Supersonic DC plasma torch for deposition of high-density wear-resistant coatings

Кузьмин, В. С.; Gulyaev, I. P.; Sergachev, D. V.; Vashchenko, Sergey; Ковалев, О. Б.; Kornienko, Elena; Tuezov, Andrey; Palagushkin, Boris

doi:10.1016/j.matpr.2019.07.230

Cited by 8 publications

(3 citation statements)

References 7 publications

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“…Of all currently known gas-thermal coating technologies, plasma spraying, due to its energy capabilities and flexibility in controlling the parameters of the spraying flow, is the most technologically advanced and high-performance method for the formation of various functional coatings. That is why the team of authors, on the basis of the previously developed electric arc plasma torch with a sectioned interelectrode insert PNK-50, developed a supersonic version of this plasma torch, which makes it possible to generate supersonic flows of thermal (air) plasma [14]. To date, we can talk about fine-tuning the design of a supersonic plasma torch to an industrial design, because.…”

Section: Supersonic Air-plasma Spraying Of Coatingsmentioning

confidence: 99%

Plasma Coatings for Protection Against Hydroabrasive and Cavitation Wear

et al. 2023

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The results of research work on the application of coatings designed to protect the working surfaces of machine parts and mechanisms operating under conditions of hydroabrasive and cavitation wear are presented. Coatings were produced by supersonic atmospheric plasma spraying of powder materials using air as a plasma gas. The experimental list of materials was chosen taking into account the experience of the authors in protecting the details of the propulsion and steering complex of river vessels using coatings applied by subsonic thermal plasma flows.

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Section: Supersonic Air-plasma Spraying Of Coatingsmentioning

confidence: 99%

Plasma Coatings for Protection Against Hydroabrasive and Cavitation Wear

et al. 2023

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“…Т. The main disadvantage (along with the limited adhesion strength to the metal base and the complexity of controlling the properties of the formed coatings) that hinders the spread of functional coatings of this type is rather high energy requirement of the process -3-20 kWh/kg of the sprayed material and the low powder utilization factor (often it not more than 50 %) during spraying due to its heating and the limited duration of the powder residence time in the zone of the plasma jet with a high temperature [2,[7][8]. Modernization of APS technologies, as a rule, is aimed at eliminating these important technical shortcomings.…”

Section: Introduction and Research Tasksmentioning

confidence: 99%

“…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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