Search Results (60)

This work presents a new approach for the fabrication of 316L/Al₂O₃ composites, based on a combination of spray granulation, radio frequency (RF) plasma spheroidization and spark plasma sintering (SPS). Initially, a suspension containing 316L and alumina powders is formulated by precisely adjusting the pH and selecting an appropriate dispersant, thereby ensuring homogeneous dispersion of the constituents. The spray granulation process then produces granules with controlled size and morphology. RF plasma spheroidization, carried out using a TekSphero-40 system, is investigated by varying parameters such as the power, gas flow rates, injection position and feed rate, in order to optimize the formation of spherical and dense particles. The analysis reveals a marked sensitivity to heat transfer from the plasma to the particles, with a tendency for fine particles to segregate, which underscores the necessity for precise control of the processing conditions. Finally, SPS densification, performed under a constant pressure and a rigorously controlled thermal cycle, yields composites with excellent density and hardness characteristics. This study thus demonstrates that the proposed hybrid process offers an optimal synergy between a uniform distribution of alumina and a controlled microstructure, opening up promising avenues for the design of high-performance composite materials for demanding applications. Full article

Gadolinium zirconate (Gd₂Zr₂O₇, GZO) has been investigated for two decades as a thermal barrier coating (TBC) material in gas turbines. The advantages of this material over conventional yttria-stabilized zirconia (YSZ) are its lower thermal conductivity, phase stability, and low sintering tendency at elevated temperatures above 1200 °C. However, a major disadvantage is the low fracture toughness of the material and the reaction with the thermally growing oxide layer (TGO). As a result, single-layer GZO coatings cannot be used as TBCs. To overcome these challenges, the present study focuses on the development of double-layer TBC systems, produced with a single gun to keep the manufacturing time low. The respective layers were optimized for specific requirements using a porous atmospheric plasma spray (APS)-YSZ interlayer covered by a suspension plasma sprayed (SPS)-GZO top layer. In furnace cycling tests at 1100 °C, the double-layer systems developed in this study were able to achieve a significant increase in thermal cycle life compared to single-layer APS-YSZ coatings. In addition, the failure mechanism after thermal cycling was investigated, and phase analysis was performed using XRD. The examination of Young’s modulus and the hardness of the layers revealed sintering in the GZO layer due to thermal cycling, while the APS layer showed only minor changes. Full article

Since the COVID-19 pandemic, efforts in the field of surface decontamination have been redoubled. Finding innovative self-cleaning devices has become a challenge, and several solutions have been proposed in the market in recent years. In this work, an optimized powder/suspension plasma spray process at atmospheric pressure, using a Triplex Pro 210^TM torch, is implemented to produce Cu-TiO₂ surface coatings on stainless steel. The purpose is to investigate the potential improvement of antibacterial efficacy by the reactive surface species generated from TiO₂ photoactivity under irradiation. A water-based suspension, prepared with AnalaR NORMAPUR^TM TiO₂, is used as a precursor to incorporate the photocatalyst into an antibacterial copper matrix. Surface antibacterial tests according to ASTM 2180 standards were performed, and experiments were performed in treated contaminated water. Sub-stoichiometric blue TiO₂ coatings showed complete bacterial elimination after 90 min of visible light irradiation, and Cu-TiO₂ surface coatings were even able to disinfect the surfaces under white light, making the application interesting for bacterial destruction under natural illumination. These materials are also intended for application in water treatment, including both pathogens and chemical micropollutants, which is a pressing issue facing many countries today. Full article

The process of obtaining powders from the 5–50 μm fraction of a W-Ni-Fe system consisting of particles with predominantly spherical shapes was investigated. Experimental studies on the plasma–chemical synthesis of a nanopowder composed of WNiFe-90 were carried out in a plasma reactor with a confined jet flow. A mixture of tungsten trioxide, nickel oxide, and iron oxide powders interacted with a flow of hydrogen-containing plasma generated in an electric-arc plasma torch. The parameters of the spray-drying process and the composition of a suspension consisting of WNiFe-90 nanoparticles were determined, which provided mechanically strong nanopowder microgranules with a rounded shape and a homogeneous internal structure that contained no cavities. The yield of the granule fraction under 50 μm was 60%. The influence of the process parameters of the plasma treatment of the nanopowder microgranules in the thermal plasma flow on the degree of spheroidization and the microstructure of the obtained particles, seen as their bulk density and fluidity, was established. It was shown that the plasma spheroidization of the microgranules of the W-Ni-Fe system promoted the formation of a submicron internal structure in the obtained spherical particles, which were characterized by an average tungsten grain size of 0.7 μm. Full article

