Skip to main content
SpringerLink
Log in

Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Technology of water-stabilized plasma torch was recently substantially updated through introduction of a so-called hybrid concept that combines benefits of water stabilization and gas stabilization principles. The high-enthalpy plasma provided by the WSP-H (“hybrid”) torch may be used for thermal spraying of powders as well as liquid feedstocks with high feed rates. In this study, results from three selected experiments with suspension plasma spraying with WSP-H technology are presented. Possibility of deposition of coatings with controlled microstructures was demonstrated for three different ceramics (YSZ—yttria-stabilized zirconia, YAG—yttrium aluminum garnet and Al2O3) introduced into ethanol-based suspensions. Shadowgraphy was used for optimization of suspension injection and visualization of the liquid fragmentation in the plasma jet. Coatings were deposited onto substrates attached to the rotating carousel with integrated temperature monitoring and air cooling, which provided an excellent reproducibility of the deposition process. Deposition of columnar-like YSZ and dense YAG and Al2O3 coatings was successfully achieved. Deposition efficiency reached more than 50%, as evaluated according to EN ISO 17 836 standard.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. A. Killinger, R. Gadow, G. Mauer, A. Guignard, R. Vassen, and D. Stover, Review of New Developments in Suspension and Solution Precursor Thermal Spray Processes, J. Therm. Spray Technol., 2011, 20(4), p 677-695

    Article  Google Scholar 

  2. K. VanEvery, M.J.M. Krane, R.W. Trice, H. Wang, W. Porter, M. Besser, D. Sordelet, J. Ilavsky, and J. Almer, Column Formation in Suspension Plasma-Sprayed Coatings and Resultant Thermal Properties, J. Therm. Spray Technol., 2011, 20(4), p 817-828

    Article  Google Scholar 

  3. L. Pawlowski, Suspension and Solution Thermal Spray Coatings, Surf. Coat. Technol., 2009, 203(19), p 2807-2829

    Article  Google Scholar 

  4. R. Vassen, H. Kaner, G. Mauer, and D. Stover, Suspension Plasma Spraying: Process Characteristics and Applications, J. Therm. Spray Technol., 2010, 19(1-2), p 219-225

    Article  Google Scholar 

  5. P. Fauchais and G. Montavon, Latest Developments in Suspension and Liquid Precursor Thermal Spraying, J. Therm. Spray Technol., 2010, 19(1-2), p 226-239

    Article  Google Scholar 

  6. P. Fauchais, M. Vardelle, S. Goutier, and A. Vardelle, Key Challenges and Opportunities in Suspension and Solution Plasma Spraying, Plasma Chem. Plasma Process., 2014, 35(3), p 511-525

    Article  Google Scholar 

  7. P. Fauchais, M. Vardelle, A. Vardelle, and S. Goutier, What Do We Know, What Are the Current Limitations of Suspension Plasma Spraying? J. Therm. Spray Technol., 2015, 24(7), p 1120-1129

    Article  Google Scholar 

  8. F.-L. Toma, A. Potthoff, L.-M. Berger, and C. Leyens, Demands, Potentials, and Economic Aspects of Thermal Spraying with Suspensions: A Critical Review, J. Therm. Spray Technol., 2015, 24(7), p 1143-1152

    Article  Google Scholar 

  9. N. Curry, K. VanEvery, T. Snyder, J. Susnjar, and S. Bjorklund, Performance Testing of Suspension Plasma Sprayed Thermal Barrier Coatings Produced with Varied Suspension Parameters, Coatings, 2015, 5(3), p 338-356

    Article  Google Scholar 

  10. A. Ganvir, N. Curry, S. Bjorklund, N. Markocsan, and P. Nylen, Characterization of Microstructure and Thermal Properties of YSZ Coatings Obtained by Axial Suspension Plasma Spraying (ASPS), J. Therm. Spray Technol., 2015, 24(7), p 1195-1204

    Article  Google Scholar 

  11. R. Musalek, G. Bertolissi, J. Medricky, J. Kotlan, Z. Pala, and N. Curry, Feasibility of Suspension Spraying of Yttria-Stabilized Zirconia with Water-Stabilized Plasma Torch, Surf. Coat. Technol., 2015, 268, p 58-62

    Article  Google Scholar 

  12. J. Matejicek, T. Kavka, G. Bertolissi, P. Ctibor, M. Vilemová, R. Musalek, and B. Nevrla, The Role of Spraying Parameters and Inert Gas Shrouding in Hybrid Water-Argon Plasma Spraying of Tungsten and Copper for Nuclear Fusion Applications, J. Therm. Spray Technol., 2013, 22(5), p 744-755

    Article  Google Scholar 

  13. M. Hrabovsky, Thermal Plasma Generators with Water Stabilized Arc, Open Plasma Phys. J., 2009, 2(1), p 99-104

    Article  Google Scholar 

  14. M. Hlina and M. Hrabovsky, Enthalpy Probe Diagnostics of Steam/Argon Plasma Jet, Plasma Phys. Technol., 2015, 2(2), p 142-145

    Google Scholar 

  15. M. Hrabovsky, Generation of Thermal Plasmas in Liquid-Stabilized and Hybrid Dc-Arc Torches, Pure Appl. Chem., 2002, 74(3), p 429-433

