Comparison of the Characteristics of CoNiCrAlY Coatings Prepared by Cold Spray and LPPS Process
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Abstract Cold spray is a new emerging coating technology in which particles in a solid state are deposited via plastic impact on a substrate at a high velocity and a temperature that is much lower than the melting point of the starting powder. Compared to the conventional thermal spray processes, dense coatings without any degradation can be obtained by cold spray process with high deposition efficiency. CoNiCrAlY coatings are widely used for land-based gas turbines to resist high-temperature oxidation and hot corrosion. Owing to the high cost of the low-pressure plasma spray (LPPS) or some degradation in the hyper-velocity oxy-fuel (HVOF) spray process, cold spray process is a prospective candidate for coating preparation. In the current study, CoNiCrAlY coatings were prepared by cold spray and LPPS processes, and a comparison of the coating’s properties between the LPPS and cold spray process was carried out. The spray conditions of cold spray were optimized by the measurements of deposition efficiency and the observations of microstructure.Keywords:
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The working principle and development status of several thermal spraying technologies was introduced,including plasma spraying,flame spraying,and arc spraying technology.The issues of improving the bonding strength of spray coatings were discussed.The development of nano-coating materials for thermal spray coating in recent years was introduced.
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Abstract Thermal spray is a generic term for a group of coating processes used to apply metallic, ceramic, cermet, and some polymeric coatings for a broad range of applications. This article provides a brief description of commercially important thermal spray processes, namely, powder-fed flame spray, wire- or rod-fed flame spray, electric arc spray, plasma arc spray, vacuum plasma spray, high-velocity oxyfuel spray, detonation gun deposition, and cold spray, and their advantages. It provides details on the microstructural characteristics of thermal spray coatings. The article also presents information on a wide variety of materials that can be thermal sprayed, such as metals, ceramics, intermetallics, composites, cermets, polymers, and functionally gradient materials. Tables are included, which list the thermal spray processes and coating properties of importance for various industrial applications.
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Recent developing tendency of thermal spray for green automotive industry are studied by searching of NDSL, KIPRIS, ScienceDirect and so on. Spraying techniques such as plasma spray, microwave treatment, dry-ice blasting, HVOF thermal spray, cold spraying, aerosol deposition are introduced, further more spraying materials such as nano particles, intermetallic compound, TiAlN, TiC, Si-Al alloys are investigated.
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Atmospheric plasma spraying (APS) is one of the most widely used thermal spraying technique which finds a lot of applications due to its versatility of spraying a wide range of materials from metallic to nonmetallic and hence more suitable for spraying of high melting point materials like refractory ceramics material, cermets etc. In recent era,any material can be used for plasma spraying on almost any type of substrate. Process parameters are the key factor that affects the formation of microstructures, bonding of coating with substrate and mechanical strength of coating. In this paper, the process parameters and their sensitivity towards the plasma modified structural elements are discussed.The microstructure of thermally sprayed coatings, which results from the solidification and sintering of the particles, frequently contain pores, oxides and cracks. The amount and distribution of these defects, as well as other coating properties as for instance thickness, hardness and bond strength, will be defined by the selected spray parameters. Therefore, the correct choice of the spray process as well as respective parameters (particle size, particle velocity, spray distance, plasma gun power, working pressure, substrate roughness, substrate temperature and so on) is very important for the deposition of good coatings and, consequently, to enlarge the useful life in service of the components.
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This chapter contains sections titled: Introduction Key Elements in Thermal Plasma Spray Technology Thermal Plasma Spraying for Coating Technologies Plasma Powder Spraying Plasma Spray CVD Plasma Spray PVD Thermal Barrier Coatings Thermal Plasma Spraying for Powder Metallurgical Engineering Thermal Plasma Spheroidization Plasma Spray CVD Plasma Spray PVD Thermal Plasma Spraying for Waste Treatments Concluding Remarks and Prospects
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Thermal spray coating involves heating of coating materials (ceramic, carbide, and metal alloys) to a semi-molten or molten state and propels to substrate. The flame temperature is in the range of 3,000 to 16,000OC but the surface temperature of the substrate rarely exceeds 500 OC depending on the thermal spray processes being used. The coating materials are feed into the spray gun in the form of powders, rods or wires. Thermal spray coating is use for the following purposes; (i) increase corrosion and wear resistance, (ii) protection against electromagnetic, or electrostatic, (iii) protection against radio frequency interference, (iv) metal buildup and, (iv) cosmetic. Thermal spray coating can be categorized into five most common processes; (i) Flame arc spraying, (ii) Electric Arc spraying, (iii) Plasma arc spraying, (iv) High-velocity Oxy/Fuel (HVOF) and (v) Detonation Gun. In this paper, thermal spraying processes will be explained, along with the advantages and disadvantages of one another.
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Recent developing tendency of thermal spray for green automotive industry are studied by searching of NDSL, KIPRIS, ScienceDirect and so on. Spraying techniques such as plasma spray, microwave treatment, dry-ice blasting, HVOF thermal spray, cold spraying, aerosol deposition are introduced, further more spraying materials such as nano particles, intermetallic compound, TiAlN, TiC, Si-Al alloys are investigated.
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