This book focuses on the basic physical process and chemical reaction of plasma spraying particle melting, flight and deposition. It introduces the basic scientific contents such as the basic characteristics and spraying principle of plasma arc, the interaction between spraying particles in flight section and plasma jet, the spreading and solidification behavior of single droplet and the performance test of flat particles, macro performance evaluation and quality optimization of coating. The typical applications of plasma spraying coating and the new developing direction of plasma spraying technology are summarized. This book will be helpful for the graduate students, researchers, as well as engineers in the field of plasma spray.
Author(s): Guozheng Ma, Shuying Chen, Haidou Wang
Series: Springer Series in Advanced Manufacturing
Publisher: Springer
Year: 2022
Language: English
Pages: 678
City: Singapore
503740_1_En_BookFrontmatter_OnlinePDF
Preface
Contents
503740_1_En_1_Chapter_OnlinePDF
1 Introduction
1.1 Technical Principle of Plasma Spraying
1.1.1 Plasma
1.1.2 Plasma Arc
1.1.3 Basic Process of Plasma Spraying
1.1.4 Working Gas for Plasma Spraying
1.2 Development and Characteristics of Plasma Spraying
1.2.1 Development History of Plasma Spraying
1.2.2 Technical Characteristics of Plasma Spraying
1.3 Typical Plasma Spraying Technology
1.3.1 Conventional Plasma Spraying (PS)
1.3.2 Supersonic Plasma Spraying (SPS)
1.3.3 Low Pressure Plasma Spraying (LPPS)
1.3.4 Water-stabilized Plasma Spraying (WSPS)
1.3.5 Tricathode Plasma Spraying
1.3.6 Suspension Plasma Spraying
1.3.7 Reactive Plasma Spraying
1.4 Developing Direction of Plasma Spraying Technology
1.4.1 Development Prospects of Basic Theory
1.4.2 Trends for Hardware Development
1.4.3 Prospects of Spraying Materials
References
503740_1_En_2_Chapter_OnlinePDF
2 Microcosmic Interaction Between Plasma Jet and Spraying Particles
2.1 Basic Characteristics of Plasma Jet
2.1.1 Simulation and Experiment of Gas Ionization Characteristics in Spray Gun
2.1.2 Mathematical Model of Flow Field of Plasma Jet
2.1.3 Temperature Field Distribution Characteristics of Plasma Jet
2.1.4 Velocity Field Distribution Characteristics of Plasma Jet
2.1.5 Composition Characteristics of Plasma Jet
2.2 Heat Transfer in Jet and Formation of Spraying Droplets
2.2.1 Temperature Monitoring of Particles
2.2.2 Heating-up and Evaporation of Particles
2.2.3 Effect of Process Parameters on Particle Temperature
2.3 Momentum Transfer and Particle Acceleration in Jet
2.3.1 Particle Velocity Monitoring
2.3.2 Force Analysis of Particles
2.3.3 Effect of Process Parameters on Particle Velocity
2.4 Mass Transfer in Jet and Physical and Chemical Reaction of In-Flight Particles
2.4.1 Particle Quenching Collector
2.4.2 Physical Refinement of Particles
2.4.3 Reaction of Particles with Ambient Air
2.4.4 Self-reaction of Particles
References
503740_1_En_3_Chapter_OnlinePDF
3 Impact Spread Behavior of Flying Droplets and Properties of Splats
3.1 General Characteristics of Droplet Impact Process
3.1.1 Deposition Characteristic Parameters of Droplet
3.1.2 Mechanisms of Droplet Spreading
3.1.3 Factors Influencing the Droplet Spreading Process
3.1.4 Monitoring the Droplet Spreading Process
3.1.5 Characteristics of Droplet Grain Growth
3.2 Numerical Simulation of Droplet Impact Behavior
3.2.1 Simulation of Droplet Impact and Spreading Process
3.2.2 Boundaries and Conditions for Droplet Impact Simulation
3.2.3 Physical Model of Droplet Impact Process
3.2.4 Influence of Viscosity Coefficient on Droplet Spreading Process
3.3 Capture of Splats and Fundamentals of Image Analyses
3.3.1 Acquisition Device of a Single Splat
3.3.2 Image Processing Functions
3.3.3 The Process of Extracting Splats
3.3.4 Splat Morphological Parameters
3.4 Solidification Morphology of Splats
3.4.1 Typical Morphology of Splats
3.4.2 Effect of Typical Parameters on the Appearance of Splats
3.4.3 Statistical Characteristics of Splat Morphology
3.4.4 Statistical Signation of Splat Solidification Types
3.5 Evaluating the Bonding Strength of Splats
3.5.1 Scratch Measurement Mechanism
3.5.2 Morphology of Typical Splats
3.5.3 Multiple Physical Signals During the Debonding of Splats
3.5.4 Debonding Process and Mechanism of Splats
3.5.5 Characterization of Bonding Strength of Splats
3.6 Evaluating the Residual Stress of Splats
3.6.1 Principle of the FIB-DIC Residual Stress Test
3.6.2 Principle of the DIC Non-contact Strain Test
3.6.3 Calibration of Stress Release Coefficient
3.6.4 Residual Stress Measurement of Typical Particles
3.6.5 Error Analysis of Residual Stress Testing Process
