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Parameters Controlling Liquid Plasma Spraying: Solutions, Sols, or Suspensions

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Abstract

This article presents what is our present knowledge in plasma spraying of suspension, sol, and solution in order to achieve finely or nano-structured coatings. First, it describes the different plasma torches used, the way liquid jet is injected, and the different measurements techniques. Then, drops or jet fragmentation is discussed with especially the influence of arc root fluctuations for direct current plasma jets. The heat treatment of drops and droplets is described successively for suspensions, sols, and solutions both in direct current or radio-frequency plasmas, with a special emphasize on the heat treatment, during spraying, of beads and passes deposited. The resulting coating morphologies are commented and finally examples of applications presented: Solid Oxide Fuel Cells, Thermal Barrier coatings, photocatalytic titania, hydroxyapatite, WC-Co, complex oxides or metastable phases, and functional materials coatings.

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Abbreviations

b :

Thermal effusivity (W s0.5/m2 K)

C D :

Plasma drag coefficient (−)

d dt :

Droplet diameter (m)

d ℓ :

Liquid drop diameter (m)

d i :

Internal diameter of injection nozzle (m)

d m :

Minimum droplet diameter (m)

d p :

Condensed particle diameter (m)

f :

frequency (Hz)

h :

Heat transfer coefficient (W/m2 K)

h p :

Plasma enthalpy (MJ/kg)

I :

Arc current (A)

L v :

Latent heat of vaporization of liquid (J/kg)

Nu :

Nusselt number (−)

P :

Power dissipated in the torch (kW)

\( \ifmmode\expandafter\bar\else\expandafter\=\fi{P} \) :

Time averaged power dissipated (\( \ifmmode\expandafter\bar\else\expandafter\=\fi{V} \times I \)) (kW)

r ℓ :

Drop or droplet radius (m)

S i :

Surface of injection nozzle (m2)

T :

Plasma temperature (K)

T d :

Pass temperature (K or °C)

T n :

Nucleation temperature (K or °C)

T p :

Particle temperature (K or °C)

T s :

Substrate or already deposited layers temperature (K or °C)

T M :

melting temperature (K or °C)

U :

Velocity difference between plasma and drop or droplet (U = v − v ℓ) (m/s)

U R :

Velocity of atomizing gas relation to that of liquid (m/s)

v :

Plasma velocity (m/s)

v ℓ :

Injected liquid velocity (m/s)

v p :

Particle velocity (m/s)

\( \ifmmode\expandafter\bar\else\expandafter\=\fi{V} \) :

Time averaged voltage (V)

Δp :

Pressure difference between the liquid tank and surrounding atmosphere (Pa)

ΔP :

Amplitude of power time fluctuation (ΔP = I × ΔV) (kW)

ΔV :

Amplitude of voltage time fluctuation (V)

κ:

Plasma thermal conductivity (W/m K)

κd :

Pass or deposited layer thermal conductivity (W/m K)

κs :

Substrate or already deposited layers thermal conductivity (W/m K)

ρ:

Plasma specific mass (kg/m3)

ρA :

Specific mass of atomizing gas (kg/m3)

ρℓ :

Liquid specific mass (kg/m3)

σℓ :

Surface tension of liquid (N/m)

τf :

Drop or droplet fragmentation time (s)

τvℓ :

Drop or droplet vaporization time (s)

ALR:

Atomizing gas/liquid mass ratio (−)

CCD:

Charge-Coupled-Device

CEA:

Commissariat à 1’ Energie Atomique

dc:

Direct current

DTA:

Differential thermal analysis

EB PVD:

Electron beam physical vapor deposition

HA:

Hydroxyapatite

i.d.:

Internal diameter

LSCM:

La0.75Sr0.25Cr0.5Mn0.5O3

RF:

Radio frequency

SDC:

Samarium doped cerium

slm:

Standard liter per minute

SMD:

Sauter mean diameter (m)

SOFC:

Solid oxide fuel cell

SPCTS Laboratory:

«Science des Procédés Céramiques et Traitement de Surface» (Science of ceramic and surface treatment processes), University of Limoges, France

SPPS:

Solution precursor plasma spray

TBC:

Thermal barrier coating

TGA:

Thermo gravimetric analysis

YSZ:

Yttrium stabilized zirconia

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Authors and Affiliations

  1. SPCTS UMR 6638 CNRS, University of Limoges, Limoges, France

    P. Fauchais, R. Etchart-Salas, V. Rat & J.F. Coudert

  2. CEA le Ripault, DMAT/SDI/LPTH, Monts, France

    N. Caron & K. Wittmann-Ténèze

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  1. P. Fauchais
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  2. R. Etchart-Salas
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  3. V. Rat
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  4. J.F. Coudert
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  6. K. Wittmann-Ténèze
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Correspondence to V. Rat.

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Fauchais, P., Etchart-Salas, R., Rat, V. et al. Parameters Controlling Liquid Plasma Spraying: Solutions, Sols, or Suspensions. J Therm Spray Tech 17, 31–59 (2008). https://doi.org/10.1007/s11666-007-9152-2

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