<p>Most thermal spray coating processes can be divided into three sub-processes; substrate surface preparation, the thermal spray operation and a post-coating surface finishing operation such as honing or grinding. Reliable and robust surface preparation is needed to guarantee maximum coating adhesion to substrates. Traditionally, the grit blasting process is used for surface preparation of materials receiving a thermal spray coating. However, in high volume production, the reproducibility of surface topography decays with time as grit particles are recycled through surface preparation operation. The focus of this project is to enhance the coating's ability to adhere to an aluminum substrate by incorporating high pressure water jet as a surface preparation operation. </p> <p>Water pressure, standoff distance, number of orifices, orifice size and rotation speed are process parameters identified as having an effect on surface roughness and coating adhesion strength. Through classical statistical analysis, main effects as well as 2 and 3 factor interactions are revealed and studied.</p> <p>A direct and significant relationship exists between water pressure, standoff distance and number of orifices. Correlation exists among adhesion strength and surface roughness parameters Ra, Rq and Rtm, respectively. Recommendations are made for further investigation into reducing water pressure and rotation speed requirements while sustaining the same level of surface modification.</p> / Master of Science

An examination of parameters affecting the control of a jet vectoring technique used in the Coanda-assisted Spray Manipulation (CSM) is presented. The CSM makes use of an enhanced Coanda effect on axisymmetric geometries through the interaction of a high volume primary jet flowing through the center of a collar and a secondary high-momentum jet parallel to the first and adjacent to the convex collar. The control jet attaches to the convex wall and vectors according to known Coanda effect principles, entraining and vectoring the primary jet, resulting in controllable r-θ directional spraying. Several control slots (both annular and unique sizes) and expansion radii were tested over a range of momentum flux ratios to determine the effects of these variables on the vectored jet angle and profile. Two- and three-component Particle Image Velocimetry (PIV) was used to determine the vectoring angle and the profile of the primary jet in each experiment. The experiments show that the control slot and expansion radius, along with the momentum ratios of the two jets, predominantly affected the vectoring angle and profile of the primary jet. The Reynolds number range for the primary jet at the exit plane was between 20,000 and 80,000. The flow was in the incompressible Mach number range (Mach< 0.3).

Master‘s thesis deals with the forming of hypereutectic aluminium alloys using sacrificial coatings. Literature research is focused on analysing the characteristics of aluminium and its alloys. Attention is also focused to the heat treatment of aluminium alloys and the influence of alloying elements on these alloys. Analysis of characteristics and increase the useful properties of Al - Ni alloys is another object of literary research. Attention is also focused to the analysis of thermal spraying methods by focusing on the principle of individual methods and the characteristics of the coatings made by these methods. The object of experimental part is to prepare the hypereutectic aluminium alloys using sacrificial nickel based coatings. This is an unconventional manufacturing process comprising coating the surface of the aluminium substrate with using HVOF technology and subsequent thermal exposure. Furthermore, the work deals with the metallographic evaluation of prepared samples with a particular focus on the influence of temperature and time of heat treatment on the final structure of the experimental samples.

Cerium oxide (Ceria) at nano scale has gained significant attention due to its numerous technological applications. Ceria in both doped and undoped forms are being explored as oxygen sensor, catalysis, protective coating against UV and corrosion, solid oxide fuel cell (SOFC) electrolyte and newly discovered antioxidant for biomedical applications. Therefore, there is an imminent need of a technology which can provide a cost effective, large scale manufacturing of nanoceria and its subsequent consolidation, specially using thermal spray. This dissertation aims to develop a scientific understanding towards the development of pure and doped ceria- based coating for a variety of technological applications, from SOFC applications to corrosion resistant coating. Atmospheric plasma spray (APS) and solution precursor plasma spray (SPPS) techniques for the fabrication of nano ceria coating were investigated. For feedstock powder preparation, a spray drying technique was used for the agglomeration of cerium oxide nano particles to achieve high density coating. Deposition efficiencies and coating porosity as a function of processing parameters were analyzed and optimized using a statistical design of experiment model. The coating deposition efficiency was dependent on the plasma temperature and vaporization pressure of the ceria nanoparticles. However, low standoff distance and high carrier gas flow rate were responsible for the improved density upto 86 [plus or minus] 3%.An alternative novel SPPS technique was studied for a thin film of cerium oxide deposition from various cerium salt precursors in doped and undoped conditions. The SPPS process allows controlling the chemistry of coating at a molecular level. The deposition mechanism by single scan experiments and the effect of various factors on coating microstructure evolution were studied in terms of splats formation. It was found that the precursor salt (nitrate of cerium) with lower thermal decomposition temperatures was suitable for a high density coating. The high concentration and low spray distance significantly improve the splat morphology and reduced porosity (upto 20%). The feasibility of the trivalent cations (Sm 3+ and Gd 3+) doping into cerium oxide lattice in high temperature plasma was discussed and experimentally studied. XRD analysis revealed the nano crystalline characteristic of the coating and lattice expansion due to doping. The extensive transmission electron microscopy, Scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy and thermo gravimetric were conducted to evaluate the precursors, and coating microstructure. Due to facial switching between Ce4+ and Ce3+ oxidation state, the cerium oxide surface becomes catalytically active. Thus, the APS ceria coatings were investigated for their applicability under extreme environmental conditions (high pressure and temperature). The air plasma sprayed coated 17-4PH steel was subjected to high pressure (10 Kpsi) and temperature (300 oF) corrosive environment. The coated steel showed continuous improvement in the corrosion resistance at 3.5 wt% NaCl at ambient temperature for three months study whereas, high pressure did not reveal a significant role in the corrosion process, and however, one needs to do further research. The ceria coated steel also revealed the improvement in corrosion protection (by 4 times) compared to the bare steel at low pH, 300 oF and 4000 Psi environment. This study projects the importance of cerium oxide coatings, their fabrication, optimization and applications.

