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  • 1
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 84 (2001), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: Yttria-partially-stabilized zirconia was atmospherically plasma sprayed by systematically varying the process conditions including carrier gas flow rate, torch power, standoff distance, and Ar/H2 ratio in the plasma gas mixture. The in-flight particle parameters such as temperature, velocity, number, and size were determined using a commercially available diagnostic system. The particle parameters were controlled by the particle trajectory in the plume and plasma jet characteristics. The average temperature and the velocity of particles, which reached their maximum at an intermediate carrier gas flow rate of 3.5 L/min, varied as much as 6% and 25%, respectively, with a 75% variation in the carrier gas flow rate by going from the lowest to the intermediate rates. The average temperature and the velocity of particles were lower for a lower torch power, a higher Ar/H2 ratio, and a larger standoff distance. It was necessary to obtain data on particle populations larger than 1000 for statistically reliable and reproducible information from the diagnostic system.
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  • 2
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 84 (2001), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: Spray prints of thermal spray coatings were created on glass slides for air-plasma-sprayed 8-wt%-yttria-partially-stabilized zirconia (YSZ) deposits. The spray parameters such as carrier gas flow rate, standoff distance, and torch power were systematically changed to investigate the influence of these parameters on the YSZ deposit characteristics. The deposit properties such as deposition efficiency (DE), substrate coverage, deposit thickness, and roughness were measured. The deposits sprayed with a 3.5–4.0 L/min carrier gas flow rate at an 80 mm standoff distance exhibited higher values of DE within the range of studied process parameters. The DE increased as much as 25% by varying the carrier gas flow rate from 2.0 to 4.0 L/min. The deposits sprayed at a higher standoff distance and low torch power gave poor deposit characteristics. The deposit characteristics were compared with the in-flight particle parameters and revealed that the deposit characteristics strongly depended on the in-flight particle temperature. Using the in-flight particle properties, the flattening ratio and the splat thickness were calculated. The average size of particles adhering to the substrate was found to drastically change with a change of process conditions, being much less than the average size of the starting powder.
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  • 3
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 83 (2000), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: The effects of pore sizes, shapes, and orientations on the mechanical properties of thermally sprayed ceramic coatings are investigated. The analysis is conducted using detailed finite-element models with geometries similar to those of actual ceramic coatings containing many embedded pores. These microstructural models include many randomly placed pores of different sizes and shapes and are loaded in tension to determine their effective elastic moduli along the spray and transverse directions. We modeled coatings with statistical distributions of pore sizes and shapes that followed those of actual Al2O3–TiO2 coatings. Because the pores in such a model are of different sizes and shapes, the model must be large enough to contain sufficient pores before the average modulus obtained from uniaxial loading can be identified as an effective property. Using differently sized models, we determined the variability of the average moduli. Such information is valuable when homogenized or continuum material models are used in the stress analyses of coatings. Our computed results show that a model must be large enough to contain 50–100 pores before the averaging of properties is accurate. Using the Al2O3–TiO2 models, we also simulated microindentation tests. Unlike the results determined from uniaxial loading, the elastic moduli estimated from indentation possessed large variations. Apparently, the morphology of the pores immediately beneath the indentation or within the zone of influence has a significant effect on the response of the indenter and the measured modulus. The implications of these results and the computational capability to predict the mechanical properties of porous, plasma-sprayed ceramic coatings are discussed here.
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  • 4
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 82 (1999), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: The size–shape distribution of voids, which includes cracks and pores, was determined using quantitative stereological analysis. The analysis was performed on a water-stabilized plasma-spray-formed Al2O3–13 wt% TiO2. The individual voids were assumed to have an oblate spheroidal shape, which could simulate shapes ranging from spherical pores to cracks. The cracks were generally intralamellar or translamellar, and the pores were interlamellar. The information obtained from two-dimensional plane sections was unfolded to three-dimensional information using stereological analysis. The quantitative information of voids was acquired in terms of shape and size.
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  • 5
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 81 (1998), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: The amorphous phase in hydroxyapatite coatings has been examined by using X-ray diffractometry, Fourier transform infrared spectroscopy, optical microscopy, and thermal analysis methods. The amorphous phase mostly consists of a dehydroxylated calcium phosphate. When heated, crystallization of hydroxyl-rich areas produces hydroxyapatite, followed by diffusion of hydroxyl ions, thus increasing the amount of crystalline phase. Hydroxyl-deficient amorphous areas crystallize to oxyapatite at 700°C. Thus, crystallization occurs over a range of temperatures and is dependent on the hydroxyl content of the amorphous phase and the partial water-vapor pressure. The activation energies of crystallization to hydroxyapatite, diffusion of hydroxyl ions, and crystallization to oxyapatite are 274, 230, and 440 kJ/mol, respectively. Shrinkage from these processes leads to a crack network and decreases the mechanical strength of the coating.