Yb-doped Y₂O₃ stabilized ZrO₂ (YbYSZ) coatings, developed through solution precursor plasma spraying (SPPS), are engineered to resist calcium–magnesium–alumino–silicate (CMAS) infiltration by leveraging their unique micro-nano structures. This provides superior anti-wetting properties, crucial for preventing CMAS penetration at high temperatures. The investigation focused on the structural and compositional changes in YbYSZ-SPPS coatings subjected to prolonged thermal exposure at 1300 °C. Results indicate that while the coatings undergo significant sintering, leading to densification and microstructural evolution, the elemental composition and phase stability remain largely intact after up to 8 h of heat treatment. Despite some reduction in CMAS resistance, the coatings maintained their overall protective performance, demonstrating the potential of SPPS coatings for long-term use in high-temperature environments where CMAS infiltration is a concern. These findings contribute to the development of more durable TBCs for advanced thermal protection applications. Full article

Higher operating temperatures for gas turbine engines require highly durable thermal barrier coatings (TBCs) with improved insulation properties. A suspension plasma spray process (SPS) had been developed for the deposition of columnar-structured TBCs. SPS columnar TBCs are normally achieved at a short standoff distance (50.0 mm–75.0 mm), which is not practical when coating complex-shaped engine hardware since the plasma torch may collide with the components being sprayed. Therefore, it is critical to develop SPS columnar TBCs at longer standoff distances. In this work, a commercially available pressure-based suspension delivery system was used to deliver the suspension to the plasma jet, and a high-enthalpy TriplexPro-210 plasma torch was used for the SPS coating deposition. Suspension injection pressure was optimized to maximize the number of droplets injected into the hot plasma core and achieving the best particle-melting states and deposition efficiency. The highest deposition efficiency of 51% was achieved at 0.34 MPa injection pressure with a suspension flow rate of 31.0 g/min. With the optimized process parameters, 1000 μm thick columnar-structured SPS 8 wt% Y₂O₃-stabilized ZrO₂ (8YSZ) TBCs were successfully developed at a standoff distance of 100.0 mm. The SPS TBCs have a columnar width between 100 μm and 300 μm with a porosity of ~22%. Furnace cycling tests at 1125 °C showed the SPS columnar TBCs had an average life of 1012 cycles, which is ~2.5 times that of reference air-plasma-sprayed dense vertically cracked TBCs with the same coating thickness. The superior durability of the SPS columnar TBCs can be attributed to the high-strain-tolerant microstructure. SEM cross-section characterization indicated the failure of the SPS TBCs occurred at the ceramic top coat and thermally grown oxide (TGO) interface. Full article

Oxidation of the bond coat during turbine operation leads to additional stresses in the thermal barrier coating (TBC) system that promotes spalling of the thermal insulation. Therefore, the oxidation behavior of a TBC system plays an important role in the thermal cycling of a TBC system. To delay the loss of thermal insulation, research has typically focused for a long time on the composition and microstructure of the ceramic topcoats and metallic bond coats. More recently, heat treatment for the diffusion annealing of the bond coat has also become a focus of research. Several studies have shown that pre-oxidation of the bond coat prior to the application of the ceramic topcoat slows down the subsequent oxidation of the bond coat in service. The improved thermal cyclability has been demonstrated in studies for systems with atmospheric plasma-sprayed (APS), suspension plasma-sprayed (SPS) or electron beam physical vapor deposition (EB-PVD) top coatings. However, no study has directly compared the effects of pre-oxidation on different topcoats. Therefore, this study compared the effect of pre-oxidation on APS and SPS coatings with the same bond coat. For both topcoats, pre-oxidation slowed the subsequent TGO growth and thus increased the lifetime of the coatings. The improvement in lifetime was particularly pronounced for the systems with an SPS topcoat. Overall, the lifetime of the coatings with an APS topcoat was higher as the critical energy release rate within the coating was not exceeded in these coatings. Full article

