NDLI: Splat Morphology and Influence of Feeding Rate During Reactive Plasma Spray of Aluminum Powder

Content Provider	Springer Nature Link
Author	Shahien, Mohammed Yamada, Motohiro Fukumoto, Masahiro
Copyright Year	2016
Abstract	Fabrication of aluminum nitride (AlN) coatings using conventional plasma spraying processes directly has been deemed impossible. It is attributed to the thermal decomposition of the AlN feedstock particles during spraying without a stable melting phase. Using the reactivity of the plasma (reactive plasma spraying: RPS) showed a promising consideration for in situ formation of AlN thermally sprayed coatings. Several AlN-based coatings were fabricated through the RPS of aluminum powders in the N$_{2}$/H$_{2}$ plasma. The focus of this study is in discussing the morphology of splat deposition during the nitriding of Al particles. Furthermore, the influence of the feeding rate during the RPS and nitriding of Al powders will be investigated. The nitride content, as well as the unreacted molten Al phase, strongly influences splat deposition and morphology during the RPS of Al. The collected splats can be divided into reacted, partially reacted, and unreacted splats. The reacted splats tend to show a disk or egg-shell shape. The partially reacted mainly had outside nitride shells and an unreacted molten Al part in the center. The unreacted splats tended to show a splash shape. The main controlling factor is the time of the droplet impact on the substrate during the reaction sequence. The particle size and spray distance showed significant effects on the splat formation due to their effect on the nitriding conversion and the melting behavior of the particles during RPS nitriding. The powder feeding rate was investigated through increasing the injection rate and by using a low carrier gas flow rate. Increasing the powder feeding rate significantly improved the coating thickness. However, it suppressed the nitriding conversion of the large Al particles. Thus, with increasing the amount of the powder in the plasma, the Al molten particles are easily aggregated and agglomerate together upon colliding on the substrate with an AlN shell on the surface. This prevents the N$_{2}$ from having access to all of the aggregated particles. Therefore, the fabricated coatings using large Al particles consist of surface AlN layers and the central parts of AlN and Al composite layers. On the other hand, it was possible to fabricate about 500-μm-thick AlN coatings using fine Al particles of 15 μm and increasing the feeding rate. Using the fine particles improved the nitriding reaction due to the improvement of the surface area (the reaction area). Moreover, the nitriding process of the Al particles with increasing the feeding rate was also investigated.
Starting Page	1490
Ending Page	1501
Page Count	12
File Format	PDF
ISSN	10599630
Journal	Journal of Thermal Spray Technology
Volume Number	25
Issue Number	8
e-ISSN	15441016
Language	English
Publisher	Springer US
Publisher Date	2016-05-12
Publisher Place	New York
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	aluminum powder particle size powder feeding rate reactive plasma spray splat morphology Surfaces and Interfaces, Thin Films Tribology, Corrosion and Coatings Characterization and Evaluation of Materials Operating Procedures, Materials Treatment Analytical Chemistry
Content Type	Text
Resource Type	Article
Subject	Surfaces, Coatings and Films Materials Chemistry Condensed Matter Physics

Sl.	Authority	Responsibilities	Communication Details
1	Ministry of Education (GoI), Department of Higher Education	Sanctioning Authority	https://www.education.gov.in/ict-initiatives
2	Indian Institute of Technology Kharagpur	Host Institute of the Project: The host institute of the project is responsible for providing infrastructure support and hosting the project	https://www.iitkgp.ac.in
3	National Digital Library of India Office, Indian Institute of Technology Kharagpur	The administrative and infrastructural headquarters of the project	Dr. B. Sutradhar bsutra@ndl.gov.in
4	Project PI / Joint PI	Principal Investigator and Joint Principal Investigators of the project	Dr. B. Sutradhar bsutra@ndl.gov.in Prof. Saswat Chakrabarti will be added soon
5	Website/Portal (Helpdesk)	Queries regarding NDLI and its services	support@ndl.gov.in
6	Contents and Copyright Issues	Queries related to content curation and copyright issues	content@ndl.gov.in
7	National Digital Library of India Club (NDLI Club)	Queries related to NDLI Club formation, support, user awareness program, seminar/symposium, collaboration, social media, promotion, and outreach	clubsupport@ndl.gov.in
8	Digital Preservation Centre (DPC)	Assistance with digitizing and archiving copyright-free printed books	dpc@ndl.gov.in
9	IDR Setup or Support	Queries related to establishment and support of Institutional Digital Repository (IDR) and IDR workshops	idr@ndl.gov.in

Challenges Upon Reactive Plasma Spray Nitriding: Al Powders and Fabrication of AlN Coatings as a Case Study

Effect of particle morphology on flow characteristics of a composite plasma spray powder

Influence of NH$_{4}$Cl Powder Addition for Fabrication of Aluminum Nitride Coating in Reactive Atmospheric Plasma Spray Process

Reactive Atmospheric Plasma Spraying of AlN Coatings: Influence of Aluminum Feedstock Particle Size

Experimental study of particle deposition characteristics of alumina using plasma spraying

Effects of Substrate Roughness on Splat Formation for Ni-Cr Particles Plasma Sprayed onto Aluminum Substrates

Particle characterization and splat formation of plasma sprayed zirconia

Mathematical Modeling and Numerical Simulation of Splat Cooling in Plasma Spray Coatings

Al-SiC powder preparation for electronic packaging aluminum composites by plasma spray processing

Splat Morphology and Influence of Feeding Rate During Reactive Plasma Spray of Aluminum Powder

Similar Documents

Challenges Upon Reactive Plasma Spray Nitriding: Al Powders and Fabrication of AlN Coatings as a Case Study

Effect of particle morphology on flow characteristics of a composite plasma spray powder

Influence of NH$_{4}$Cl Powder Addition for Fabrication of Aluminum Nitride Coating in Reactive Atmospheric Plasma Spray Process

Reactive Atmospheric Plasma Spraying of AlN Coatings: Influence of Aluminum Feedstock Particle Size

Experimental study of particle deposition characteristics of alumina using plasma spraying

Effects of Substrate Roughness on Splat Formation for Ni-Cr Particles Plasma Sprayed onto Aluminum Substrates

Particle characterization and splat formation of plasma sprayed zirconia

Mathematical Modeling and Numerical Simulation of Splat Cooling in Plasma Spray Coatings

Al-SiC powder preparation for electronic packaging aluminum composites by plasma spray processing

Splat Morphology and Influence of Feeding Rate During Reactive Plasma Spray of Aluminum Powder