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  • 6
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 80 (1997), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: Free-standing alumina-13% titania samples were manufactured with a water-stabilized plasma spray gun to a thickness of ∼5 mm. A thin layer of aluminum was arc sprayed prior to depositing the thick coating and etched away using hydrochloric acid. The so-obtained free-standing plate was cut into four-point-bend-test specimens with dimensions of ∼5 mm × 5 mm × 50 mm. The as-sprayed material consisted of a supersaturated solid solution, where titania was frozen inside the alumina matrix. Heat treatment was performed at 1450°C for 24 h and then at 1100°C for another 24 h. After heat treatment, titania precipitates were observed. The major phases of the as-sprayed and heat-treated samples were γ- and α-alumina, respectively. The porosity was ∼10% for as-sprayed samples; this value was reduced to ∼3% after heat treatment. Four-point bend tests were performed on the as-sprayed and heat-treated specimens in cross-section and in-plane directions. An acoustic emission technique was used to examine the cracking during the tests in situ. Microcracking prior to failure was observed for as-sprayed samples that were tested in the cross-section direction. However, when tested in the in-plane direction, catastrophic failure with less evidence of microcracking occurred. For heat-treated specimens, microcracks were usually observed when tests were performed in either of the orientations. Energy and amplitude distributions for each testing condition were examined. These distributions changed after heat treatment; however, no significant differences were distinguished when tests were performed in the cross-section or in-plane directions.
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  • 7
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 80 (1997), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: The elastic response behavior of thermal spray deposits at Knoop indentations has been investigated using indentation techniques. The ratio of hardness to elastic modulus, which is an important prerequisite for the evaluation of indentation fracture toughness, is determined by measuring the elastic recovery of the in-surface dimensions of Knoop indentations. The elastic moduli of thermal spray deposits are in the range of 12%-78% of the comparable bulk materials and reveal the anisotropic behavior of thermal spray deposits. A variety of thermal spray deposits has been examined, including Al2O3, yttria-stabilized ZrO2(YSZ), and NiAl. Statistical tools have been used to evaluate the error estimates of the data.
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  • 8
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 81 (1998), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: An experimental system consisting of an axial feed plasma gun, a variable-rate liquid delivery system, a liquid atomizer-feeder, and a substrate movement and control system was designed and assembled for preparing nanograined ceramic deposits. Sprayed deposits were produced with different spray and sol feed parameters and investigated in both the as-sprayed and heat-treated conditions. As-sprayed deposits were predominately hydroxide phases and were strongly adherent to the substrates. Postspray heat treatment at 873 K led to conversion of the alumina and zirconia deposits to γ-alumina and tetragonal zirconia phases, respectively. Subsequent heat treatment at 1273 K resulted in densification of the deposits and formation of high-temperature phases. A small increase in the grain size was observed with heat treatment, but the specimens still retained nanosized grains.
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  • 9
    Electronic Resource
    Electronic Resource
    Westerville, Ohio : American Ceramics Society
    Journal of the American Ceramic Society 80 (1997), S. 0 
    ISSN: 1551-2916
    Source: Blackwell Publishing Journal Backfiles 1879-2005
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics , Physics
    Notes: To understand the influence of processing parameters on the microstructure of plasma-sprayed deposits, smallangle neutron scattering measurements were made of the processing-parameter-dependent specific surface area of the voids in gray alumina deposits. These studies indicate that the voids are in the form of pores between the splats and around inclusions or unmelted particles, and are also in the form of cracks within the splats which may develop during cooling. The porous volume increases as the angle between the spray gun and the substrate (the “spray angle”) decreases. This study also indicates that the cracks are preferentially oriented, and that the crack orientation also depends on the spray angle. The interlamellar pores, however, are preferentially oriented parallel to the substrate surface, and the orientation of the pore is independent of the spray angle.
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  • 10
    Electronic Resource
    Electronic Resource
    Springer
    Journal of materials science 24 (1989), S. 3511-3520 
    ISSN: 1573-4803
    Source: Springer Online Journal Archives 1860-2000
    Topics: Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics
    Notes: Abstract Plasma sprayed coatings have a complex structure which is produced by the overlaying of many molten or semi-molten particles in the diameter range of 20 to 120 µm. There is a need to characterize the failure behaviour of coatings and this has been carried out by using acoustic emission (AE) methodology. Coatings of NiCrAIY bond coat with a zirconia-12 wt% yttria overlay were applied to discshaped specimens of U-700 alloy. A waveguide of 1 mm diameter platinum was TIG welded to the specimen and allowed it to be suspended in a tubular furnace. The specimen was thermally cycled to 1150° C and the AE monitored. One method of examining the AE is from the viewpoint of the accumulative count data. It is also convenient to establish the temperatures for “initial” AE and “significant” AE (i.e., the temperature at which 100 counts is exceeded) so that coatings may be compared. Several other analyses have been carried out with the aim of establishing parameters which are related to the crack size and crack population. These studies have been used to postulate types of cracking mechanisms which may occur in plasma sprayed coatings during thermal cycling. It is shown that microcracking gave rise to a large amount of AE. However, this coating still survived more thermal cycles than a coating which exhibited macrocracking events. Data of this nature will be presented and the results discussed.
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