Understanding plasma spraying

This article intends to summarize our actual knowledge in plasma spraying with an emphasis on the points where work is still in progress. It presents successively: the plasma torches with the resulting plasma jets and their interactions with the surrounding environment; the powder injection with the heat, momentum and mass transfers between particles and first plasma jets and then plasma plume; the particles flattening and solidification, forming splats which then layer to form the coating; the latest developments related to the production of plasma sprayed finely structured coatings.

[1]  J. Bisson,et al.  Diagnostics for advanced materials processing by plasma spraying , 2005 .

[2]  Leon L. Shaw,et al.  Development and implementation of plasma sprayed nanostructured ceramic coatings , 2001 .

[3]  P. Fauchais,et al.  Nitridation process and mechanism of Ti-6Al-4V particles by dc plasma spraying , 2003 .

[4]  H. Nishiyama,et al.  Three-dimensional effects of carrier gas and particle injections on the thermo-fluid fields of plasma jets , 2002 .

[5]  T. L. Bergman,et al.  Three-dimensional simulation of thermal plasma spraying of partially molten ceramic agglomerates , 2000 .

[6]  H. W. Ng,et al.  Influence of process parameters on the deposition footprint in plasma-spray coating , 2003 .

[7]  L. Shaw,et al.  The dependency of microstructure and properties of nanostructured coatings on plasma spray conditions , 2000 .

[8]  D. Kolman,et al.  Modeling of Oxidation During Plasma Spraying of Iron Particles , 2002 .

[9]  V. Sobolev,et al.  In-flight behaviour of steel particles during plasma spraying , 1999 .

[10]  P. Fauchais,et al.  Coating generation: Vaporization of particles in plasma spraying and splat formation , 1996 .

[11]  M. Vardelle,et al.  Impacting particle temperature monitoring during plasma spray deposition , 1990 .

[12]  C. Berndt,et al.  Evaluation of microhardness and elastic modulus of thermally sprayed nanostructured zirconia coatings , 2001 .

[13]  Dongyan Xu,et al.  Motion and heating of non-spherical particles in a plasma jet , 2003 .

[14]  R. Young,et al.  Two-dimensional model for thermal plasma chemical vapor deposition , 1995 .

[15]  Christian Moreau,et al.  The long-term stability of plasma spraying , 2002 .

[16]  Pierre Freton,et al.  Comparison between a two- and a three-dimensional arc plasma configuration , 2000 .

[17]  J. Ilavsky,et al.  In-flight oxidation of high-alloy steels during plasma spraying , 1999 .

[18]  Computer-aided torch trajectory generation for automated coating of parts with complex surfaces , 1994 .

[19]  E. Lavernia,et al.  Synthesis of nanostructured Cr3C2-25(Ni20Cr) coatings , 2000 .

[20]  P. Fauchais,et al.  Heat and Mass Transfer Under Plasma Conditions , 1996 .

[21]  A. H. King,et al.  Effect of different substrate conditions upon interface with plasma sprayed zirconia—a TEM study , 2002 .

[22]  P. Fauchais,et al.  Controlling particle injection in plasma spraying , 2001 .

[23]  R. Mcpherson.  On the formation of thermally sprayed alumina coatings , 1980 .

[24]  D. T. Gawne,et al.  Computer modelling of the influence of process parameters on the heating and acceleration of particles during plasma spraying , 2000 .

[25]  P. Fauchais,et al.  Plasma—particle momentum and heat transfer: Modelling and measurements , 1983 .

[26]  M. Boulos.  RF induction plasma spraying: State-of-the-art review , 1992 .

[27]  P. Fauchais,et al.  MODELING OF THE PLASMA SPRAY PROCESS : FROM POWDER INJECTION TO COATING FORMATION , 2001 .

[28]  N. Themelis,et al.  IN-FLIGHT OXIDATION AND EVAPORATION OF PLASMA-SPRAYED IRON PARTICLES , 2003 .

[29]  Xi Chen,et al.  Application of Steenbeck's minimum principle for three-dimensional modelling of DC arc plasma torches , 2003 .

[30]  J. R. Fincke,et al.  Particle temperature measurement in the thermal spray process , 2001 .

[31]  W. J. Brindley,et al.  Modeling Oxidation Induced Stresses in Thermal Barrier Coatings , 1998 .

[32]  Javad Mostaghimi,et al.  Deposition of tin droplets on a steel plate: simulations and experiments , 1998 .

[33]  Pierre Fauchais,et al.  Experimental and Theoretical Study of the Impact of Alumina Droplets on Cold and Hot Substrates , 2003 .

[34]  Jean-Pierre Delplanque,et al.  Thermo–fluid mechanisms controlling droplet based materials processes , 2002 .

[35]  Lech Pawlowski,et al.  The Science and Engineering of Thermal Spray Coatings , 1995 .

[36]  M. Pasandideh-Fard,et al.  Splat shapes in a thermal spray coating process: Simulations and experiments , 2002 .

[37]  E. Pfender,et al.  A two-fluid model of turbulence for a thermal plasma jet , 1995 .

[38]  C. Moreau,et al.  Simultaneous independent measurement of splat diameter and cooling time during impact on a substrate of plasma-sprayed molybdenum particles , 2001 .

[39]  P. Fauchais,et al.  Diagnostics of thermal spraying plasma jets , 1992 .

[40]  P. Fauchais,et al.  Influence of particle parameters at impact on splat formation and solidification in plasma spraying processes , 1995 .

[41]  C. Berndt,et al.  Bimodal distribution of mechanical properties on plasma sprayed nanostructured partially stabilized zirconia , 2002 .

[42]  R. L. Williamson,et al.  A Computational Examination of the Sources of Statistical Variance in Particle Parameters During Thermal Plasma Spraying , 2000 .

