallic ones (Cu, Ni and their alloys). In order to obtain high exothermic contribution to the heating of powders, the combination “air + polymeric addition (polyethylene) of LDPE grade” was chosen as mixed heat carrier (operating fluid) for the basic version of simulated process. During the analysis of equilibria for the considered multicomponent systems (17 variants), a set of following parameters has been used to characterize the energy intensity of the target powder heating process: the equivalence ratio for reacting mixture and its adiabatic temperature; the energy efficiency of material heating with and without taking into account the effect of fuel addition; specific energy consumption for the powder melting; autothermicity degree of the process during the combined heating (electrothermal heating by the arc of plasma torch and heat flux from the “air + solid fuel additions” mixture) of refractory powders. As a result of the assessment, the preferred (from thermodynamic standpoint) regimes of the considered processes have been found and the possibility to realize an energy-efficient heating of these oxide and metal materials (without oxidation of the latter to CuOx, NiO) with a reduced part of the electric channel of energy transfer, resulted from the carrying out of appreciable effect of the fuel-initiated mechanism of heating in the analyzed C–H–O–N–Mesystems, has been shown in the paper.

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Structure and Protective Properties of Plasma-Sprayed Coatings

Tokarev

2022

International Scientific Siberian Transport Forum TransSiberia - 2021

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Equipment and technologies of air-plasma spraying of functional coatings

Cited by 18 publications

References 6 publications

Investigation of Upgraded Technology for Plasma Spraying of Bronze Powder Using the Combined Process with Hydrocarbon Additions

Investigation of Upgraded Technology for Plasma Spraying of Bronze Powder Using the Combined Process with Hydrocarbon Additions

Thermodynamic Estimation of the Parameters for the C–H–O–N–Me-Systems as Operating Fluid Simulants for New Processes of Powder Thermal Spraying and Spheroidizing

Structure and Protective Properties of Plasma-Sprayed Coatings

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