Sensing, control, and in situ measurement of coating properties: An integrated approach toward establishing process-property correlations

Journal of Thermal Spray Technology

Volumn 18, Issue 2, 2009, Pages 243-255

  Sampath, S ^a   Srinivasan, V ^a   Valarezo, A ^a   Vaidya, A ^a   Streibl, T ^a  

^a Stony Brook University   (United States)

Author keywords

CoNiCrAlY; In situ coating property measurement; In flight particle state; Process map; Process monitoring and control; TBC; YSZ

Indexed keywords

CONICRALY; IN SITU COATING PROPERTY MEASUREMENT; IN-FLIGHT PARTICLE STATE; PROCESS MAP; PROCESS MONITORING AND CONTROL; TBC; YSZ;

CERAMIC COATINGS; ION BEAMS; KNOWLEDGE BASED SYSTEMS; PROCESS MONITORING; SPRAYED COATINGS; STRATEGIC PLANNING; THERMAL BARRIER COATINGS; THERMAL SPRAYING; YTTRIA STABILIZED ZIRCONIA; ZIRCONIA;

PROCESS CONTROL;

EID: 67349249692     PISSN: 10599630     EISSN: None     Source Type: Journal    
DOI: 10.1007/s11666-009-9314-5     Document Type: Conference Paper

References (43)

