Search results for: cold spray coating

Authors: T. S. Sidhu

Abstract:

Amongst the existing coatings methods, the cold spray is new upcoming process to deposit coatings. As from the name itself, the cold spray coating takes place at very low temperature as compare to other thermal spray coatings. In all other thermal spray coating process the partial melting of the coating powder particles takes place before deposition, but cold spray process takes place in solid state. In cold spray process, the bonding of coating power with substrate is not metallurgical as in other thermal spray processes. Due to supersonic speed and less temperature of spray particles, solid state, dense, and oxide free coatings are produced. Due to these characteristics, the cold spray coatings have been used to protect the materials against hot corrosion. In the present study, the cold spray process, cold spray fundaments, its types, and its applications for high temperatures are discussed in the light of presently available literature. In addition, the assessment of cold spray with the competitive technologies has been conferred with available literature.

Keywords: cold spray coating, hot corrosion, thermal spray coating, high-temperature materials

Procedia PDF Downloads 204

Authors: Harminder Singh

Abstract:

Cold spray is a novel and emerging technology for the fabrication of coating. In this study, coating is successfully developed by this process on superalloy surface. The selected coating composition is already proved as corrosion resistant. The microstructure of the newly developed coating is examined by various characterization techniques, for testing its suitability for high temperature corrosive conditions of waste incinerator. The energy producing waste incinerators are still running at low efficiency, mainly due to their chlorine based highly corrosive conditions. The characterization results show that the developed cold sprayed coating structure is suitable for its further testing in highly aggressive conditions.

Keywords: coating, cold spray, corrosion, microstructure

Procedia PDF Downloads 350

Authors: Nazanin Sheibanian, Raffaella Sesana, Sedat Ozbilen

Abstract:

In recent years, high-entropy alloys (HEAs) have attracted considerable attention due to their unique properties and potential applications. In this study, novel HEA coatings were prepared on Mg substrates using mechanically alloyed HEA powder feedstocks based on Al_(0.1-0.5)CoCrCuFeNi and MnCoCrCuFeNi multi-material systems. The coatings were deposited by the Cold Spray (CS) process using three different temperatures of the process gas (N2) (650°C, 750°C, and 850°C) to examine the effect of gas temperature on coating properties. In this study, Infrared Thermography (non-destructive) was examined as a possible quality control technique for HEA coatings applied to magnesium substrates. Active Thermography was employed to characterize coating properties using the thermal response of the coating. Various HEA chemical compositions and deposition temperatures have been investigated. As a part of this study, a comprehensive macro and microstructural analysis of Cold Spray (CS) HEA coatings has been conducted using macrophotography, optical microscopy, scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM+EDS), X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), microhardness tests, roughness measurements, and porosity assessments. These analyses provided insight into phase identification, microstructure characterization, deposition, particle deformation behavior, bonding mechanisms, and identifying a possible relationship between physical properties and thermal responses. Based on the figures and tables, it is evident that the Maximum Relative Radiance (∆RMax) of each sample differs depending on both the chemical composition of HEA and the temperature at which Cold Spray is applied.

Keywords: active thermography, coating, cold spray, high- entropy alloy, material characterization

Procedia PDF Downloads 42

Authors: Jana Petrů, Tomáš Zlámal, Robert Čep, Lenka Čepová

Abstract:

This article is focused on the thermal spray coating machining issue. Those are irreplaceable in many areas of nowadays industrial branches such as aerospace industry, mostly thanks to their excellent qualities in production and also in renovation of machinery parts. The principals of thermal spraying and elementary diversification are described in introduction. Plasma coating method of composite materials -cermets- is described more thoroughly. The second part describes thermal spray coating machining and grinding in detail. This part contains suggestion of appropriate grinding tool and assessment of cutting conditions used for grinding a given part. Conclusion describes a problem which occurred while grinding a cermet thermal spray coating with a specially designed grindstone and a way to solve this problem.

Keywords: coating, aerospace, plasma, grinding

Procedia PDF Downloads 516

Authors: Ionel Botef

Abstract:

Studies show that, for qualitative coatings, the knowledge of cold spray technology must focus on a variety of interdisciplinary fields and a framework for problem solving. The integrated disciplines include, but are not limited to, engineering, material sciences, and physics. Due to its importance, the purpose of this paper is to summarize the state of the art of this technology alongside its theoretical and experimental studies, and explore the role and impact of physics upon cold spraying technology.

