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

0585665 - ÚFP 2025 RIV DE eng J - Journal Article
Tesař, Tomáš - Mušálek, Radek - Lukáč, František - Dudík, Jonáš
External Hybrid Deposition: A Novel Method for Thermal Spraying of Thermally Sensitive Materials.
Journal of Thermal Spray Technology. Roč. 33, 2, 3 (2024), s. 572-582. ISSN 1059-9630. E-ISSN 1544-1016
R&D Projects: GA ČR(CZ) GA22-21478S
Institutional support: RVO:61389021
Keywords : coatings * ceramic coating * external feeding * hybrid plasma spraying * solid lubricants
OECD category: Materials engineering
Impact factor: 3.1, year: 2022
Method of publishing: Limited access
https://link.springer.com/article/10.1007/s11666-023-01695-y

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.
Permanent Link: https://hdl.handle.net/11104/0353345