    Article  Google Scholar 

  16. T. Kavka, J. Matejicek, P. Ctibor, A. Maslani, and M. Hrabovsky, Plasma Spraying of Copper by Hybrid Water-Gas DC Arc Plasma Torch, J. Therm. Spray Technol., 2011, 20(4), p 760-774

    Article  Google Scholar 

  17. T. Kavka, J. Matejicek, P. Ctibor, and M. Hrabovsky, Spraying of Metallic Powders by Hybrid Gas/Water Torch and the Effects of Inert Gas Shrouding, J. Therm. Spray Technol., 2011, 21(3-4), p 695-705

    Article  Google Scholar 

  18. T. Kavka, V. Kopecky, V. Sember, A. Maslani, and O. Chumak, Analysis of Plasma Jets Generated in Gas and Gas-Water Torches, High Temp. Mater. Process., 2007, 11(1), p 59-70

    Article  Google Scholar 

  19. J. Jenista, H. Takana, H. Nishiyama, M. Bartlova, V. Aubrecht, P. Krenek, M. Hrabovsky, T. Kavka, V. Sember, and A. Maslani, Integrated Parametric Study of a Hybrid-Stabilized Argon-water Arc under Subsonic, Transonic and Supersonic Plasma Flow Regimes, J. Phys. D Appl. Phys., 2011, 44(43), p 435204

    Article  Google Scholar 

  20. J. Kotlan, Z. Pala, R. Musalek, and P. Ctibor, On Reactive Suspension Plasma Spraying of Calcium Titanate, Ceram. Int., 2016, 42(3), p 4607-4615

    Article  Google Scholar 

  21. L. Latka, S.B. Goryachev, S. Kozerski, and L. Pawlowski, Sintering of Fine Particles in Suspension Plasma Sprayed Coatings, Materials (Basel), 2010, 3(7), p 3845-3866

    Article  Google Scholar 

  22. C.M. Weyant and K.T. Faber, Processing-Microstructure Relationships for Plasma-Sprayed Yttrium Aluminum Garnet, Surf. Coat. Technol., 2008, 202(24), p 6081-6089

    Article  Google Scholar 

  23. S. Kuroda and T.W. Clyne, The Quenching Stress in Thermally Sprayed Coatings, Thin Solid Films, 1991, 200(1), p 49-66

    Article  Google Scholar 

  24. R. Musalek, J. Matejicek, M. Vilemova, and O. Kovarik, Non-Linear Mechanical Behavior of Plasma Sprayed Alumina under Mechanical and Thermal Loading, J. Therm. Spray Technol., 2010, 19(1-2), p 422-428

    Article  Google Scholar 

  25. P. Ctibor, J. Kubat, Z. Pala, and B. Nevrla, Plasma Spraying of Cerium-Doped YAG, J. Mater. Res., 2014, 29(19), p 2344-2351

    Article  Google Scholar 

  26. B.G. Ravi, A.S. Gandhi, X.Z. Guo, J. Margolies, and S. Sampath, Liquid Precursor Plasma Spraying of Functional Materials: A Case Study for Yttrium Aluminum Garnet (YAG), J. Therm. Spray Technol., 2008, 17(1), p 82-90

    Article  Google Scholar 

  27. P. Chraska, J. Dubsky, K. Neufuss, and J. Pisacka, Alumina-Base Plasma-Sprayed Materials Part I: Phase Stability of Alumina and Alumina-Chromia, J. Therm. Spray Technol., 1997, 6(3), p 320-326

    Article  Google Scholar 

Download references

Acknowledgment

Financial support provided by Czech Science Foundation through Grant No. GA15-12145S (Physical aspects of plasma spray deposition from liquid feedstock) is gratefully acknowledged.

Author information

Authors and Affiliations

  1. Department of Materials Engineering, Institute of Plasma Physics CAS, v.v.i., Za Slovankou 3, 182 00, Prague 8, Czech Republic

    Radek Musalek, Jan Medricky, Jiri Kotlan, Zdenek Pala, Frantisek Lukac & Tomas Chraska

  2. Department of Materials, Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Trojanova 13, 120 00, Prague 2, Czech Republic

    Tomas Tesar

  3. Treibacher Industrie AG, Auer-von-Welsbach-Straße 1, 9330, Althofen, Austria

    Nicholas Curry

Authors
  1. Radek Musalek
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jan Medricky
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tomas Tesar
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jiri Kotlan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zdenek Pala
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Frantisek Lukac
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Tomas Chraska
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Nicholas Curry
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Radek Musalek.

Additional information

This article is an invited paper selected from presentations at the 2016 International Thermal Spray Conference, held May 10-12, 2016, in Shanghai, P. R. China, and has been expanded from the original presentation.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Musalek, R., Medricky, J., Tesar, T. et al. Suspensions Plasma Spraying of Ceramics with Hybrid Water-Stabilized Plasma Technology. J Therm Spray Tech 26, 37–46 (2017). https://doi.org/10.1007/s11666-016-0493-6

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-016-0493-6

Keywords

Search

Navigation