Keywords: surface engineering, cold spray, physics, modelling

Procedia PDF Downloads 501

Authors: Raffaella Sesana, Nazanin Sheibanian, Luca Corsaro, Sedat Özbilen, Rocco Lupoi, Francesco Artusio

Abstract:

High Entropy Alloy (HEA) coatings of Al0.1-0.5CoCrCuFeNi and MnCoCrCuFeNi on Mg substrates were prepared from mechanically alloyed HEA powder feedstocks and at three different Cold Spray (CS) process gas (N2) temperatures (650, 750 and 850°C). Mechanically alloyed and cold-sprayed HEA coatings were characterized by macro photography, OM, SEM+EDS study, micro-hardness testing, roughness, and porosity measurements. As a result of mechanical alloying (MA), harder particles are deformed and fractured. The particles in the Cu-rich region were coarser and more globular than those in the A1 phase, which is relatively soft and ductile. In addition to the A1 particles, there were some separate Cu-rich regions. Due to the brittle nature of the powder and the acicular shape, Mn-HEA powder exhibited a different trend with smaller particle sizes. It is observed that MA results in a loose structure characterized by many gaps, cracks, signs of plastic deformation, and small particles attached to the surface of the particle. Considering the experimental results obtained, it is not possible to conclude that the chemical composition of the high entropy alloy influences the roughness of the coating. It has been observed that the deposited volume increases with temperature only in the case of Al0.1 and Mg-based HEA, while for the rest of the Al-based HEA, there are no noticeable changes. There is a direct correlation between micro-hardness and the chemical composition of a coating: the micro-hardness of a coating increases as the percentage of aluminum increases in the sample. Compared to the substrate, the coating has a much higher hardness, and the hardness measured at the interface is intermediate.

Keywords: characterisation, cold spraying, HEA coatings, SEM+EDS

Procedia PDF Downloads 30

Authors: Ionel Botef

Abstract:

Studies show that, for viable product realisation and maintenance, a spectrum of novel processing technologies and materials to improve performance and reduce costs and environmental impact must constantly be addressed. One of these technologies, namely the cold spray process, has enabled a broad range of coatings and applications, including many that have not been previously possible or commercially practical, hence its potential for new aerospace, electronics, or medical applications. Therefore, the purpose of this paper is to summarise the state of the art of this technology alongside its theoretical and experimental studies, and explore the role and impact of cold spraying on surface engineering.

Keywords: surface engineering, cold spray, ageing aircrafts, corrosion, microchannels, maintenance

Procedia PDF Downloads 578

Authors: Prashant Sharma, Jyotsna Dutta Majumdar

Abstract:

The present study concerns development of a composite thermal barrier coating consisting of a mixture of La2O3 and YSZ (with 8 wt.%, 32 wt.% and 50 wt.% 50% La2O3) by plasma spray deposition technique on a CoNiCrAlY based bond coat deposited on Inconel 718 substrate by high velocity oxy-fuel deposition (HVOF) technique. The addition of La2O3 in YSZ causes the formation of pyrochlore (La2Zr2O7) phase in the inter splats boundary along with the presence of LaYO3 phase. The coefficient of thermal expansion is significantly reduced from due to the evolution of different phases and structural defects in the sprayed coating. The activation energy for TGO growth under isothermal and cyclic oxidation was increased in the composite coating as compared to YSZ coating.

Keywords: plasma spraying, oxidation resistance, thermal barrier coating, microstructure, X-ray method

Procedia PDF Downloads 316

Authors: Dhanashree Aole, V. Hariharan, Swati Surushe

Abstract:

Corrosion can cause serious and expensive damage to the automobile components. Various proven techniques for controlling and preventing corrosion depend on the specific material to be protected. Electrochemical Impedance Spectroscopy (EIS) and salt spray tests are commonly used to assess the corrosion degradation mechanism of coatings on metallic surfaces. While, the only test which monitors the corrosion rate in real time is known as Linear Polarisation Resistance (LPR). In this study, electrochemical tests (EIS & LPR) and spray test are reviewed to assess the corrosion resistance and durability of different coatings. The main objective of this study is to correlate the test results obtained using linear polarization resistance (LPR) and Electrochemical Impedance Spectroscopy (EIS) with the results obtained using standard salt spray test. Another objective of this work is to evaluate the performance of various coating systems- CED, Epoxy, Powder coating, Autophoretic, and Zn-trivalent coating for vehicle underbody application. The corrosion resistance coating are assessed. From this study, a promising correlation between different corrosion testing techniques is noted. The most profound observation is that electrochemical tests gives quick estimation of corrosion resistance and can detect the degradation of coatings well before visible signs of damage appear. Furthermore, the corrosion resistances and salt spray life of the coatings investigated were found to be according to the order as follows- CED> powder coating > Autophoretic > epoxy coating > Zn- Trivalent plating.

