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SERDP Plasma ID update. 21st HCAT Program Review Toronto, September 26, 2002. Program objective. Develop plasma spray for smooth, low porosity coatings for IDs standard, small particle, nanoagglomerates Evaluate new miniature guns for minimal spray diameter. How it all fits together.

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serdp plasma id update

SERDP Plasma ID update

21st HCAT Program Review

Toronto, September 26, 2002

program objective
Program objective
  • Develop plasma spray for smooth, low porosity coatings for IDs
    • standard, small particle, nanoagglomerates
  • Evaluate new miniature guns for minimal spray diameter
findings so far
Findings so far
  • Nanoagglomerate WC-Co is not really commercially available
    • therefore cannot be used
  • Minimum ID that can be coated with good properties is 2.5 - 3”
    • coatings are high rate, so ideal for landing gear and utility actuators
    • Sulzer Metco may evaluate new, smaller F 300 gun
  • T 400, WC-12Co, WC self-fluxing (WC12Co)33Ni9Cr3.5Fe2Si2B2.5C now optimized
    • Latest WC-Co and self-fluxing look very good
sample holder
Sample holder

Pull test

Metallography

Corrosion

Almen

Wear

Sulzer F 210

Praxair SG 2700

measurement of porosity
NRC standard polishing procedure(Jean-Gabriel Legoux)

Cutting

high speed diamond wheel

Mounting

vacuum infiltration

Polishing

SiC grind

9m diamond, 3m diamond

OP-A acidic alumina

Measurement of porosity

a) vacuum mount, b) Bakelite hot mount (smears)

6.4% porosity 2.7% porosity

issues to be resolved

T400 coating

Tube

overspray

3” ID

7” long

0.0165” thick 600 ” Ra

0.0115” thick 300 ” Ra

Issues to be resolved
  • Tube rotates, spray head goes in and out
id vs od spray microstructure
ID vs OD spray microstructure

WC-Co 38m powder, 60

OD spray, 3% porosity

WC-Co 38m powder, 60

ID spray, 9% porosity

  • Overspray incorporates into coating as go down tube
    • Additional air jets to blow overspray powder away under test at Praxair
are guns different
Are guns different?
  • Sulzer Metco gun has additional gas sources to cool gun
    • appears to be effective in blowing out more overspray
  • Will be checking the different guns and making mods to gas flow as necessary
  • NRC has made “FumeSpector” dust storm monitor
to be done next few months
To be done next few months
  • Minimize overspray incorporation
  • Spray test samples using holder
  • Property and performance testing
    • metallography, adhesion, Almen,
    • wear, abrasion, corrosion, fatigue