Skip to main content
SpringerLink
Log in

Current problems in plasma spray processing

  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

This article summarizes eight contributions from a thermal spray conference that was held in late 1991 at Brookhaven National Laboratory, Upton, Long Island, New York. Plasma spray processing is discussed in terms of plasma-particle interactions, deposit formation dynamics, thermal properties of thermal barrier coatings, mechanical properties of coatings, feedstock materials, porosity, manufacture of intermetallic coatings, and synchrotron X-ray microtomographic methods for thermal spray materials. Each section is intended to present a concise statement of a specific practical and/or scientific problem. It then describes current work that is being performed to investigate this area, and finally suggests areas of research that may be fertile for future activity.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. E. Pfender, W.L.T. Chen, and R. Spores; A New Look at Thermal and Dynamic Characteristics of a Plasma Jet, inThermal Spray Research and Applications, T.F. Bernecki, Ed., ASM International, 1991,p 1-10.

  2. Ph. Roumilhac, J.F. Coudert, and P. Fauchais, Designing Parameters of Spraying Plasma Torches,Thermal Spray Research and Applications,T.F. Bernecki, Ed., ASM International, 1991,p 11-18.

  3. J.R. Fincke and W.D. Swank, The Effect of Plasma Jet Fluctuations on Particle Time-Temperature Histories,Thermal Spray Coatings: Properties, Processes and Applications, T.F. Bernecki, Ed., ASM International, 1991, p 193-198.

  4. M. Vardelle, A. Vardelle, Ph. Roumhilac, andP. Fauchais, Influence of the Surrounding Atmosphere under Plasma Spraying Conditions,Thermal Spray Technology New Ideas and Processes, D.L.Houck, Ed., ASM International, 1989, p 117.

  5. J.R. Fincke, R. Rodriguez, and CG. Pentecost, Measurement of Air Entrainment in Plasma Jets,Thermal Spray Research and Applications, T.F. Bernecki, Ed., ASM International, 1991, p 45-48.

  6. K.A. Kowalski, D.R. Marantz, R. Neiser, and M.F. Smith, Diagnostic Behavior of the Wire-Arc-Plasma Spray Process,Thermal Spray: International Advances in Coatings Technology, C.C.Berndt, Ed., ASM International, 1992, p 337-342.

  7. J.M. Houben, Ph.D. thesis, Eindhoven University of Technology, Eindhoven, Holland.

  8. M. Moss, Dispersion Hardening in Al-V by Plasma-Jet Spray Quenching,Acta Metall., Vol 16, 1968, p 321–332.

    Article  CAS  Google Scholar 

  9. S. Safai and H. Herman, Microstructural Investigation of Plasma-Sprayed Aluminum Coatings,Thin Solid Films, Vol 45, 1977, p 295–307.

    Article  CAS  Google Scholar 

  10. S. Sampath and H. Herman, Microstructural Development of Plasma Sprayed Coatings, Paper 53,Proc. 12th Int. Thermal Spraying Conference, Vol 1, Welding Institute, London, 1989.

    Google Scholar 

  11. S. Sampath, Ph.D. thesis, “Rapid Solidification during Plasma Spraying,” SUNY at Stony Brook, Aug 1989.

  12. W.J. Brindley and R.A. Miller, Thermal Barrier Coatings for Better Engine Efficiency,Adv. Mater. Proc, Vol 136 (No. 2) Aug 1989, p 29–33.

    Google Scholar 

  13. J.T. DiMasi, K.D. Sheffler, and M. Ortiz, “Thermal Barrier Coating Life Prediction Model Development, Phase I—Final Report,” NASA Contractor Report CR 182230, Pratt & Whitney, Dec 1989.

  14. R.A. Miller, Life Modeling of Thermal Barrier Coatings for Aircraft Gas Turbine Engines,Trans. ASME J. Eng. Gas Turbines Power, Vol 111, 1989,p 301–305.

    Article  CAS  Google Scholar 

  15. R.A. Miller, Assessment of Fundamental Materials Needs for Thick Thermal Barrier Coatings (TTBC’s) for Truck Diesel Engines,Proc. 1990 Coatings for Advanced Heat Engine Workshop, Aug 6-9, 1990, Castine, ME, also NASA Technical Memoranda TM-103130, May 1990.

  16. R.E. Taylor, Things Mother Never Taught Me (about Thermophysical Properties of Solids), inThermal Conductivity 21, C.J. Cremers and H.A. Fine, Ed., Plenum Press, 1990, p 41-49.