Keywords: Linear Polarization Resistance (LPR), Electrochemical Impedance Spectroscopy (EIS), salt spray test, sacrificial and barrier coatings

Procedia PDF Downloads 490

Authors: B. Dikici, I. Ozdemir, M. Topuz

Abstract:

The corrosion behaviour of 316L stainless steel coatings obtained by cold spray method was investigated in this study. 316L powders were deposited onto Al5052 aluminum substrates. The coatings were produced using nitrogen (N₂) process gas. In order to further improve the corrosion and mechanical properties of the coatings, heat treatment was applied at 250 and 750 °C. The corrosion performances of the coatings were compared using the potentiodynamic scanning (PDS) technique under in-vitro conditions (in Ringer’s solution at 37 °C). In addition, the hardness and porosity tests were carried out on the coatings. Microstructural characterization of the coatings was carried out by using scanning electron microscopy attached with energy dispersive spectrometer (SEM-EDS) and X-ray diffraction (XRD) technique. It was found that clean surfaces and a good adhesion were achieved for particle/substrate bonding. The heat treatment process provided both elimination of the anisotropy in the coating and resulting in healing-up of the incomplete interfaces between the deposited particles. It was found that the corrosion potential of the annealed coatings at 750 °C was higher than that of commercially 316 L stainless steel. Moreover, the microstructural investigations after the corrosion tests revealed that corrosion preferentially starts at inter-splat boundaries.

Keywords: biomaterials, cold spray, 316L, corrosion, heat treatment

Procedia PDF Downloads 338

Authors: T. Zlámal, J. Petrů, M. Pagáč, P. Krajkovič

Abstract:

For the required function of components with the thermal spray coating, it is necessary to perform additional machining of the coated surface. The paper deals with assessing the surface integrity of Metco 2042, a plasma sprayed coating, after its machining. The selected plasma sprayed coating serves as an abradable sealing coating in a jet engine. Therefore, the spray and its surface must meet high quality and functional requirements. Plasma sprayed coatings are characterized by lamellar structure, which requires a special approach to their machining. Therefore, the experimental part involves the set-up of special cutting tools and cutting parameters under which the applied coating was machined. For the assessment of suitably set machining parameters, selected parameters of surface integrity were measured and evaluated during the experiment. To determine the size of surface irregularities and the effect of the selected machining technology on the sprayed coating surface, the surface roughness parameters Ra and Rz were measured. Furthermore, the measurement of sprayed coating surface hardness by the HR 15 Y method before and after machining process was used to determine the surface strengthening. The changes of strengthening were detected after the machining. The impact of chosen cutting parameters on the surface roughness after the machining was not proven.

Keywords: machining, plasma sprayed coating, surface integrity, strengthening

Procedia PDF Downloads 227

Authors: Ken Ninez Nurpramesti Prinindya, Yuli Setiyorini

Abstract:

Crown enclosure high temperature flares damaged and reduced dimensions crown. Generally crown on EHTF could have a life time up to twenty years. Therefore, this study aims to increase the value of thermal resistance with the effect post treatment on NiCr coated arc spray method. The variation of post treatment temperature, was at 650°C, 750°C, and 850°C. Morphology on the surface and the adhesion strength was analyzed by SEM-EDX, Surface Roughness and Pull - off test. XRD testing was conducted to determine the contained in NiCr coated. Thermal stability of NiCr coated was tested by DSC-TGA. The most optimal results was owned by NiCr coating with post treated at 850°C. It has good thermal stability until 1000°C because of Cr2O3 formation in coated specimen. The higher temperature of post treatment coating was showed better result on porosity and roughness surface value.