[43]  P. Fauchais,et al.  OXIDATION OF STAINLESS STEEL PARTICLES WITH AND WITHOUT AN ALUMINA SHELL DURING THEIR FLIGHT IN A PLASMA JET , 2000 .

[44]  Christer Persson,et al.  Modelled and measured residual stresses in plasma sprayed thermal barrier coatings , 1997 .

[45]  S. Xue,et al.  Effect of the Coil Angle in an Inductively Coupled Plasma Torch: A Novel Two-Dimensional Model , 2003 .

[46]  Y. Lee,et al.  Particle dynamics and particle heat and mass transfer in thermal plasmas. Part I. The motion of a single particle without thermal effects , 1985 .

[47]  H. Herman,et al.  Modeling and experimental observation of evaporation from oxidizing molybdenum particles entrained in a thermal plasma jet , 2002 .

[48]  A Lefort,et al.  Transport properties in a two-temperature plasma: theory and application. , 2001, Physical review. E, Statistical, nonlinear, and soft matter physics.

[49]  Pierre Fauchais,et al.  Quo vadis thermal spraying? , 2001, International Thermal Spray Conference.

[50]  Maher I. Boulos,et al.  Turbulence in induction plasma modelling , 1994 .

[51]  Per Nylén,et al.  Models for the simulation of spray deposition and robot motion optimization in thermal spraying of rotating objects , 1999 .

[52]  M. Vardelle,et al.  Volatilization of metal powders in plasma sprays , 2002 .

[53]  R. Mcpherson.  Formation of metastable phases in flame- and plasma-prepared alumina , 1973 .

[54]  T. W. Clyne,et al.  Residual Stresses in Thermal Spray Coatings and Their Effect on Interfacial Adhesion: A Review of Recent Work , 1996 .

[55]  S. Chandra,et al.  On a three-dimensional volume tracking model of droplet impact , 1999 .

[56]  J. Bisson,et al.  Thermal spraying of nanostructured cermet coatings , 2001 .

[57]  R. S. Devoto.  TRANSPORT COEFFICIENTS OF PARTIALLY IONIZED ARGON. , 1967 .

[58]  H. Kaji,et al.  Three-dimensional transition map of flattening behavior in the thermal spray process , 2005 .

[59]  Yong Qing Fu,et al.  Recent advances of superhard nanocomposite coatings: a review , 2003 .

[60]  Pierre Proulx,et al.  Extended-field electromagnetic model for inductively coupled plasma , 2001 .

[61]  P. Fauchais,et al.  Plasma spray processes: diagnostics and control? , 1999 .

[62]  S. Xue,et al.  Modelling the effect of ferrite on an inductively coupled plasma torch: II. Finite ferrite permeability , 2002 .

[63]  P. Fauchais,et al.  FUNDAMENTALS OF PLASMA PARTICLE MOMENTUM AND HEAT TRANSFER , 1993 .

[64]  Armelle Vardelle,et al.  The Dynamics of Deposit Formation in Thermal-Spray Processes , 2000 .

[65]  C. Ding,et al.  Nanostructured zirconia coating prepared by atmospheric plasma spraying , 2002 .

[66]  Ali Dolatabadi,et al.  Modeling thermal spray coating processes: a powerful tool in design and optimization , 2003 .

[67]  K. Hollis,et al.  Analysis of the nonthermal emission signal present in a molybdenum particle-laden plasma-spray plume , 1998 .

[68]  J. R. Fincke,et al.  Simultaneous measurement of particle size, velocity, and temperature in thermal plasmas , 1990 .

[69]  R. McPherson,et al.  The relationship between the mechanism of formation, microstructure and properties of plasma-sprayed coatings , 1981 .

[70]  P. Fauchais,et al.  Calculation of Combined Diffusion Coefficients from the Simplified Theory of Transport Properties , 2015, Proceeding of Progress in Plasma Processing of Materials, 2001.

[71]  S. Chandra,et al.  A stochastic model to simulate the formation of a thermal spray coating , 2003 .

[72]  P. Fauchais,et al.  Two-colour pyrometer for the statistical measurement of the surface temperature of particles under thermal plasma conditions , 1987 .

[73]  Xi Chen,et al.  Three-dimensional simulation of a plasma jet with transverse particle and carrier gas injection , 2001 .

[74]  M. Einarsrud,et al.  Microstructural characterization and microstructural effects on the thermal conductivity of AlN(Y2O3) ceramics , 2002 .

[75]  E. Pfender,et al.  Entrainment of cold gas into thermal plasma jets , 1991 .

[76]  Yong Rae Kwon,et al.  Specifying and verifying real-time systems with timing uncertainty , 2000, J. Syst. Softw..

[77]  P. Fauchais,et al.  Knowledge concerning splat formation: An invited review , 2004 .

[78]  Y. Lee,et al.  Particle dynamics and particle heat and mass transfer in thermal plasmas. Part II. Particle heat and mass transfer in thermal plasmas , 1985 .

[79]  Christopher C. Berndt,et al.  Nanomaterial powders and deposits prepared by flame spray processing of liquid precursors , 1997 .

[80]  S. Kuroda,et al.  Quenching stress in plasma sprayed coatings and its correlation with the deposit microstructure , 1995 .

[81]  E. Hämäläinen,et al.  Novel method for in-flight particle temperature and velocity measurements in plasma spraying using a single CCD camera , 2001 .

[82]  M. Boulos.  THE INDUCTIVELY COUPLED RADIO FREQUENCY PLASMA , 1997 .

[83]  P. Fauchais,et al.  Diffusion in two-temperature thermal plasmas. , 2002, Physical review. E, Statistical, nonlinear, and soft matter physics.