  17. C.C. Berndt, Tensile Adhesion Testing Methodology for Thermally Sprayed Coatings,J. Mater. Eng., Vol 12,1990, p 151–158.

    CAS  Google Scholar 

  18. S. Amada, H. Yamada, S. Yematsu, and T. Saotome, Modelling and Measurements of Adhesive Strength of Thermally Sprayed Coatings,Thermal Spray: International Advances in Coatings Technology, C.C. Bemdt, Ed., ASM International, 1992, p 915-920.

  19. C.C. Berndt and R. McPherson, Assessment of the Adhesion of Plasma Sprayed Coatings,Surf.J. Int., Vol l(No.2), 1986,p49–52.

    Google Scholar 

  20. C.C. Berndt, J. Ilavsky, and J. Karthikeyan, Microhardness—Lifetime Correlations for Plasma Sprayed Thermal Barrier Coatings, inThermal Spray: International Advances in Coatings Technology, C.C. Berndt, Ed., ASM International, 1992, p 941-946.

  21. C.C. Berndt and R.A. Miller, Failure Analysis of Plasma-Sprayed Thermal Barrier Coatings,Thin Solid Films, Vol 119, 1984,p 173–184, also NASA TM 83777.

    Article  CAS  Google Scholar 

  22. E. Lugscheider, Plasma Spraying for Wear Applications, inThermal Spray: Advances in Coatings Technology, D.L.Houck, Ed., ASM International, 1988, p 173-184.

  23. G. Schwier, Plasma Spray Powders for Thermal Barrier Coatings,Advances in Thermal Spray, The Welding Institute of Canada, Montreal, Canada, 1986, p 277–286.

    Google Scholar 

  24. D. Chauxian, R.A. Zatorski, H. Herman, and D. Ott, Oxide Powders for Plasma Spraying—The Relationship Between Powder Characteristics and Coating Properties,Thin Solid Films, Vol 118,1984, p 467–475.

    Article  Google Scholar 

  25. D.L. Houck, Techniques for the Production of Flame and Plasma Spray Powders,Modern Developments in Powder Metallurgy, Vol 12, 13, and 14,1980, p 485–504.

    Google Scholar 

  26. A.R. Nicoll and H. Eschnauer, Retesting Thermal-Spray Powders,Surf. Coat. Technol., Vol 30(No.l), 1987,p 95–106.

    Article  CAS  Google Scholar 

  27. Materials Science and Engineering for the 1990s, National Academy Press, 1989.

  28. S. Brunauer, L.S. Deming, W.E. Deming, and E. Teller, On A Theory of the Van der Waal’s Adsorption of Gases,J. Am. Chem. Soc, Vol 62,1940, p 1723–1732.

    Article  CAS  Google Scholar 

  29. S. Brunauer,The Adsorption of Gases and Vapors, Princeton University Press, 1945.

  30. P.W. Schmidt, inThe Fractal Approach to Heterogeneous Chemistry, D. Avnir, Ed., John Wiley & Sons, 1989.

  31. Po-zen Wong and A.J. Bray, Small Angle Scattering of Rough and Fractal Surfaces,J. Appl. Crystallogr., Vol21, 1988,p 786–794.

    Article  Google Scholar 

  32. J.K. Kjems, T. Freltoft, D. Richter, and S.K. Sinha, Neutron Scattering from Fractals,Physica, Vol 136B, 1986, p 285–290.

    Google Scholar 

  33. A.J. Hurd, D.W. Schaefer, and J.E. Martin, Surface and Mass Fractals in Vapor-Phase Aggregates,Phys.Rev. A, Vol35,1987,p2361–2364.

    Article  CAS  Google Scholar 

  34. R.H. Ericksen, J.C. Swearengen, and R.E. Allred, Mechanical Properties of Plasma Sprayed 1100 Aluminum as a Composite Matrix,Sampe Quart., Vol 7(No. 1), 1975, p 1–8.

    CAS  Google Scholar 

  35. M.R. Jackson, J.R. Rairden, J.S. Smith, and R.W. Smith, Production of Metallurgical Structures by Rapid Solidification Plasma Deposition,J. Met., Vol 33(No. 11),1981,p 23–27.

    CAS  Google Scholar 

  36. M. Scholl, P. Clayton, E. Elmore, and J. Wooten, Sprayforming by High-Power High-Velocity Plasma Spraying,Thermal Spray Coatings: Properties, Processes and Applications, T.F. Bernecki, Ed., ASM International, 1992, p 281-288.