Keywords: Arc spray process, NiCr wire, post-treatment coating, high temperature-corrosion resistance

Procedia PDF Downloads 419

Authors: Hyeong-Jin Kim, Jong Kook Lee

Abstract:

Zirconia has biological, mechanical and optical properties, so, it used as a dental implant material in human body. But, it is difficult to form directly bonding with living tissues after the procedure and induces the falling away from implanted parts of the body. To improve this phenomenon, it is essential to increase the surface roughness of zirconia implants and induce a forming-ability of strong bonds. In this study, we performed a room temperature spray coating on zirconia specimen to obtain a highly roughened zirconia surface. To get optimal surface roughness, we controlled the distance between the nozzle and the substrate, coating times and powder condition. Bonding microstructure, surface roughness, and chemical composition of the coating layer were observed by SEM, XRD and roughness tester.

Keywords: implant, aerosoldeposition, zirconia, dental

Procedia PDF Downloads 181

Authors: Kazem Sabet-Bokati, Ilia Rodionov, Marciel Gaier, Kevin Plucknett

Abstract:

Protective coatings play a pivotal role in mitigating corrosion and preserving the integrity of metallic structures exposed to harsh environmental conditions. The diversity of corrosive environments necessitates the development of protective coatings suitable for various conditions. Accurately selecting and interpreting analysis methods is crucial in identifying the most suitable protective coatings for the various corrosive environments. This study conducted a comprehensive comparative analysis of traditional and advanced methods to assess the anti-corrosion performance of sacrificial and barrier coatings. The protective performance of pure epoxy, zinc-rich epoxy, and cold galvanizing coatings was evaluated using salt spray tests, together with electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization methods. The performance of each coating was thoroughly differentiated under both atmospheric and immersion conditions. The distinct protective performance of each coating against atmospheric corrosion was assessed using traditional standard methods. Additionally, the electrochemical responses of these coatings in immersion conditions were systematically studied, and a detailed discussion on interpreting the electrochemical responses is provided. Zinc-rich epoxy and cold galvanizing coatings offer superior anti-corrosion performance against atmospheric corrosion, while the pure epoxy coating excels in immersion conditions.

Keywords: corrosion, barrier coatings, sacrificial coatings, salt-spray, EIS, polarization

Procedia PDF Downloads 16

Authors: Amine Rezzoug, Said Abdi, Nadjet Bouhelal, Ismail Daoud

Abstract:

This paper investigates the application of metallic coatings on high fiber volume fraction carbon/epoxy polymer matrix composites. For the grip of the metallic layer, a method of modifying the surface of the composite by introducing a mixture of copper and steel powder (filler powders) which can reduce the impact of thermal spray particles. The powder was introduced to the surface at the time of the forming. Arc spray was used to project the zinc coating layer. The substrate was grit blasted to avoid poor adherence. The porosity, microstructure, and morphology of layers are characterized by optical microscopy, SEM and image analysis. The samples were studied also in terms of hardness and erosion resistance. This investigation did not reveal any visible evidence damage to the substrates. The hardness of zinc layer was about 25.94 MPa and the porosity was around (∼6.70%). The erosion test showed that the zinc coating improves the resistance to erosion. Based on the results obtained, we can conclude that thermal spraying allows the production of protective coating on PMC. Zinc coating has been identified as a compatible material with the substrate. The filler powders layer protects the substrate from the impact of hot particles and allows avoiding the rupture of brittle carbon fibers.

Keywords: arc spray, coating, composite, erosion

Procedia PDF Downloads 412

Authors: Yusuf Yılmaz, Kevser Dincer, Derya Saygılı

Abstract:

In this study, performance of PEMs was experimentally investigated. Coating on the cathode side of the PEMs fuel cells was accomplished with the spray method by using NaCaNiBO. A solution having 0,1 gr NaCaNiBO +10 mL methanol was prepared. This solution was taken out and filled into a spray. Then the cathode side of PEMs fuel cells was cladded with NaCaNiBO by using spray method. After coating, the membrane was left out to dry for 24 hours. The PEM fuel cells were mounted to the system in single, double, triple and fourfold manner in order to spot the best performance. The performance parameter considered was the power to current ratio. The best performance was found to occur at the 300th second with the power/current ratio of 3.55 Watt/Ampere and on the fourfold parallel mounting after the coating; whereas the poorest performance took place at the 210th second, power to current ratio of 0.12 Watt/Ampere and on the twofold parallel connection after the coating.

