Mass, momentum, and energy transfer in supersonic aerosol deposition processes

Li, Chenxi; Singh, Narendra; Andrews, Austin J.; Olson, Bernard A.; Schwartzentruber, Thomas E.; Hogan, Christopher J.

doi:10.1016/j.ijheatmasstransfer.2018.10.028

Cited by 32 publications

(22 citation statements)

References 43 publications

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“…Results are displayed in Figure for impaction with atmospheric pressure upstream and variable pressure downstream (1333–6000 Pa) for both molecular nitrogen (whose properties do not differ appreciably from air) and pure helium. As discussed in recent works, [ 12,51 ] trajectory calculations show that there is a particle size for which the impaction velocity is maximized in supersonic nozzle systems. For larger particles, acceleration in the nozzle and at the nozzle outlet is insufficient for particles to achieve the maximum fluid velocity at impact.…”

Section: Resultsmentioning

confidence: 97%

“…Measurements can be supplemented with computational fluid dynamics (CFD)‐particle trajectory calculations to examine the velocities with which particles deposit on the substrate. Following the method described by Li et al [ 12 ] and Ghosh et al [ 39 ] and expanded upon in the Supporting Information, we determine the velocity, temperature, and pressure profiles inside the utilized nozzle system (approximating the geometry as 2D) and subsequently utilize a Mach and Knudsen number‐dependent drag model applicable to low‐pressure supersonic flows (based on experimental and direct simulation Monte Carlo data) [ 49,50 ] to determine particle velocities at impact with the substrate. Results are displayed in Figure for impaction with atmospheric pressure upstream and variable pressure downstream (1333–6000 Pa) for both molecular nitrogen (whose properties do not differ appreciably from air) and pure helium.…”

Section: Resultsmentioning

confidence: 99%

“…Because bow shock effects are typically reduced by operating at lower pressure, in AD, submicrometer‐to‐micrometer particles uniquely maintain high velocities at impact. [ 12 ] Translational particle energy to thermal energy conversion upon impact leads to plastic deformation in both particles and the substrate, and the coating is bonded to the substrate predominantly via mechanical interlocking. [ 13 ]…”

Section: Introductionmentioning

confidence: 99%

“…Recent research has provided much greater insight into the requirements of particles for AD, [ 17,18 ] particle velocities at impact in AD, [ 12 ] and the result of individual high‐speed particle impacts. [ 19 ] However, a critical step in AD remains the aerosolization of particles with the proper size distribution range (large enough for inertial impaction, but small enough to be accelerated) and chemical composition.…”

Section: Introductionmentioning

confidence: 99%

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Spray Pyrolysis‐Aerosol Deposition for the Production of Thick Yttria‐Stabilized Zirconia Coatings

et al. 2021

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Aerosol deposition (AD) is a coating technique wherein particles are impacted onto a target substrate at reduced pressures, and supersonic particle impact velocities lead to coating consolidation. The limiting step in AD application is often not supersonic deposition operation, but aerosolization of powder particles with the proper size distribution; the translational impact velocity is strongly size‐dependent. It is demonstrated that by directly synthesizing particles in the gas phase, size‐controlled ceramic particles can be injected into AD systems. This in situ formation step obviates the need for particle aerosolization. Ultrasonic spray pyrolysis (USP) is applied to produce yttria‐stabilized zirconia (YSZ), and USP is directly coupled with AD to produce consolidated, thick, YSZ coatings on metal substrates. USP‐AD yields YSZ coatings on stainless steel and aluminum substrates with porosities <0.20, which grow to thicknesses beyond 100 μm. Aerodynamic particle spectrometry and electron microscopy reveal that the depositing particles are 200 nm–1.2 μm in diameter, though each particle is composed of nanocrystalline YSZ. Supporting computational fluid dynamics calculations demonstrate that the YSZ particle impact speeds are above 300 m s−1. Thermal conductivity measurements demonstrate that USP‐AD coatings have conductivities consistent with those produced from high‐temperature processes.

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Section: Resultsmentioning

confidence: 97%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Spray Pyrolysis‐Aerosol Deposition for the Production of Thick Yttria‐Stabilized Zirconia Coatings

et al. 2021

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“…Accordingly, several studies are currently dealing with flow simulations in the AD process. [42][43][44][45][46] Successfully deposited films feature an excellent substrate adhesion, a crack-and pore-free film structure as well as properties that are similar to those of classical bulk ceramics. However, the identical functional properties of the bulk ceramics (electric, piezoelectric, dielectric, magnetic) are usually not achieved.…”

Section: Setup Of a Pad Device And Process Principlementioning

confidence: 99%

Powder aerosol deposition method — novel applications in the field of sensing and energy technology

Schubert

Hanft

Nazarenus

et al. 2019

Funct. Mater. Lett.

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The Aerosol Deposition (AD) method is a dry spray coating process for the production of dense ceramic coatings at room temperature directly from the ceramic raw powder. In order to avoid confusion with liquid aerosol technology, the term powder aerosol deposition (PAD) is introduced here, to highlight that the aerosol consists only of ceramic powder and carrier gas. Especially in the field of functional ceramics, PAD is a promising alternative to conventional sinter-based production processes. This review focuses on the PAD of functional ceramics in the field of sensing and energy technology. In this context, especially current developments and trends are presented. On the part of the sensors, gas and temperature sensors are especially considered, whereas in the field of energy technology, the focus is on vibration energy harvesting, thermoelectric generators, superconductors, and solar cells as well as on all solid-state batteries and fuel cells. Besides the different applications of PAD films, this review also highlights opportunities for influencing the film properties by the used powder or the process parameters.

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Powder Aerosol Deposition and Polymers: Is There Hope for a Common Future?

Thiel,

Lienkamp

2024

Adv Eng Mater

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Polymer‐Ceramic Composites (PCC) are promising functional materials with a wide range of applications in energy technology, microelectronics and sensor technology, as protective coatings, in wastewater treatment or for biomedical purposes. Unfortunately, ceramics require high‐temperature sintering, while polymers only have a limited thermal stability. Therefore, PCC fabrication is quite complex and requires strict process control. This severely limits the efficiency and economy of the process, and the reproducibility of the desired materials properties. Powder Aerosol Deposition (PAD) is a spray coating process in which ceramic powders are accelerated by a pressure difference using a carrier gas. They are then deposited as nanocrystalline, dense coatings onto different kinds of substrates without the need for additional sintering. Current research focuses on materials obtained from PAD of ceramic powders. Yet there are also examples of mixed polymer and ceramic particles that have been successfully deposited in PAD processes. So far, much of this works does not go beyond the trial‐and‐error stage, so that a general concept for successful deposition of PCCs by PAD is not yet available. This review revisits the fundamentals of the PAD process and its most important process parameters that were studied experimentally and in‐silico. It connects these with recent work on the combination of polymers and ceramics in the PAD process in order to highlight and evaluate the future of this field from a polymer science perspective.This article is protected by copyright. All rights reserved.

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Mass, momentum, and energy transfer in supersonic aerosol deposition processes

Cited by 32 publications

References 43 publications

Spray Pyrolysis‐Aerosol Deposition for the Production of Thick Yttria‐Stabilized Zirconia Coatings

Spray Pyrolysis‐Aerosol Deposition for the Production of Thick Yttria‐Stabilized Zirconia Coatings

Powder aerosol deposition method — novel applications in the field of sensing and energy technology

Powder Aerosol Deposition and Polymers: Is There Hope for a Common Future?

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