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External Hybrid Deposition: A Novel Method for Thermal Spraying of Thermally Sensitive Materials

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Abstract

Hybrid plasma spraying has been proved to provide novel coating microstructures as a result of the simultaneous injection of a dry coarse powder and a liquid feedstock into the plasma jet. Such microstructure contains both large splats originating from the conventional dry powder and finely dispersed miniature splats deposited from the liquid. This approach enables preparation of coatings from virtually all materials which are conventionally processed using plasma spraying. However, incorporation of materials susceptible to volatilization or decomposition at high temperatures is still challenging even using this concept due to the high thermal energy transferred toward the feedstocks to be deposited. Hereby, an innovative approach of incorporation of thermally sensitive materials into a coating sprayed using a high-enthalpy plasma torch is proposed using so-called external feeding deposition. As a case study, three coarse-powder-based feedstocks (Al2O3, YSZ, and Cr2O3) were complemented with three suspension-based feedstocks (MoS2, WS2, and ZnS, respectively) deposited using the novel method. In all three coatings, the additional thermally sensitive materials were successfully deposited, retaining their original structure and morphology, which was confirmed using scanning electron microscopy and X-ray diffraction.

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Acknowledgment

Financial support of the 22-21478S grant “High-enthalpy deposition of hybrid plasma spray coatings” funded by Czech Science Foundation is gratefully acknowledged.

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Authors and Affiliations

  1. Institute of Plasma Physics, The Czech Academy of Sciences, Za Slovankou 1782/3, 182 00, Prague, Czechia

    Tomas Tesar, Radek Musalek, Frantisek Lukac & Jonas Dudik

  2. Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Brehova 7, 115 19, Prague, Czechia

    Jonas Dudik

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  1. Tomas Tesar
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  2. Radek Musalek
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  3. Frantisek Lukac
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  4. Jonas Dudik
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Correspondence to Tomas Tesar.

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This article is an invited paper selected from presentations at the 2023 International Thermal Spray Conference, held May 22-25, 2023, in Québec City, Canada, and has been expanded from the original presentation. The issue was organized by Giovanni Bolelli, University of Modena and Reggio Emilia (Lead Editor); Emine Bakan, Forschungszentrum Jülich GmbH; Partha Pratim Bandyopadhyay, Indian Institute of Technology, Karaghpur; Šárka Houdková, University of West Bohemia; Yuji Ichikawa, Tohoku University; Heli Koivuluoto, Tampere University; Yuk-Chiu Lau, General Electric Power (Retired); Hua Li, Ningbo Institute of Materials Technology and Engineering, CAS; Dheepa Srinivasan, Pratt & Whitney; and Filofteia-Laura Toma, Fraunhofer Institute for Material and Beam Technology.

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Tesar, T., Musalek, R., Lukac, F. et al. External Hybrid Deposition: A Novel Method for Thermal Spraying of Thermally Sensitive Materials. J Therm Spray Tech 33, 572–582 (2024). https://doi.org/10.1007/s11666-023-01695-y

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