Keywords: nano-composites, proton exchange membranes, performance improvement, fuel cell

Procedia PDF Downloads 339

Authors: Abhijit Pattnayak, Abhijith N.V, Deepak Kumar, Jayant Jain, Vijay Chaudhry

Abstract:

Hard and dense ceramic coatings deposited on the surface provide the ideal solution to the poor tribological properties exhibited by some popular stainless steels like EN-36, 17-4PH, etc. These steels are widely used in nuclear, fertilizer, food processing, and marine industries under extreme environmental conditions. The present study focuses on the development of Al₂O₃-CeO₂-rGO-based coatings on the surface of 17-4PH steel using High-Velocity Oxygen Flame (HVOF) thermal spray process. The coating is developed using an oxyacetylene flame. Further, we report the physical (Density, Surface roughness, Surface energetics), Metallurgical (Scanning electron microscopy, X-ray diffraction, Raman), Mechanical (Hardness(Vickers and Nano Hard-ness)), Tribological (Wear, Scratch hardness) and Chemical (corrosion) characterization of both As-sprayed coating and the Substrate (17-4 PH steel). The comparison of the properties will help us to understand the microstructure-property relationship of the coating and reveal the necessity and challenges of such coatings.

Keywords: thermal spray process, HVOF, ceramic coating, hardness, wear, corrosion

Procedia PDF Downloads 54

Authors: Khalidou Ba, Abdelkrim Chahine, Mohamed Ebn Touhami

Abstract:

A strong industrial interest is focused on the development of coatings for anticorrosion protection. In this context, phosphate composite materials are expanding strongly due to their chemical characteristics and their interesting physicochemical properties. Sol-gel coatings offer high homogeneity and purity that may lead to obtain coating presenting good adhesion to metal surface. The goal behind this work is to develop efficient coatings for corrosion protection of steel to extend its life. In this context, a sol gel process allowing to obtain thin film coatings on carbon steel with high resistance to corrosion has been developed. The optimization of several experimental parameters such as the hydrolysis time, the temperature, the coating technique, the molar ratio between precursors, the number of layers and the drying mode has been realized in order to obtain a coating showing the best anti-corrosion properties. The effect of these parameters on the microstructure and anticorrosion performance of the films sol gel coating has been investigated using different characterization methods (FTIR, XRD, Raman, XPS, SEM, Profilometer, Salt Spray Test, etc.). An optimized coating presenting good adhesion and very stable anticorrosion properties in salt spray test, which consists of a corrosive attack accelerated by an artificial salt spray consisting of a solution of 5% NaCl, pH neutral, under precise conditions of temperature (35 °C) and pressure has been obtained.

Keywords: sol gel, coating, corrosion, XPS

Procedia PDF Downloads 101

Authors: Harjot Singh Gill, Neelkanth Grover, Jwala Parshad Singla

Abstract:

The main aim of this research work is to present the effect of coating on two different grades of grey cast iron using detonation spray method. Ni20Cr and Al2O3-13TiO2 powders were sprayed using detonation gun onto GI250 and GIHC substrates and the results as well as coating surface morphology of the coating is studied by XRD and SEM/EDAX analysis. The wear resistance of Ni20Cr and Al2O3-13TiO2 has been investigated on pin-on-disc tribometer using ASTM G99 standards. Cumulative wear rate and coefficient of friction (µ) were calculated under three normal load of 30N, 40N, 50N at constant sliding velocity of 1m/s. Worn out surfaces were analyzed by SEM/EDAX. The results show significant resistance to wear with Al2O3-13TiO2 coating as compared to Ni20Cr and bare substrates. SEM/EDAX analysis and cumulative wear loss bar charts clearly explain the wear behavior of coated as well as bare sample of GI250 and GIHC.

Keywords: detonation spray, grey cast iron, wear rate, coefficient of friction

Procedia PDF Downloads 337

Authors: Renu Kumari, Jyotsna Dutta Majumdar

Abstract:

In the present study, composite coating consisting of hydroxyapatite (HA) + 50 wt% TiO2 has been developed on Ti-6Al-4V substrate by plasma spray deposition technique. Followed by plasma spray deposition, detailed surface roughness and microstructural characterization were carried out by using optical profilometer and scanning electron microscopy (SEM), respectively. The composition and phase analysis were carried out by energy-dispersive X-ray spectroscopy analysis, and X-ray diffraction (XRD) technique, respectively. The bio-activity behavior of the uncoated and coated samples was also compared by dipping test in Hank’s solution. The average surface roughness of the coating was 10 µm (as compared to 0.5 µm of as-received Ti-6Al-4V substrate) with the presence of porosities. The microstructure of the coating was found to be continuous with the presence of solidified splats. A detailed XRD analysis shows phase transformation of TiO2 from anatase to rutile, decomposition of hydroxyapatite, and formation of CaTiO3 phase. Standard dipping test confirmed a faster kinetics of deposition of calcium phosphate in the coated HA+50% wt.% TiO2 surface as compared to the as-received substrate.

