OPTIMIZATION STUDY OF THE OPERATING CONDITIONS TO IMPROVE THE QUALITY OF SURFACES COATING OBTAINED BY PLASMA SPRAYING PROCESS

Abstract

In the present paper we aim to present a numerical optimizing study on the operating conditions of an atmospheric plasma spraying process. The focus is mainly made on the powder injection parameters and the objective is to improve the quality of surface coatings.

First, a ‘validation’ test of the Jets&Poudres code is conducted based on various numerical and experimental former works. The results of the Jets&Poudres code seem to be a good compromise between the results of different numerical methods and the experimental measurements.

Second, a Taguchi experimental design is conducted to explore the influence parts for five operating parameters in the spraying process. This, results in a primary gas flow rate of 45 SL/min, a spray distance of 12 cm, a particle size around 55μm, a powder feed rate ranging close to 1 l/min and finally an electric power of about 25 kW.

Finally, a test case for a ternary gas mixture is conducted on 15000 particles using the Jets&Poudres code to assess the conclusions drawn in the studies using the experimental design. The results are confronted together and discussed.

Keywords

• Plasma Spraying,Thin Coatings,Deposit quality,Sommerfeld Number,Taguchi Experimental Design

References

1. [1] A. Ghasemi, N. Hashemian, A. Noorpoor, P. Heidarnejad, “Exergy Based Optimization of a Biomass and Solar Fuelled CCHP Hybrid Seawater Desalination Plant”. Journal of Thermal Engineering, 2017.
2. [2] S. C. Kaushik, R. Kumar, R. Arora, “Thermo-economic Optimization and Parametric Study of an Irreversible Regenerative Brayton Cycle” Journal of Thermal Engineering (ICES2015), 2016.
3. [3] R. Djebali, “A confrontation of three design techniques' results for optimizing plasma spraying operating conditions toward deposit requirements: Lattice Boltzmann, Finite Difference and Taguchi experimental design”. International Journal of Energy Optimization and Engineering, 2017.
4. [4] R. Kumar, S.C. Kaushik and R. Kumar, “Performance Optimization of Brayton Heat Engine at Maximum Efficient Power using Temperature Dependent Specific Heat of Working Fluid”. Journal of Thermal Engineering, 2015.
5. [5] R. Kumar, S.C. Kaushik and R. Kumar, “Power Optimization of an Irreversible Regenerative Brayton Cycle with Isothermal Heat Addition”. Journal of Thermal Engineering, 2015.
6. [6] A. K. Hussein, “Multi-objective Optimization of a Three-dimensional Internally Finned Tube Based on Response Surface Methodology (RSM)”. Journal of Thermal Engineering, 2015.
7. [7] Y.S. Hadiwidodo and S. Bin-Mohd, “ Taguchi experiment design for investigation of freshened properties of self-compacting concrete”. American J. of Engineering and Applied Sciences, 2010.
8. [8] N. H. Mohamad Nor, N. Muhamad, M.H.I. Ibrahim, M. Ruzi, S. Ahmad and K.R. Jamaludin, “Injection molding parameter optimization of Ti-6Al-4V powder mix with palm stearin and polyethylene for highest green strength using Taguchi method. International Journal of Mechanical and Materials Engineering, 2011.

9. [9] B. Pateyron, ‘Jets&Poudres’ code available at http://jets.poudres.free.fr.
10. [10] R. Djebali, M. ElGanaoui, A. Jaouabi, and B. Pateyron, “Lattice Boltzmann scrutiny of spray jet and impact characteristics under dispersion effects of powder injection parameters in APS process”. International Journal of Thermal Sciences, 2016.
11. [11] Y.P. Wan, V.Gupta, Q. Deng, S. Sampath and V. Prasad, “Modeling and visualization of plasma spraying of functionally graded materials and its application to the optimization of spray conditions”. J. Therm. Spray Technol., 2013.
12. [12] W.C. Smith, T.J. Jewett, S. Sampath, W.D. Swank and J.R. Fincke, “In Thermal Spray: A United Forum for Scientific and Technological Advances”. (Ed.) C.C. Berndt, (Pub.) ASM International, Materials Park, OH. 1997.
13. [13] M. Vardelle, A. Vardelle and P. Fauchais, “Spray parameters and particle behavior relationships during plasma spraying”. J. Therm. Spray Technol. 1993.
14. [14] R. Djebali, M. Toujani and B. Pateyron, “Taguching the Atmospheric Plasma Spraying Process: Influence of Processing Factors on Droplet Impact Properties Obtained on Dense ZrO2 and H2Ar75% Plasma Gas”. CMC-Computers, Materials & Continua, 2013.
15. [15] C. Escure, M. Vardelle, and P. Fauchais, “Experimental and Theoretical study of the impact of alumina droplet on cold and hot substrates”. Plasma Chemistry and Plasma Processing, 2003.