Understanding the role of in-flight particle temperature and velocity on the residual stress depth profile and other mechanical properties of atmospheric plasma sprayed Al2O3 coating

Ghara, Tina; Bandyopadhyay, P.P.

doi:10.1016/j.jeurceramsoc.2022.04.019

Cited by 17 publications

(24 citation statements)

References 72 publications

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“…R. A. Abbas et al [16] observed that the surface roughness increased with an increase in spray distance due to non-melted or insufficiently melted particles. T. Ghara et al [9] observed that an increase in particle velocity from 197 to 219 m/s reduced the porosity and roughness values. However, a further increase in particle velocity increased the porosity and surface roughness of Al 2 O 3 coatings [9].…”

Section: Resultsmentioning

confidence: 99%

“…T. Ghara et al [9] observed that an increase in particle velocity from 197 to 219 m/s reduced the porosity and roughness values. However, a further increase in particle velocity increased the porosity and surface roughness of Al 2 O 3 coatings [9]. Such a phenomenon was assigned to the splashing behavior of the splat at a higher velocity of feedstock particles [9,15].…”

Section: Resultsmentioning

confidence: 99%

“…Thus, the number of non-molten or semi-molten particles that reached the surface was reduced. The alumina surface is composed of a larger number of fully melted particles in the presence of a splat formation, resulting in lower surface roughness [9,13]. R. A. Abbas et al [16] observed that the surface roughness increased with an increase in spray distance due to non-melted or insufficiently melted particles.…”

Section: Resultsmentioning

confidence: 99%

“…However, a further increase in particle velocity increased the porosity and surface roughness of Al 2 O 3 coatings [9]. Such a phenomenon was assigned to the splashing behavior of the splat at a higher velocity of feedstock particles [9,15]. Additionally, at a higher temperature, the molten particles demonstrated lower viscosity values, and a less viscous liquid is more likely to splash [15].…”

Section: Resultsmentioning

confidence: 99%

“…Process control and optimization are essential to fulfill the requirements of the actual application [7,8]. The coating structure heavily depends on the melting degree of ceramic particles in the plasma and their impact velocity; therefore, understanding in-flight particle temperature and velocity is essential to obtain the desired coating performance [9]. In general, insufficient particle melting and low speed at impact lead to high porosity levels and poor intersplat bonding [4][5][6][7][8]10,11].…”

Section: Introductionmentioning

confidence: 99%

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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: 99%