Keywords: titanium, plasma spraying, microstructure, bio-activity, TiO2, hydroxyapatite

Procedia PDF Downloads 284

Authors: Ionel Botef

Abstract:

Aerospace products operate in very aggressive environments characterized by high temperature, high pressure, large stresses on individual components, the presence of oxidizing and corroding atmosphere, as well as internally created or externally ingested particulate materials that induce erosion and impact damage. Consequently, during operation, the materials of individual components degrade. In addition, the impact of maintenance costs for both civil and military aircraft was estimated at least two to three times greater than initial purchase values, and this trend is expected to increase. As a result, for viable product realisation and maintenance, a spectrum of issues regarding novel processing technologies, innovation of new materials, performance, costs, and environmental impact must constantly be addressed. One of these technologies, namely the cold-gas dynamic-spray process has enabled a broad range of coatings and applications, including many that have not been previously possible or commercially practical, hence its potential for new aerospace applications. Therefore, the purpose of this paper is to summarise the state of the art of this technology alongside its theoretical and experimental studies, and explore how the cold-gas dynamic-spray process could be integrated within a framework that finally could lead to more efficient aircraft maintenance. Based on the paper's qualitative findings supported by authorities, evidence, and logic essentially it is argued that the cold-gas dynamic-spray manufacturing process should not be viewed in isolation, but should be viewed as a component of a broad framework that finally leads to more efficient aerospace operations.

Keywords: aerospace, aging aircraft, cold spray, materials

Procedia PDF Downloads 95

Authors: Ahmad Alazemi, M. Sherif El-Eskandrany, Mohamad Kishk, Thanyan AlOnaizi, Ahmad Alduweesh, Shorouq Abdullaleel

Abstract:

Arc melting technique followed by top-down approach, using a high-energy ball milling technique were employed to synthesize nanocrystalline of Cu50(Zr50-xNix)50 (x = 0, 10, 20 and 30 at.%) powder particles. The end-products of the alloy powders obtained after 50 h of the ball milling time were uniform in composition and had spherical-like morphology with an average particle size of 0.75 µm in diameter. The powders, which consisted of nanocrystalline grains with an average grain size of 10 nm in diameter, were used as feedstock materials for double face coating of stainless (SUS304) sheets, using cold spraying process. The coating materials enjoyed nanocrystalline structure and uniform composition. Biofilms were grown on 20-mm2 SUS304 sheets coated coupons inoculated with 1.5 × 108 CFU ml−1 E. coli. Significant biofilm inhibition was recorded in the nanoparticles coated coupons in comparison to non-coated SUS304 coupon. In conclusion, this study demonstrates that formation of biofilms can be significantly inhibited by Cu-based alloys especially in case of high (Ni) content. The inhibition of biofilm formation by nanocrystalline powders of Cu-based provides a practical approach to achieve the inhibition of biofilms formed by an emerging pathogen.

Keywords: biofilm, Cu, E.coli, FE-HRTEM/EDS, nanomaterials, nanocrystalline

Procedia PDF Downloads 394

Authors: Hyeongdo Jeong, Jong Kook Lee

Abstract:

Granule morphology and microstructure were affected by slurry viscosity, chemical composition, particle size and spray drying process. In this study, we investigated granule morphology of zirconia powder with solid content on two-fluid spray drying. Zirconia granules after spray drying show sphere-like shapes with a diameter of 40-70 μm at low solid contents (30 or 40 wt%) and specific surface area of 5.1-5.6 m²/g. But a donut-like shape with a few cracks were observed on zirconia granules prepared from the slurry of high solid content (50 wt %), green compacts after cold isostatic pressing under the pressure of 200 MPa have the density of 2.1-2.2 g/cm³ and homogeneous fracture surface by complete destruction of granules. After the sintering at 1500 °C for 2 h, all specimens have relative density of 96.2-98.3 %. With increasing a solid content from 30 to 50 wt%, grain size increased from 0.3 to 0.6 μm, but relative density was inversely decreased from 98.3 to 96.2 %.