1. C. Moreau, P. Gougeon, M. Lamontagne, V. Lacasse, G. Vaudreuil, and P. Cielo, On-Line Control of the Plasma Spraying Process by Monitoring the Temperature, Velocity and Trajectory of In-Flight Particles, Thermal Spray Industrial Applications: Proceedings of 7th National Thermal Spray Conference (Boston, MA), ASM International, 1994
2. J.R. Fincke, D.C. Haggard, and W.D. Swank, Particle temperature measurement in the thermal spray process. Journal of Thermal Spray Technology. 10(2), 255, 266 (2001)
3. J.R. Fincke, W.D. Swank, R.L. Bewley, D.C. Haggard, M. Gevelber, and D. Wroblewski, Diagnostics and control in the thermal spray process. Surface & Coatings Technology, 2001. 146: P. 537-543
4. W.D. Swank, J.R. Fincke, and D.C. Haggard, A Particle Temperature Sensor for Monitoring and Control of the Thermal Spray Process, Thermal Spray Science and Technology: Proceedings of the 8th National Thermal Spray Conference (Houston, TX), ASM International, 1995
5. J. Vattulainen, E. Hamalainen, R. Hernberg, P. Vuoristo, and T. Mantyla, Novel method for in-flight particle temperature and velocity measurements in plasma spraying using a single CCD camera. J Therm Spray Techn 10(1), 94-104 (2001)
6. B.R. Marple, J. Voyer, J.F. Bisson, and C. Moreau, Thermal spraying of nanostructured cermet coatings. Journal of Materials Processing Technology 117(3), 418-423 (2001)
7. H. Zhang, H.B. Xiong, L.L. Zheng, A. Vaidya, L. Li, and S. Sampath, Melting Behavior of In-Flight Particles and its Effects on Splat Morphology in Plasma Spraying, International Mechanical Engineering Congress and Exposition (New Orleans, LA), ASM International, 2002
8. L. Li, X.Y. Wang, G. Wei, A. Vaidya, H. Zhang, and S. Sampath, Substrate melting during thermal spray splat quenching. Thin Solid Films, 2004. 468(1-2): P. 113-119.
9. M. Friis, C. Persson, and J. Wigren, Influence of particle in-flight characteristics on the microstructure of atmospheric plasma sprayed yttria stabilized ZrO2. Surface & Coatings Technology. 141(2-3), 115-127 (2001)
10. M. Prystay, P. Gougeon, and C. Moreau, Structure of plasma-sprayed zirconia coatings tailored by controlling the temperature and velocity of the sprayed particles. Journal of Thermal Spray Technology 10(1), 67-75 (2001)
11. C. Moreau and L. Leblanc, Optimization and process control for high performance thermal spray coatings. Durable Surfaces. 197, 27-57 (2001)
12. J.F. Bisson, C. Moreau, M. Dorfman, C. Dambra, and J. Mallon, Influence of hydrogen on the microstructure of plasma-sprayed yttria-stabilized zirconia coatings. J. Therm. Spray Technol. 14(1), 85-90 (2005)
13. V. Srinivasan, M. Friis, A. Vaidya, T. Streibl, and S. Sampath, Particle injection in direct current air plasma spray: Salient observations and optimization strategies. Plasma Chem. Plasma Process. 27(5), 609-623 (2007)
14. V. Srinivasan, A. Vaidya, T. Streibt, M. Friis, and S. Sampath, On the reproducibility of air plasma spray process and control of particle state. J. Therm. Spray Technol. 15(4), 739-43 (2006)
15. X. Jiang, J. Matejicek, and S. Sampath, Substrate temperature effects on the splat formation, microstructure development and properties of plasma sprayed coatings Part II: Case study for molybdenum. Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing. 272(1), 189-198 (1999)
16. X.Y. Jiang, Y.P. Wan, H. Herman, and S. Sampath, Role of condensates and adsorbates on substrate surface on fragmentation of impinging molten droplets during thermal spray. Thin Solid Films. 385(1-2), 132-141 (2001)
17. R.A. Miller and C.C. Berndt, Performance of thermal barrier coatings in high heat flux environments. Thin Solid Films. 119(2), 195-202 (1984)
18. S. Sampath, X. Jiang, Splat formation and microstructure development during plasma spraying: Deposition temperature effects. Materials Science and Engineering a - Structural Materials Properties Microstructure and Processing. 304, 144-150 (2001)
19. S. Sampath, X. Jiang, A. Kulkarni, J. Matejicek, D.L. Gilmore, and R.A. Neiser, Development of process maps for plasma spray: Case study for molybdenum. Materials Science and Engineering a - Structural Materials Properties Microstructure and Processing. 348(1-2), 54-66 (2003)
20. S. Sampath, X.Y. Jiang, J. Matejicek, A.C. Leger, and A. Vardelle, Substrate temperature effects on splat formation, microstructure development and properties of plasma sprayed coatings Part I: Case study for partially stabilized zirconia. Materials Science and Engineering a - Structural Materials Properties Microstructure and Processing. 272(1), 181-188 (1999)
21. A. Tricoire, A. Vardelle, P. Fauchais, F. Braillard, A. Malie, and P. Bengtsson, Macrocrack formation in plasma-sprayed YSZ TBCs when spraying thick passes. High Temperature Material Processes. 9(3), 401-413 (2005)