The main objective of this study was to use flash boiling atomization as a new method to inject suspensions with high solid content into the high-power plasma flow. The water-based suspension was prepared with submicron titanium oxide particles with an average size of 500 nm. The investigated solid concentrations were 20, 40, 55 and 70 wt%. Two plasma torches operated at 33, 70 and 110 kW were used to investigate the effect of increasing power on the deposited microstructure and deposition efficiency. At low torch power, the deposition efficiency decreased with increasing solid concentration, and deposits with a high number of unmelted particles were obtained with 70 wt% suspensions. At high torch power, the deposition efficiency increased with increasing solid concentration, and dense deposits were obtained with 70 wt% suspensions. XRD analysis was performed on all deposits to determine the distribution of rutile and anatase phases. The percentage of the anatase phase varied from 35.7% to 66.9%, depending on the power input and solid concentration. Full article

The astonishing safety and capacity characteristics of solid-state-batteries are encouraging researchers and companies to work on the manufacturing, development, and characterization of battery materials. In the present work, the effects of laser beam interaction with a liquid feedstock plasma-sprayed ceramic solid-state-battery (SSB) material coating were studied. Lithium Titanium Oxide (LTO) in the form of an aqueous suspension consisting of submicron powder particles was plasma-sprayed for the first time using a high-power axial III plasma torch on an aluminum substrate. The plasma-sprayed LTO coating suspension was subsequently post-processed using a fiber laser. The energy input of the laser beam on the surface of the deposited layer was the main variable. By varying the laser power and laser processing speed, the energy input values were varied, with values of 3.8 J/mm², 9.6 J/mm², 765.9 J/mm², and 1914.6 J/mm², and their effects on some key characteristics such as laser-processed zone dimensions and chemical composition were investigated. The results indicated that changing the laser beam parameter values has appreciable effects on the geometry, surface morphology, and elemental distribution of laser-processed zones; for instance, the highest energy inputs were 33% and 152%, respectively, higher than the lowest energy input. Full article

This study presents novel insights into thermal stress development and crack propagation mechanisms in single- and multilayered suspension plasma-sprayed (SPS) coatings of gadolinium zirconate (GZ) and yttria-stabilized zirconia (YSZ), thermally treated at 1150 °C. By combining image processing with finite element simulation, we pinpointed sites of high-stress concentration in the coatings, leading to specific cracking patterns. Our findings reveal a dynamic shift in the location of stress concentration from intercolumnar gaps to pores near the top coat/thermally grown oxide (TGO) interface with TGO thickening at elevated temperatures, promoting horizontal crack development across the ceramic layers. Significantly, the interface between the ceramic layer and TGO was found to be a critical area, experiencing the highest levels of both normal and shear stresses. These stresses influence failure modes: in double-layer SPS structures, relatively higher shear stresses can result in mode II failure, while in single-layer systems, the predominant normal stresses tend to cause mode I failure. Understanding stress behavior and failure mechanisms is essential for enhancing the durability of thermal barrier coatings (TBCs) in high-temperature applications. Therefore, by controlling the interfaces’ roughness along with improving interfacial toughness, the initiation and propagation of cracks can be delayed along these interfaces. Moreover, efforts to optimize the level of microstructural discontinuities, such as intercolumnar gaps and pores, within the creaming layer and close to the TGO interface should be undertaken to reduce crack formation in the TBC system. Full article

Photocatalytic coatings can degrade volatile organic compounds into non-toxic products, which has drawn the attention of scholars around the world. However, the pollution of dust on the coating adversely affects the photocatalytic efficiency and service life of the coating. Here, a series of TiO₂-polyfluoroalkoxy (PFA) coatings with different contents of PFA were fabricated by suspension plasma spraying technology. The results demonstrate that the hybrid coatings contain a large number of circular and ellipsoidal nanoparticles and a porous micron-nano structure due to the inclusion of PFA. According to the optimized thermal spraying process parameters, TiO₂ nanoparticles were partially melted to retain most of the anatase phases, whereas PFA did not undergo significant carbonization. As compared to the TiO₂ coating, the static contact angle of the composite coating doped with 25 wt.% PFA increased from 28.2° to 134.1°. In addition, PFA strongly adsorbs methylene blue, resulting in a greater involvement of methylene blue molecules in the catalyst, where the catalytic rate of hybrid coatings is up to 95%. The presented nanocomposite coatings possess excellent photocatalytic and self-cleaning properties and are expected to find wider practical applications in the field of photocatalysis. Full article