Keywords: zirconia, solid content, granulation, spray drying

Procedia PDF Downloads 179

Authors: Asiful Hossain Seikh, Mohammad Asif Alam, Ubair Abdus Samad, Jabair A. Mohammed, S. M. Al-Zahrani, El-Sayed M. Sherif

Abstract:

In this current investigation, aliphatic amine-cured diglycidyl ether of bisphenol-A (DGEBA) based epoxy coating was mixed with certain weight % hardener polyaminoamide (1:2) and was coated on carbon steel panels with and without 1% nano crystalline Al powder. The corrosion behavior of the coated samples were investigated by exposing them in the salt spray chamber, for 500 hours. According to ASTM-B-117, the bath was kept at 35 °C and 5% NaCl containing mist was sprayed at 1.3 bars pressure. Composition of coatings was confirmed using Fourier-transform infrared spectroscopy (FTIR). Electrochemical characterization of the coated samples was also performed using potentiodynamic polarization technique and electrochemical impedance spectroscopy (EIS) technique. All the experiments were done in 3.5% NaCl solution. The nano Al coated sample shows good corrosion resistance property compared to bare Al sample. In fact after salt spray exposure no pitting or local damage was observed for nano coated sample and the coating gloss was negligibly affected. The surface morphology of coated and corroded samples was studied using scanning electron microscopy (SEM).

Keywords: epoxy, nano aluminium, potentiodynamic polarization, salt spray, electrochemical impedence spectroscopy

Procedia PDF Downloads 115

Authors: Feng-Tsai Weng, Rick Wang, Yan-Cong Liao

Abstract:

Passivation is a kind of surface treatment for material to reinforce the corrosion resistance specially the stainless alloy. Passive film, is to getting more potential compared to their status before passivation. An oxidation film can be formed on the surface of stainless steel, which has a strong corrosion resistance ability after passivation treatment. In this research, a new passivation technology is proposed for a special stainless alloy which contains a 12-14% Chromium. This method includes the A-A-A (alkaline-acid-alkaline) process basically, which was developed by Carpenter that can neutralize trapped acid. Besides, a corrosion resistant coating layer was obtained by immersing the parts in a water bath of mineral oil at high temperature. Salt spray test ASTM B368 was conducted to investigated performance of corrosion resistant of the passivated stainless steel alloy parts. Results show much better corrosion resistant that followed a coating process after A-A-A Passivation process, than only using A-A-A process. The passivation time is with more than 380 hours of salt spray test ASTM B368, which is equal to 3000 hours of Salt spray test ASTM B117. Proposed passivation method of stainless steel can be completed in about 3 hours.

Keywords: passivation, alkaline-acid-alkaline, stainless steel, salt spray test

Procedia PDF Downloads 333

Authors: Jin Gao, Jin Zhang, Xiaogang Li

Abstract:

Outdoor exposure experiments were conducted in three extreme environments, namely the Chinese plateau mountain environment (Lhasa), the cold–temperate environment (Mohe), and the marine atmospheric environment (Wanning), to track a new long-life environment-friendly polyurethane coating. The relationship between apparent properties, namely gloss and microstructural changes, was analyzed, and the influence of typical climatic environment on the aging mechanism of polyurethane coatings was discussed. Results show that the UV radiation in the Lhasa area causes photoaging degradation, micropores are formed on the coating surface, and the powdering phenomenon is obvious. Photodegradation occurs in the Wanning area, and a hydrolysis reaction is observed. The hydrolysis reaction catalyzes the photoaging, the coating surface becomes yellow, and the powdering becomes serious. Photoaging is also present in the Mohe area, but it is mainly due to temperature changes that in turn change the internal stress of the coating. Microcracks and bumps form on the coating surface.

Keywords: aging, atmospheric environment, outdoor exposure, polyurethane coating

Procedia PDF Downloads 88

Authors: Minoo Tavakoli, Alireza Kiani Rashid, Abbas Afrasiabi

Abstract:

An aluminum coating deposited on mild steel substrate by electric arc spray and diffused to the base steel material by diffusion treatment at 800 and 900°C for 1 and 3 hours in a static air. Alloy layers formed by diffusion at both temperatures were investigated, and their features were compared with those of pack cementation aluminized steel. High-temperature oxidation tests were carried out in air at 600 °C for 145 hours. Results indicated that the aluminide coatings obtained from this process have significantly improved the high-temperature oxidation resistance in both methods due to the Al2O3 scale formation. Furthermore, it showed that the isothermal oxidation resistance of arc spray technique is better than pack cementation method. This can be attributed to voids that formed at the intermetallic layer /Al layer interface which is increased in the pack cementation method.

