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Suspension plasma spraying of sub-stoichiometric titania by hybrid water/argon stabilized plasma torch
Mušálek, Radek ; Ctibor, Pavel ; Medřický, Jan ; Tesař, Tomáš ; Kotlan, Jiří ; Lukáč, František
In this study, suspension plasma spraying of sub-stoichiometric titania was attempted using hybrid water/argon stabilized plasma torch (WSP-H). Porous coatings with fine cauliflower-like columnar microstructure were successfully deposited in two separate experiments with different power levels of the plasma torch. In both cases, high solid-load content (40 wt. %) of the water-based suspension resulted in considerable coating thickness increase per deposition cycle. Coating annealing and partial remelting of the surface asperities were also achieved by additional pass of plasma torch in front of the coating surface. According to X-ray diffraction, all coatings consisted dominantly of rutile phase. Detailed microscopic observation of the as-sprayed and annealed deposits showed that the local coloration of the coating (ranging from dark blue to beige) was driven by the local overheating of the rough coating surface which could also promote the oxygen intake. Moreover, sample annealing was also observed to increase the sample reflectivity as observed by UV-VIS-NIR scanning spectrophotometry
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The role of microstructure on wettability of plasma sprayed yttria stabilized zirconia coatings
Komarov, P. ; Čelko, L. ; Remešová, M. ; Skorokhod, K. ; Jech, D. ; Klakurková, L. ; Slámečka, K. ; Mušálek, Radek
Atmospheric plasma spraying utilizing initial powder materials in micrometric size has been successfully used for various applications in different fields of the industry over the past several decades. Nowadays, the new trend in plasma spraying is to use sub-micron or nano-sized powder feedstocks in the form of colloidal suspension. This relatively new technology enables to obtain specific types of dense vertically cracked, fully dense or columnar microstructure. The aim of this work is to investigate the influence of coatings microstructure and topography on its water wetting properties. Two different microstructures, i.e. lamellar and columnar, were sprayed from chemically the same yttria-stabillized zirconia (YSZ) ceramics powders by the means of conventional atmospheric plasma spray and suspension hybrid water stabilized plasma spray techniques, respectively. Microstructural and phase composition of the initial powders and as-sprayed coatings were investigated using optical microscopy, scanning electron microscopy and X-ray diffraction techniques. Topography of coatings surface was measured by means of non-contact optical profilometry. The YSZ coatings wettability was evaluated based on water droplet contact angle using Sessile droplet method. The coatings microstructure reveals the important role in the change of droplet contact angle, where lamellar microstructure was found close to hydrophilic-hydrophobic transition and columnar microstructure was found superhydrophobic
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Properties of hydroxyapatite surface deposited by plasma spray technologies
Matějková, M. ; Čížek, Jan ; Mušálek, Radek ; Dlouhý, I.
The surface properties of hydroxyapatite (HA) deposited on the Ti-6Al-4V substrates by plasma spraying were studied. Two different plasma spray technologies (hybrid plasma spray system (WSP-H) and conventional atmospheric plasma spray technology (APS)) and two various feedstock (suspension for WSP-H and powder for APS) were used for deposition of HA layers potentially suitable for bio-applications. The layers properties (thickness, chemical and phase composition) and coating-substrate interface quality were analyzed. The XRD analysis showed formation of small amount of new phases (TTCP and CaO) in layers deposited by WSP-H. Better coating-substrate interface quality of samples prepared by WSP-H was observed. The results showed the deposition of HA through liquid feedstock via WSP-H as a promising route, complementing the traditional APS powder deposition in the near future.
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Preparation of spheroidized and nano-structural spinels by the SPPS method
Brožek, Vlastimil ; Lukáč, František ; Medřický, Jan ; Mušálek, Radek ; Mašláni, Alan ; Mastný, L. ; Brodil, R.
Solution Precursor Plasma Spraying (SPPS) method, using hybrid water-stabilised plasma torch (WSP®-H), is presented in this study. Precursor, in a form of a solution of inorganic salts, is injected into the plasma jet, where the temperature can reach up to 25 000 K and a series of reactions lead to the formation of spherical sub-micrometric sized particles. The complete process of evaporating the liquid, crystallization, thermic decomposition, melting and recrystallization takes place in few milliseconds before the particles solidify. Melted nanoparticles can be either directly collected in order to obtain ultrafine powders or deposited onto a substrate to form micro-splats and continuous polycrystalline, and often partially amorphous, coatings. The possibility of continuous and discontinuous changes of stoichiometric composition in tetrahedral and octahedral configurations were analysed for the deposits of MgAl2O4, CoAl2O4 and CoFe2O4 spinels. Furthermore, thin colourful coatings of ruby and modified cobalt oxides were deposited onto ceramic and metallic substrates.
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Plasma spraying from liquids: plasma liquid interaction and coating build up
Tesař, Tomáš ; Mušálek, Radek ; Medřický, Jan ; Lukáč, František
Plasma spraying from liquid feedstocks is a rapidly developing field of thermal spraying since the coatings prepared from liquids exhibit some unique features, such as high hardness, thermal shock resistance or low thermal and electric conductivity. The key factor influencing the final coating character and properties is the input material which may be in the form of a suspension or a solution. Parameters of the selected suspension (solids concentration, viscosity, surface tension, chemical composition, etc.) or solution (concentration, etc.) determine its interaction with the plasma jet which strongly influences the coating buildup. This proceeding introduces the problematics of the interaction between the liquid feedstock material with the plasma jet and presents the way of evaluation of the coating buildup.
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Black Chromia Plating for the Solar Radiation Absorbers
Brožek, Vlastimil ; Březina, Václav ; Brom, Petr ; Kubatík, Tomáš František ; Vilémová, Monika ; Mastný, L. ; Novák, M.
Black chromia layers were produced on copper, zirconium and aluminium substrates. These layers are aimed to serve as solar collectors. Efficiency of the layers during UV-VIS, UV radiation and WSP® plasma torch radiation is described. The chromia layers were prepared by a new procedure, i.e. deposition of ammonium dichromate solution using plasma torch or so called Liquid Precursor Plasma Spraying (LPPS). Solution of ammonium dichromate is fed into plasma stream, where dissociation takes place under temperatures of 4000 K – 25000 K. Up to nanometric oxide particles can be produced; the resulting size is dependent on solution concentration and feeding nozzle diameter. The particles impact on substrate and form coating. Using 2 wt.% to 5 wt.% solution of ammonium dichromate and feeding nozzle of 0.2 mm in diameter is the size of produced chromia particles about 6 µm which results in formation of 2 µm to 3 µm thick coating, i.e. according to the theory an optimal thickness 2.5 um for absorption layers, necessary condition for formation energy traps for IR radiation emitters up to 100°C. Moreover, black chromia coating is a suitable corrosion barrier of metallic substrates. \n\n
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First experiments with suspension sprayed coatings of Al2O3 using hybrid plasma torch
Tesař, Tomáš ; Mušálek, Radek ; Medřický, Jan ; Kotlan, Jiří ; Pala, Zdeněk
Hybrid water stabilized plasmatron WSP-H represents an interesting alternative to common torches for thermal spraying, because it provides a unique combination of plasma velocity and enthalpy available for material processing. In this paper, influence of deposition parameters on coating characteristics was studied. Nanometric Al2O3 powder dispersed in ethanol was used as a model material. The coating was examined by scanning electron microscopy and X-ray diffraction and the results showed clear dependence of microstructure and phase composition on spraying distance and feed rate of the suspension. Results are promising for further optimization of the deposition process.
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