Engineering a new class of thermal spray nano-based microstructures from agglomerated nanostructured particles, suspensions and solutions: an invited review
| Autor: | Basil R. Marple, Pierre Fauchais, Ghislain Montavon, Rogerio S. Lima |
|---|---|
| Přispěvatelé: | Axe 2 : procédés de traitements de surface, Science des Procédés Céramiques et de Traitements de Surface (SPCTS), Université de Limoges (UNILIM)-Ecole Nationale Supérieure de Céramique Industrielle (ENSCI)-Institut des Procédés Appliqués aux Matériaux (IPAM), Université de Limoges (UNILIM)-Université de Limoges (UNILIM)-Institut de Chimie du CNRS (INC)-Centre National de la Recherche Scientifique (CNRS)-Université de Limoges (UNILIM)-Ecole Nationale Supérieure de Céramique Industrielle (ENSCI)-Institut des Procédés Appliqués aux Matériaux (IPAM), Université de Limoges (UNILIM)-Université de Limoges (UNILIM)-Institut de Chimie du CNRS (INC)-Centre National de la Recherche Scientifique (CNRS), Laboratoire LERMPS (LERMPS), Université de Technologie de Belfort-Montbeliard (UTBM), Industrial Materials Institute, National Research Council of Canada (NRC), Consiglio Nazionale delle Ricerche [Roma] (CNR) |
| Jazyk: | angličtina |
| Rok vydání: | 2011 |
| Předmět: |
Acoustics and Ultrasonics
Nanometres Nanoparticle Average diameter Research and development management 02 engineering and technology Liquid precursors Processing Route Cryogenic grinding 01 natural sciences Suspension (chemistry) Thermal barrier coating Research and development Coating Thermal spray techniques Yttria stabilized Thermal barrier Thermal spray coatings Thermal spray process Fuel cells Alumina coating Precursor plasma spray 010302 applied physics [PHYS]Physics [physics] Agglomeration Industrial applications Network architecture Manufacture Thermal flows Thermal plasma 021001 nanoscience & nanotechnology Condensed Matter Physics Solid oxide Surfaces Coatings and Films Electronic Optical and Magnetic Materials Feedstock particles Industrial communities Ion beams Physical Sciences Coating structures Powders 0210 nano-technology Electrochemical impedance spectroscopy Wear-resistant Oxide powder Materials science Spray guns Size ranges Parameter variation Nanotechnology Thermal spray engineering.material Arc voltage fluctuations Feedstocks Solution precursor plasma spray Hot gas Nanostructured particles Liquid drop 0103 physical sciences Conventional coatings Sprayed coatings Micrometre-sized particles Thermal spraying Spray process Sprayed particles Measurement device Diagnostic tools Solution precursor Suspensions (fluids) Liquids HVOF thermal spraying Spray technique Thermal barrier coatings engineering Solid electrolytes Zirconia Bimodal structures Nanometre Nanostructured coatings Complex mechanisms Hot gas flow Mixed precursors |
| Zdroj: | Journal of Physics D: Applied Physics Journal of Physics D: Applied Physics, IOP Publishing, 2011, 44 (9), pp.93001. ⟨10.1088/0022-3727/44/9/093001⟩ Journal of Physics D: Applied Physics, IOP Publishing, 2011, 44, pp.93001-193001-53. ⟨10.1088/0022-3727/44/9/093001⟩ |
| ISSN: | 0022-3727 1361-6463 |
| DOI: | 10.1088/0022-3727/44/9/093001⟩ |
| Popis: | From the pioneering works of McPherson in 1973 who identified nanometre-sized features in thermal spray conventional alumina coatings (using sprayed particles in the tens of micrometres size range) to the most recent and most advanced work aimed at manufacturing nanostructured coatings from nanometre-sized feedstock particles, the thermal spray community has been involved with nanometre-sized features and feedstock for more than 30 years. Both the development of feedstock (especially through cryo-milling, and processes able to manufacture coatings structured at the sub-micrometre or nanometre sizes, such as micrometre-sized agglomerates made of nanometre-sized particles for feedstock) and the emergence of thermal spray processes such as suspension and liquid precursor thermal spray techniques have been driven by the need to manufacture coatings with enhanced properties. These techniques result in two different types of coatings: on the one hand, those with a so-called bimodal structure having nanometre-sized zones embedded within micrometre ones, for which the spray process is similar to that of conventional coatings and on the other hand, sub-micrometre or nanostructured coatings achieved by suspension or solution spraying. Compared with suspension spraying, solution precursor spraying uses molecularly mixed precursors as liquids, avoiding a separate processing route for the preparation of powders and enabling the synthesis of a wide range of oxide powders and coatings. Such coatings are intended for use in various applications ranging from improved thermal barrier layers and wear-resistant surfaces to thin solid electrolytes for solid oxide fuel cell systems, among other numerous applications. Meanwhile these processes are more complex to operate since they are more sensitive to parameter variations compared with conventional thermal spray processes. Progress in this area has resulted from the unique combination of modelling activities, the evolution of diagnostic tools and strategies, and experimental advances that have enabled the development of a wide range of coating structures exhibiting in numerous cases unique properties. Several examples are detailed. In this paper the following aspects are presented successively (i) the two spray techniques used for manufacturing such coatings: thermal plasma and HVOF, (ii) sensors developed for in-flight diagnostics of micrometre-sized particles and the interaction of a liquid and hot gas flow, (iii) three spray processes: conventional spraying using micrometre-sized agglomerates of nanometre-sized particles, suspension spraying and solution spraying and (iv) the emerging issues resulting from the specific structures of these materials, particularly the characterization of these coatings and (v) the potential industrial applications. Further advances require the scientific and industrial communities to undertake new research and development activities to address, understand and control the complex mechanisms occurring, in particular, thermal flow—liquid drops or stream interactions when considering suspension and liquid precursor thermal spray techniques. Work is still needed to develop new measurement devices to diagnose in-flight droplets or particles below 2 µm average diameter and to validate that the assumptions made for liquid–hot gas interactions. Efforts are also required to further develop some of the characterization protocols suitable to address the specificities of such nanostructured coatings, as some existing ‘conventional’ protocols usually implemented on thermal spray coatings are not suitable anymore, in particular to address the void network architectures from which numerous coatings properties are derived. |
| Databáze: | OpenAIRE |
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