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Predictive long-term control of a transient plasma spray process for the deposition of a yttria stabilized zirconia thermal barrier coating

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Identifier	Thesis 2101
Author	Spearin, Aaron Andrew, 1977-
Title	Predictive long-term control of a transient plasma spray process for the deposition of a yttria stabilized zirconia thermal barrier coating
Publisher	Central Connecticut State University
Date	2010
Resource Type	Master's Thesis
Notes	The purpose of these experiments was to determine the significant factors contributing to the variations in properties associated with a quality deposited plasma spray ceramic coating – to predictably control the inputs to air plasma spray processes to maintain consistent coatings throughout the life of a plasma gun. It was verified that coating gain is a function of deposit efficiency, traverse speed, number of spray passes, and powder feedrate. Deposit efficiency is a function of powder feedrate, voltage, gun hours, gun distance, amperage and argon flowrate. Powder feedrate and voltage are both transient due to powder hopper level and cathode deterioration, respectively. These transients translate to variations in coating gain. A drop in deposit efficiency may be offset by adjustments to amperage, argon flow, or hydrogen flow, the secondary plasma gas (a voltage adjustment). To a point where deposit efficiency drop cannot be compensated, coating gain can be adjusted by changes to traverse speed, number of spray passes, and powder feedrate. Post-finishing surface roughness is a function of traverse speed and other plasma spray inputs, not solely dependent on surface finishing operations. Quality microstructure is a function of gun distance, powder feedrate, voltage, argon flow, and amperage. Over the life of a plasma gun, adjustments to these inputs need to create a balance between process efficiency, thickness gain, microstructure, and surface roughness. To date, no single broad mathematical model fully describes the impact of these inputs. Once the future work is complete and this model is created, predictive plasma spray process control is likely.
Subject	Coatings -- Thermal properties Plasma spraying Process control
Department	Department of Engineering Technology
Advisor	Baumann, Peter F.
Type	Text
Digital Format	application/pdf
Language	eng
OCLC number	696193991
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Predictive long-term control of a transient plasma spray process for the deposition of a yttria stabilized zirconia thermal barrier coating

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