Commonly used sample introduction systems for inductively coupled plasma mass spectrometry (ICP-MS) are generally not well-suited for single particle ICP-MS (spICP-MS) applications due to their high sample requirements and low efficiency. In this study, the first completely 3D-printed, polymer SIS was developed to facilitate spICP-MS analysis. The system is based on a microconcentric pneumatic nebulizer and a single-pass spray chamber with an additional sheath gas flow to further facilitate the transport of larger droplets or particles. The geometry of the system was optimized using numerical simulations. Its aerosol characteristics and operational conditions were studied via optical particle counting and a course of spICP-MS measurements, involving nanodispersions and cell suspensions. In a comparison of the performance of the new and the standard (quartz microconcentric nebulizer plus a double-pass spray chamber) systems, it was found that the new sample introduction system has four times higher particle detection efficiency, significantly better signal-to-noise ratio, provides ca. 20% lower size detection limit, and allows an extension of the upper limit of transportable particle diameters to about 25 µm. Full article

In recent years, there has been growing interest in thermal spray techniques using suspension or solution-based coatings. These techniques offer precise control over particle size and microstructure, improving feedstock flowability and allowing for high-quality coating customization. Spray parameters, such as stand-off distance (SOD) and feedstock flow rate, can alter the performance and characteristics of these coatings. Geothermal power plant heat exchangers often face issues like corrosion, scaling, and fouling. The literature suggests that these issues could be mitigated, at least in part, by the use of spray coatings. In this study, TiO₂ coatings were applied on a carbon steel substrate using suspension plasma spray (SPS) to enhance the performance of geothermal heat exchanger materials. The impact of SOD (50, 75, and 100 mm) and feedstock flow rate (10, 20, and 30 mL/min) on these coatings was examined through various techniques, including scanning electron microscope (SEM), profilometry, X-ray diffraction (XRD), and adhesion testing. The results demonstrated that coatings deposited using a 10 mL/min feedstock flow rate were well adhered to the substrate due to the efficient melting of the coating material, but as the SOD and feedstock flow rate increased due to poor thermal and kinetic energy exchange between the torch and feedstock particles, adhesion between the coating and substrate decreased. Full article

The laser sintering process and modification of yttria-stabilized zirconia (YSZ) coatings subjected to electrophoretic deposition (EPD) on YSZ air-plasma-sprayed (APS) thermal barrier coatings (TBCs) were investigated. A Ni-based superalloy was plasma-sprayed using yttria-stabilized zirconia (YSZ) to create a thermal barrier coating with a 400 μm thickness. The electrophoretic deposition (EPD) technique was used to deposit the nanopowder of YSZ on the surface of YSZ TBCs. In this study, a technology based on the direct sintering of a green EPD layer using a laser beam was employed. The best conditions for the deposition overlay of the YSZ coating using a DC current were obtained with an applied voltage of 40 V, deposition time of 5 min, and suspension concentration of 10 g/L. Iodine was added to the solutions as a stabilizing agent. To overcome the problems of high sintering temperatures, laser sintering was adopted as a new approach. The microstructures of all the specimens were studied using field emission scanning electron microscopy (FESEM) with energy-dispersive X-ray spectroscopy (EDS) analysis. Surface roughness was investigated using atomic force microscopy (AFM) analysis and the central line average (CLA). The direct laser sintering (DLS) process for the EPD overlay on the surface of the TBCs caused a reduction in surface roughness and porosity, and improvements in the microstructural and mechanical properties of the surface coatings were observed. Full article

Columnar structured thermal barrier coatings (TBCs) have been intensively investigated due to their potential to enhance the durability and reliability of gas turbine engine components. These coatings consist of vertically aligned columns that provide excellent resistance to thermal cycling. In this study, the lifetime of columnar suspension-plasma-sprayed (SPS) TBCs was evaluated using burner rig tests. The tests were carried out under high-temperature conditions. Significantly, the pre-oxidation of the bondcoat during diffusion bonding treatment was found to have a substantial impact on the performance of the SPS TBCs. The optimized treatment resulted in columnar SPS TBCs demonstrating excellent thermal stability and resistance under the test conditions. The lifetime of the coatings was significantly extended compared to conventional TBCs by pre-oxidation of the CoNiCrAlY bondcoat in argon, which suggests that columnar SPS TBCs have great potential for use in gas turbine engines. Full article