3.6.6 Formation Mechanism of Droplet Residual Stress
References
503740_1_En_4_Chapter_OnlinePDF
4 Characterization of Primary Defects and Quality Evaluation of Coatings
4.1 Microscopic Process of Coating Growth
4.1.1 Space Distribution of Particles
4.1.2 Wetting Mechanism of First-layered Flattening Particles
4.1.3 Wetting Mechanism of Follow-up Flattening Particles
4.1.4 Pore Forming Mechanism in Coating
4.2 Characterization Methods of Coating Porosity
4.2.1 Image Analysis Method
4.2.2 Three-dimensional Computed Tomography Method
4.2.3 Weighing Method
4.2.4 Drainage Method
4.2.5 Electrolytic Coloring
4.2.6 Air Permeability Comparison Method
4.2.7 Small-Angle Neutron Scattering Method
4.2.8 Microwave Method
4.2.9 Ultrasonic Method
4.3 Quantitative Characterization of Coating Bonding Strength
4.3.1 Traditional Test Method
4.3.2 Bonding Strength Measurement with the Static Load Indentation Method and Acoustic Emission Technology
4.3.3 Bonding Strength Measurement Impact Indentation Method and Acoustic Emission Technology
4.3.4 Other Testing Methods
4.4 Testing Method for Residual Stress of Coatings
4.4.1 Nondestructive Testing
4.4.2 Mechanical Method
4.4.3 Nanoindentation Method
4.4.4 Focused Ion Beam-Electron Beam Method
4.5 Other Performance Tests for Coatings
4.5.1 Microhardness Test
4.5.2 Elastic Modulus
4.5.3 Fracture Toughness
References
503740_1_En_5_Chapter_OnlinePDF
5 Coating Quality Control Based on Traditional Process Measures
5.1 Pretreatment Process
5.1.1 Sand Blasting
5.1.2 Dry Ice-Assisted Deposition
5.1.3 Mechanical Roughing
5.1.4 Laser Texturing
5.2 Traditional Optimization of Spraying Process Parameters
5.2.1 Typical Adjustable Spraying Parameters
5.2.2 Orthogonal Experiment Method
5.2.3 Response Surface Method
5.2.4 Neural Network Method
5.2.5 Other Methods
5.3 Afterprocessing—Heat Treatments
5.3.1 Laser Remelting
5.3.2 Induction Remelting
5.3.3 Electron Beam Remelting
5.3.4 Argon Arc Remelting
5.3.5 Homogeneous Heat Treatment
5.3.6 Hot Isostatic Pressing
5.3.7 Flame Remelting
5.4 Afterprocessing—Other Methods
5.4.1 Hole Sealing Treatment
5.4.2 Ultrasonic Shock Treatment
5.4.3 Steam Treatment
5.4.4 Electro Polarization Treatment Process
References
503740_1_En_6_Chapter_OnlinePDF
6 Coating Quality Control Based on State Optimization of Droplets and Splats
6.1 Microstructure and Deoxidation Reaction Control of BaTiO3 Coating
6.1.1 Experimental Process
6.1.2 Effect of Spraying Atmosphere on Microstructure and Mechanical Properties of BaTiO3 Coating
6.1.3 Defect Formation Mechanisms of BaTiO3 Coatings in Different Atmospheric Conditions
6.1.4 Dielectric Properties of BaTiO3 Coating and Its Oxygen Loss and Reduction Mechanism
6.2 Micro Formation Mechanism and Microstructure Control of WC-10Co4Cr Coating
6.2.1 Experimental Process
6.2.2 Behavior and Interaction Mechanisms of WC Particles During Flighting, Spreading and Solidification
6.2.3 Evolution of Original Structural Characteristics of WC Coating
6.2.4 Evolution of WC Coating Microstructure Characteristics
6.3 Quality Optimization of the Fe-Based Amorphous Coatings
6.3.1 Test Methods and Equipment
6.3.2 Droplet Flight Characteristics of Fe-Based Amorphous Alloy Coatings
6.3.3 Solidification Types of Flat Particles and Its Mechanisms
6.3.4 Phase Characteristics of Coating and Determination of Amorphous Phase Content
6.3.5 Micromorphology and Mechanical Properties of Fe-Based Amorphous Alloy Coatings
6.4 Quality Optimization of the Thermal Barrier Coatings
6.4.1 Condition Monitoring of In-flight Particles
6.4.2 Analysis of Physicochemical Properties and Spreading Morphology of Droplets
6.4.3 Microstructure Characteristics of Coatings
6.4.4 Microcosmic Defects and Properties
6.4.5 Thermal Insulation Properties
6.4.6 High-Temperature Oxidation Resistance
6.4.7 Thermal Shock Resistance
References
503740_1_En_7_Chapter_OnlinePDF
7 Typical Plasma Sprayed Coatings and Applications
7.1 Typical Wear Resistance Coatings and Applications
7.1.1 Tribological Properties of Typical Amorphous Coatings
7.1.2 Tribological Properties of Typical Alloy Coatings
7.1.3 Tribological Properties of Oxide Ceramic Coatings
7.1.4 Tribological Properties of Carbide Ceramic Coatings
7.2 Typical Thermal Barrier Coatings and Applications
7.2.1 Novel Thermal Barrier Coatings
7.2.2 Typical Structures of Plasma Sprayed Thermal Barrier Coatings
7.2.3 Properties of Thermal Barrier Coatings
7.3 Typical Functional Coatings and Applications
7.3.1 Stealth Absorbent Coating
7.3.2 Biomedical Coating
7.3.3 Solid Oxide Fuel Cell Coating
7.3.4 Bionic Superhydrophobic Coating
References
