Powder Loading Effects of Yttria-Stabilized Zirconia in Atmospheric dc Plasma Spraying
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Powder loading effects have been reexamined for various yttria-stabilized zirconia powders under atmospheric dc plasma spraying. A laser illumination method was utilized to observe powder injection into the plasma jet, while single particle and ensemble methods to measure particle state parameters. Statistical temperature distributions of in-flight particles suggested a rapid increase in the number of semi-molten particles above a certain powder loading rate. Despite drops in the particle temperature and velocity due to the powder loading effect, the deposition efficiency tends to have increased in some cases. Reliability of the single particle and ensemble methods has also been examined at various powder feed rates. Particle temperature measurement by the ensemble method at low powder feed rates could cause a significant error, which may affect powder injection optimization. Particle plume trajectory was not affected as much by the powder loading, which hence had only a limited effect on the particle diagnostics.
KeywordsPlasma spraying Loading effects Diagnostics Particle state parameters Temperature distribution
This work is supported by the GOALI-FRG program sponsored by the U.S. National Science Foundation under award CMMI 0605704. Support through the Industrial Consortium for Thermal Spray Technology is gratefully acknowledged. The experimental work regarding the high power conditions utilizing a Triplex Pro-200 plasma torch was conducted at Sulzer Metco. Powder injection was observed with the help of Mr. Daniel Crawford, Control Vision Inc. We also would like to thank Mr. Travis Wentz and Dr. Vasudevan Srinivasan for their help in the spray experiments and Mr. Jose R. Colmenares-Angulo for useful discussion on the sensors. We also appreciate Dr. Christian Moreau, National Research Council Canada, for his valuable comment on the single particle measurement at high powder feed rates.
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