Metallic plasma sprayed coatings are widely used in the aerospace industry for repair on worn engine components. However, the inherent defects in these coatings limit the variety of repairs and reduce the service life of the repaired parts. A potential solution to overcome this problem is to mix small amounts of inexpensive graphene oxide in the powder feedstock. The incredible strength to weight ratio of graphene oxide makes it a viable additive to improve mechanical properties of metallic plasma sprayed coatings. The powder system chosen for this research is Nickel-5Aluminum since it is a common coating for such repairs. The greatest challenge was retaining graphene oxide, which combusts at 400°C, while melting the Nickel above 1450°C using a high temperature plasma plume. Graphene oxide was successfully retained in the coatings using either of two configurations: (1) Injecting the graphene oxide powder via solution suspension separately from the metal powder, or (2) Installing a shroud on the front of the plasma gun and backfilling with Argon to inhibit combustion. The uniquely designed solution suspension configuration resulted in a higher deposition efficiency of graphene oxide while the inert shroud configuration had a more homogeneous distribution and retention of graphene oxide in the coatings. The best overall coating was achieved using the inert shroud configuration using a powder mixture containing 2% weight Edge Functionalized Graphene Oxide. Vickers microhardness increased 46% and tensile adhesion strength increased 26% over control samples. This is possible due to the mechanisms of dislocation strengthening and stress transfer previously reported in graphene oxide reinforced Aluminum composites formed by flake powder metallurgy. It was also observed that the energy released by the combustion of graphene oxide helps to uniformly melt the Nickel particles and improve the coating microstructure, allowing for more forgiving spray parameters. The methods developed and results attained in this research open opportunities for graphene oxide to be added as inexpensive reinforcements to other metallic compositions for widespread use in metal matrix composite manufacturing.

Surface engineering is increasingly becoming inevitable for meeting the high-performance requirements constantly expected from modern engineering components. Higher demands for combined functionalities, which a base material alone cannot provide, motivate intensive academic studies on various types of coatings, with the ultimate objective of their practical utilisation in industries. Especially the study of wear has become of critical importance for the industry development of new components, as wear-related mechanisms frequently compromise the durability and reliability of machines. Consequently, the need for effective wear control has become progressively vital in pursuing advanced and dependable technology for the future. Different coating technologies are being developed to forestall the wear of engineering components. More specifically, the thermal spraying technique of atmospheric plasma spraying (APS) has been proven particularly efficient in implementing thick film coating for aeronautic, automotive and medical applications. However, advanced coatings are required for improved performance and extended durability in harsh operating environments. These developments have stimulated research on developing novel coating through optimised deposition parameters and modified feedstock characteristics to achieve a more redefined microstructure. The primary scope of the research associated with this thesis is to target the study and research of plasma-sprayed ceramic coatings designed to provide exceptional wear resistance to targeted components as well as improved mechanical properties. The presented work involves an investigation of varying feedstock powder particle-size distributions, different coating chemistries and comparing the suspension plasma injection technology to its more traditional powdered feedstock variant. The result obtained suggested that the influence of powder-size particles affects the resultant microstructure with a finer composition, denoted by a lower porosity of 1.3% compared to the coarser powder fed 1.9% (both presenting a standard deviation of 0.2%). However, it could be seen that both the presence of optimised spraying parameters and finer feedstock particles were significant in obtaining improved mechanical properties. Furthermore, an examination of the powder-fed coating revealed slightly improved hardness properties to the newly developed suspension-sprayed samples. However, the powder-fed coatings distinctly exhibited superior resistance to sliding wear with an average specific wear of 5.7 (± 0.9 standard deviation) compared to the 12.8 (± 1 standard deviation) × 10-6 mm3∙N-1∙m-1of suspension-based coatings. In conclusion, it was observed that the chemical composition of the alumina-chromia composite coating demonstrated exceptional hardness properties among the analysed samples (1603 Vicker Hardness 0.2) and superior sliding wear resistance (0.59 × 10-6mm3∙N-1∙m-1).