  37. D. Stover, D. Moulatsiotis, W. Diehl, E. El-Magd, and R. Hecker, Low Pressure Plasma Sprayed Bulk Superalloy UDIMET 700: Mechanical Properties and Microstructure,Thermal Spray Research and Applications, T.F. Bernecki, Ed., ASM International, 1991, p 375-381.

  38. R. Tiwari, H. Herman, S. Sampath, and B. Gudmundsson, Plasma Spray Consolidation of High Temperature Composites,Mater. Sci. Eng.,VolA144,1991,p 127–131.

    CAS  Google Scholar 

  39. T.N. McKechnie, Y.K. Liaw, F.R. Zimmerman, and R.M. Poorman, Metallurgy and Properties of Plasma Spray Formed Materials,Thermal Spray: International Advances in Coatings Technology, C.C.Berndt, Ed., ASM International, 1992, p 839-846.

  40. R. Tiwari, H. Herman, and S. Sampath, Vacuum Plasma Spraying of MoSi2 and Its Composites,Mater. Sci. Eng., Vol A155,1992, p 95–100.

    CAS  Google Scholar 

  41. S. Sampath, R. Tiwari, and H. Herman, Rapid Solidification Processing of Intermetallic Composites Through Plasma Spray,Proc. TMS Fall Meeting Symp. on Microstructural Design by Solidification Processing, Nov 1992, to be published.

  42. D.A. Jager, D. Stover, and W. Chlump, High Pressure Plasma Spraying in Controlled Atmosphere up to Two Bar,Thermal Spray: International Advances in Coatings Technology, C.C. Berndt, Ed., ASM International, 1992, p 69-74.

  43. L.E. Weiss, F. Prinz, and D. Adams, Solid Freeform Fabrication by Thermal Spray Shape Deposition,Thermal Spray: International Advances in Coatings Technology, C.C. Berndt, Ed., ASM International, 1992, p 847-852.

  44. P. Spanne and M. L. Rivers, Computerized Microtomography Using Synchrotron Radiation from the NSLS,Nucl. Instrum. Methods Phys. Res., Vol B24/25, 1987, p 1063–1067.

    Google Scholar 

  45. K.W. Jones, P. Spanne, W.B. Lindquist, W.C. Conner, and M. Ferrero, Determination of Polymerization Particle Morphology Using Synchrotron Computed Microtomography,Nucl. Instrum. Methods Phys.Res., Vol B68,1992, p 105–110.

    CAS  Google Scholar 

  46. K.W. Jones, R.S. Bockman, B.M. Gordon, M.L. Rivers, A.J. Saubermann, G. Schidlovsky, and P. Spanne, Biomedical Applications of Synchrotron X-Ray Microscopy,Proc. 2nd Int. Work- shop—XRFand PIXE Applications in Life Science, R. Moro and R. Cesareo, Ed., World Scientific Publishing Co., Singapore, 1990, p 163–174.

    Google Scholar 

  47. K.W. Jones, P. Spanne, S.W. Webb, W.C. Conner, R.A. Beyerlein, W.J. Reagan, and F.M. Dautzenberg, Catalyst Analysis Using Synchrotron X-Ray Microscopy,Nucl. Instrum. Methods Phys. Res., Vol B56/57,1991, p 427–432.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. SUNY at Stony Brook, The Thermal Spray Laboratory, Stony Brook, New York

    C. C. Berndt & H. Herman

  2. Dept. of Applied Science, Brookhaven National Laboratory, Upton, New York

    K. Jones & P. Spanne

Authors
  1. C. C. Berndt
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. W. Brindley
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. N. Goland
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. H. Herman
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. D. L. Houck
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. K. Jones
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. R. A. Miller
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. R. Neiser
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. W. Riggs
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. S. Sampath
    View author publications

    You can also search for this author in PubMed Google Scholar

  11. M. Smith
    View author publications

    You can also search for this author in PubMed Google Scholar

  12. P. Spanne
    View author publications

    You can also search for this author in PubMed Google Scholar

Additional information

This article is a compilation and editing of individual author submissions. The author(s) of each section will be acknowledged by a footnote at the beginning headline of the respective section.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Berndt, C.C., Brindley, W., Goland, A.N. et al. Current problems in plasma spray processing. JTST 1, 341–356 (1992). https://doi.org/10.1007/BF02647162

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF02647162

Key Words

Search

Navigation