Keywords: electric arc spray, pack cementation, oxidation resistance, aluminized steel

Procedia PDF Downloads 434

Authors: Abhijith N. V., Abhijit Pattnayak, Deepak Kumar

Abstract:

Nowadays, a group of alloys, namely high entropy alloys (HEA), because of their excellent properties. However, the fabrication of HEAs requires multistage techniques, especially mill-ing, sieving, compaction, sintering, inert media, etc. These processes are laborious, costly, time-oriented, and unsuitable for commercial application. This study adopted a single-stage process-based HVOF thermal spray to develop HEA coating on SS304L substrates. The wear behavior of the deposited HEA coating was explored under different milling time durations (5h, 10h, and 15h, respectively). The effect of feedstock preparation, microstructure, surface chemistry, and mechanical and metallurgical properties on wear resistance was also investigated. The microstructure and composition of both coating and feedstock were evaluated by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) analysis. Finally, the phase distribution was correlated by X-ray diffraction (XRD ) analysis. The results showed that 15h milled powder coating indicated better tribological than the base substrate and 5h,10h milled powder coating. A chemically stable Body Centered Cubic (BCC) solid solution phase was generated within the 15h milled powder-coated system, which resulted in superior tribological properties.

Keywords: high entropy alloys coating, wear mechanism, HVOF coating, microstructure

Procedia PDF Downloads 56

Authors: Feyza Tatar, Alime Cengiz, Dilara Sandikçi, Muhammed Dervisoglu, Talip Kahyaoglu

Abstract:

Blueberries are known for their bioactive properties such as high anthocyanin contents, antioxidant activities and potential health benefits. However, anthocyanins are sensitive to environmental conditions during processes. The objective of this study was to evaluate the effects of spray drying conditions on the blueberry microcapsules by Plackett-Burman experimental design. Inlet air temperature (120 and 180°C), feed pump rate (20% and 40%), DE of maltodextrin (6 and 15 DE), coating concentration (10% and 30%) and source of blueberry (Duke and Darrow) were independent variables, tested at high (+1) and low (-1) levels. Encapsulation efficiency (based on total phenol) of blueberry microcapsules was the dependent variable. In addition, anthocyanin content, antioxidant activity, water solubility, water activity and bulk density were measured for blueberry powders. The antioxidant activity of blueberry powders ranged from 72 to 265 mmol Trolox/g and anthocyanin content was changed from 528 to 5500 mg GAE/100g. Encapsulation efficiency was significantly affected (p<0.05) by inlet air temperature and coating concentration. Encapsulation efficiency increased with increasing inlet air temperature and decreasing coating concentration. The highest encapsulation efficiency could be produced by spray drying at 180°C inlet air temperature, 40% pump rate, 6 DE of maltodextrin, 13% maltodextrin concentration and source of duke blueberry.

Keywords: blueberry, microencapsulation, Plackett-Burman design, spray drying

Procedia PDF Downloads 246

Authors: Charizza D. Montarin, Daryl Jae S. Sigue, Gilford Estores

Abstract:

Philippines was moderately vulnerable to corrosion and to prevent this problem, surface coating should be applied. The main objective of this research was to develop and optimize a bio-based mixture of Pili Resin and Lime as Coating Materials. There are three (3) factors to be considered in choosing the best coating material such as chemical adhesion, friction, and the bearing/shear against the steel bar-concrete interface. Fortunately, both proportions of the Bio-based coating materials (50:50 and 65:35) do not have red rust formation complying with ASTM B117 but failed in terms of ASTM D 3359. Splitting failures of concrete were observed in the Unconfined Reinforced Concrete Samples. All of the steel bars (uncoated and coated) surpassed the Minimum Bond strength (NSCP 2015) about 203% to 285%. The experiments were about 1% to 3% of the results from the ANSYS Simulations with and without Salt Spray Test. Using the bio-based and epoxy coatings, normal splitting strengths were declined. However, there has no significant difference between the results. Thus, the bio-based coating materials can be used as an alternative for the epoxy coating materials and it was highly recommended for Low – Rise Building only.

Keywords: Canarium luzonicum, calcium oxide, corrosion, finite element simulations

Procedia PDF Downloads 281