This research investigates the efficacy of liquid-precursor thermal spray coating (TSC) as a facile wood modification technique to bring hydrophobicity and UV durability to a wooden surface. The technique was successful in depositing Cu and TiO2 particles onto southern yellow pine (SYP) veneers by using copper azole, copper quaternary, and titanium tetraisopropoxide as the precursor solutions. Using optimized settings, the average coating surface coverage of > 90% and an average coating thickness of > 5 μm were obtained. The coatings displayed up to 4H rating in the film hardness scale and up to 3B rating in adhesion strength scale, suggesting reasonable mechanical durability under mild mechanical abrasion. TSC-modified wood with TiO2 created a water repellent layer, yielding a significant increase in hydrophobicity that changed the water contact angle from 57° to 126°. Accelerated weathering test results showed that the TSC-modified wood was more resistant to discoloration compared to unmodified wood.

No description available.

Thermal spray coatings offer new alternatives in the production of electronic power modules that use alumina ceramic as an isolation layer. Current processes use direct bond copper (DBC) soldered to a nickel plated copper heat spreader. A coefficient of thermal expansion (CTE) mismatch exists between copper and alumina and leads to reliability issues that arise due to product failure during thermal cycling and lifetime operation. The substitution of an AlSiC metal matrix composite (MMC) heat spreader baseplate addresses the problem of CTE mismatch and will reduce the number of product failures related to cracking and delamination caused by this pronounced mismatch in the thermal expansion coefficient.. The substitution of an AlSiC (MMC) heat spreader baseplate also allows the production process to be achieved with a fewer number of metallization layers. Thermal spray can apply alumina ceramic coatings directly to the AlSiC (MMC) baseplates. A reduction in process steps will lead to a reduction in manufacturing costs, the main driving objective in Microelectronics Industries. Thermal spray coatings have a major problem since they have a porous microstructure which can trap undesired moisture. The moisture basically causes the coatings to have a lower dielectric breakdown voltage and a higher leakage current at normal operating voltages. This problem can be eliminated by manufacturing the electronic power modules in a controlled environment and packaging the devices in a hermetically sealed package. This thesis analyzes the data obtained from direct-voltage dielectric breakdown and direct-voltage leakage current tests conducted on coupons manufactured using the thermal plasma spray coating process and the thermal high-velocity oxyfuel (HVOF) coating process. ASTM specifications defining appropriate testing procedures are used in testing the dielectric strength of these coupons. Issues relating to the dielectric strength and dielectric leakage current are evaluated and validated at the Microelectronics Laboratory at Virginia Polytechnic Institute & State University. The objective to conduct this research study using plasma and HVOF alumina coatings as dielectric isolation layers is to support the Microelectronics Industries in developing a product with increased reliability at a lower manufacturing cost. / Master of Science