22. H.B. Guo, R. Vassen, and D. Stover, Atmospheric plasma sprayed thick thermal barrier coatings with high segmentation crack density. Surf. Coat. Technol. 186(3), 353-363 (2004)
23. J. Matejicek and S. Sampath, In situ measurement of residual stresses and elastic moduli in thermal sprayed coatings - Part 1: Apparatus and analysis. Acta Mater. 51(3), 863-872 (2003)
24. J. Matejicek, S. Sampath, D. Gilmore, and R. Neiser, In situ measurement of residual stresses and elastic moduli in thermal sprayed coatings - Part 2: Processing effects on properties of Mo coatings. Acta Mater. 51(3), 873-885 (2003)
25. S. Sampath and J. Matejicek, "Method and Apparatus for Determining Process-Induced Stresses and Elastic Modulus of Coatings by In Situ Measurement," U.S. Patent 6,478,875, 2002
26. S. Kuroda, T. Fukushima, and S. Kitahara, Simultaneous Measurement of Coating Thickness and Deposition Stress During Thermal Spraying. Thin Solid Films. 164, 157-163 (1988)
27. T. Nakamura and Y. Liu, Determination of nonlinear properties of thermal sprayed ceramic coatings via inverse analysis. International Journal of Solids and Structures. 44(6), 1990-2009 (2007)
28. Y. Liu, T. Nakamura, V. Srinivasan, A. Vaidya, A. Gouldstone, and S. Sampath, Non-linear elastic properties of plasma-sprayed zirconia coatings and associated relationships with processing conditions. Acta Mater. 55(14), 4667-4678 (2007)
29. A. Vaidya, V. Srinivasan, T. Streibl, M. Friis, W. Chi, and S. Sampath, Process maps for plasma spraying of yttria-stabilized zirconia: An integrated approach to design, optimization and reliability. Mater. Sci. Eng., A. 497(1-2), 239-253 (2008)
30. T. Streibl, A. Vaidya, M. Friis, V. Srinivasan, and S. Sampath, A Critical Assessment of Particle Temperature Distributions during Plasma Spraying: Experimental results for YSZ. Plasma Chem. Plasma Process. 26(1), 73-102 (2006)
31. Y. Liu, T. Nakamura, V. Srinivasan, A. Gouldstone, and S. Sampath. Optimizing Nonlinear Properties of Thermal Sprayed Coatings Through Processing Parameters (Boston, MA), Materials Research Society, Warrendale, PA, 2006
32. Y. Liu, T. Nakamura, G. Dwivedi, A. Valarezo, and S. Sampath, Anelastic Behavior of Plasma-Sprayed Zirconia Coatings. J. Am. Ceram. Soc 91, 4036-4043 (2008)
33. W. Chi, S. Sampath, and H. Wang, Ambient and high-temperature thermal conductivity of thermal sprayed coatings. J. Therm. Spray Technol 15(4), 773-778 (2006)
34. W. Chi, S. Sampath, and H. Wang, Microstructure-thermal conductivity relationships for plasma-sprayed yttria-stabilized zirconia coatings. J. Am. Ceram. Soc 91(8), 2636-2645 (2008)
35. A. Vaidya, G. Bancke, S. Sampath, and H. Herman, Influence of Process Variables on the Plasma Sprayed Coatings: An Integrated Study, International Thermal Spray Conference (ITSC) (Singapore), ASM International, Materials Park, OH, 2001
36. H. Zhang, H.B. Xiong, L.L. Zheng, A. Vaidya, L. Li, and S. Sampath, Melting Behavior of In-Flight Particles and its Effects on Splat Morphology in Plasma Spraying, International Mechanical Engineering Congress and Exposition (New Orleans, LA), ASME, 2002
37. W. Zhang and S. Sampath, A Universal Method for Representation of In-Flight Particle Characteristics in Thermal Spray Processes, J. Therm. Spray Technol., 2008 (accepted)
38. L. Li, A. Vaidya, S. Sampath, H. Xiong, and L. Zheng, Particle characterization and splat formation of plasma sprayed zirconia. J. Therm. Spray Technol 15(1), 97-105 (2006)
39. S. Deshpande, A. Kulkarni, S. Sampath, and H. Herman, Application of image analysis for characterization of porosity in thermal spray coatings and correlation with small angle neutron scattering. Surf. Coat. Technol 187(1), 6-16 (2004)
40. Z. Wang, A. Kulkarni, S. Deshpande, T. Nakamura, and H. Herman, Effects of pores and interfaces on effective properties of plasma sprayed zirconia coatings. Acta Mater 51(18), 5319-5334 (2003)
41. A. Kulkarni, Z. Wang, T. Nakamura, S. Sampath, A. Goland, H. Herman, J. Allen, J. Ilavsky, G. Long, J. Frahm, and R.W. Steinbrech, Comprehensive microstructural characterization and predictive property modeling of plasma-sprayed zirconia coatings. Acta Mater 51(9), 2457-2475 (2003)
42. A.A. Kulkarni, A. Goland, H. Herman, A.J. Allen, J. Ilavsky, G.G. Long, and F. De Carlo, Advanced microstructural characterization of plasma-sprayed zirconia coatings over extended length scales. J. Therm. Spray Technol 14(2), 239-250 (2005)
43. A. Vaidya, T. Streibl, L. Li, S. Sampath, O. Kovarik, and R. Greenlaw, An integrated study of thermal spray process-structure-property correlations: A case study for plasma sprayed molybdenum coatings. Materials Science and Engineering a - Structural Materials Properties Microstructure and Processing 403(1-2), 191-204 (2005)