Les procédés de photodégradation, de conversion photocatalytique du CO2 et la technologie des supercondensateurs représentent des options intéressantes pour palier aux problèmes environnementaux et pour apporter des réponses à la crise énergétique. Dans ces trois domaines, les matériaux à base d'oxydes métalliques sont très prometteurs. Cependant, les voies classiques (c'est-à-dire par voies hydrothermales ou de sol-gels) présentent un certain nombre d’inconvénients tels que leur longues durées de préparation et leurs rendements limités. En outre, la mise en oeuvre de nanopoudres suppose une opération de post-filtration dans les procédés de photodégradation et l’utilisation supplémentaire d’un liant dans la confection d’électrodes de supercondensateurs, ce qui non seulement réduit les performances respectives de ces deux procédés mais entrave également leur développement au niveau industriel. Dans cette thèse, les technologies SPPS (Solution Precursor Plasma Spray) et SPFS (Solution Precursor Flame Spray) ont été introduites pour préparer des films d'oxydes métalliques à base de ZnO, en bénéficiant des avantages de rapidité et simplicité de ces techniques de formation de dépôts. Les films ainsi obtenues ont ensuite été testés dans des expériences de photodégradation, de conversion photocatalytique du CO2 et sous forme de supercondensateurs. Tout d'abord, à notre connaissance, c'est la première fois que l'on synthétise directement des nanostructures de ZnO (par exemple des nanotubes ou des nanofils) par des procédés SPPS. Ces films nanostructurés et hiérarchisés présentent non seulement une croissance préférentielle le long du plan cristallin (002), mais contiennent aussi des lacunes d'oxygène dans leurs réseaux. La mise en œuvre de simulations DFT a permis de proposer un mécanisme possible de croissance des nanostructures de ZnO lors de leur synthèse par la voie SPPS. Deuxièmement, divers films “composites”, constitués de ZnO et d’un second oxide “MO” ont également été préparés par SPPS afin de réduire les bandes d'énergie interdites. Dans cette partie de la thèse, nous avons étudié l’effet du rapport molaire MO/ZnO sur la structure des films MO/ZnO obtenus (M = Mn et Cu); nous avons aussi préparé, par cette nouvelle méthode, des films fins CuO/ZnO et CeO2/ZnO ainsi que des films de ZnO “décorés”. Troisièmement, des films mettant en œuvre des structures du type spinelle (tels que les oxydes mixtes ZnFe2O4, NiCo2O4, ZnCo2O4 et Co3O4) ont également été synthétisés et déposés à l’aide des techniques SPPS et SPFS, ceci en raison de leur grand intérêt pour les applications susmentionnées. Il a été constaté que les structures obtenues sont très sensibles aux rapports MO/ZnO et que les morphologies de surface dépendent davantage des paramètres d'injection des solutions. En outre, la puissance de la torche joue un rôle plus critique dans la synthèse in situ de la phase spinelle binaire que la température de préchauffage du substrat. Enfin, la voie de préparation par SPPS favorise la formation de dépôts de textures floconneuses, notamment dans le cas des films de NiCo2O4 et Co3O4, tandis que des particules de formes sphériques ont été plutôt observées dans les échantillons préparés par la voie SPFS... / The fields of research dealing with photodegradation, photocatalytic conversion of CO2 and supercapacitors are important to address environmental problems and respond to the energy crisis. Metal oxides are promising materials in these three domains. However, the conventional routes (i.e. hydrothermal, sol-gel) suffer from major deficiencies, namely their multi-step natures, their long preparation duration and small-scaled yields. Moreover, the usage of nanopowders implies a post-filtration operation at the end of the photodegradation processes and requires an additional binder in supercapacitor electrodes. In this thesis, “Solution Precursor Plasma Spray” (SPPS) and “Solution Precursor Flame Spray” (SPFS) technologies have been introduced to develop metal oxide films in view of the three aforementioned applications, benefiting from the facility and rapidity advantages of this one-step process.Firstly, to our best knowledge, it is the first time that films composed by ZnO nanostructures (e.g. nanorods, nanowires) are directly synthesized via a SPPS process. These hierarchical ZnO nanostructured films not only exhibit preferential orientation growth along the (002) crystal plane, but also feature in-situ oxygen vacancies. As a result, a possible growth mechanism of ZnO nanostructures via SPPS route was proposed.Secondly, various metal oxides composite films containing ZnO and a second metal oxide were also prepared by SPPS in an effort to narrow the energy bandgaps. In this work, not only the effect of the molar CuO/ZnO and MnO/ZnO ratio was investigated, but also laminated CuO/ZnO and CeO2/ZnO films and CuO, Co3O4 and Fe2O3 decorated ZnO nanorods films were pioneeringly deposited via this novel route.Thirdly, films involving spinel-type materials (including ZnFe2O4, NiCo2O4, ZnCo2O4 and Co3O4) were also synthesized and deposited by the SPPS and SPFS technologies, owing to their high-interest in the aforementioned applications. We found that the phase compositions are more sensitive to the Fe/Zn and Ni/Co ratios and that the surface morphologies are more dependent on the patterns of the solution injection. In addition, the power of the torch plays a more critical role on the in-situ synthesis of binary spinel phase. Besides, the SPPS route promotes the formation of flake-like particles both in the NiCo2O4 and Co3O4 films, while sphere-like particles were observed in the SPFS-prepared samples.Finally, some as-prepared films were selected to evaluate their performances within the three applications. On the one hand, Orange II was successfully (100%) degraded within 2h under UV irradiation and about 85% was removed within 6h under visible light irradiation. On the other hand, Co3O4 samples exhibited specific capacitances up to 1190 F g−1 with a retention capacity of 136% after 2500 cycles at a 20 mV/s scanning rate in 2 M KOH electrolyte. Finally, when using ZnCo2O4 as photocatalyst, CO2 was converted into CO by visible light irradiation with a maximum turnover number as high as 61.38 and a selectivity as high as 90.5 %.Overall, this work not only improves the performances of the three studied processes thanks to the use of novel, fast preparation methods, but also suggests that “Solution Precursor Thermal Spray” should be a highly promising technology for further, alternative functional applications that involve finely structured metal oxides film.