Surface treatments

Plasma spraying

M.P. Delplancke – Ogletree

 Introduction

Thermal plasmas:
– Pressure close to atmosphere
– D.C. or H.F (5 – 10 MHz) electrical power generators
– High temperature in the plasma ( 5 000 – 20 000 K)
– From the chemical point of view: thermal plasmas are efficient for
processes involving highly endothermic reactions
• Smelting
• Reduction of oxides
• Dissociation of stable compounds

Industrial applications
– Direct arc furnaces (steel metallurgy) or submerged arc furnaces
(ferroalloys)
– Heating torches
– Thermal spraying
– Synthesis of powders
– Future: nuclear fusion ?
 High power arcs
Let us consider a high power circuit with:
– DC generator delivering a potential U
– Two electrodes separated by a distance D
If D and U are compatible, a discharge is created, a current appears: the Ua –I
characteristic depends on D
The set point P where U=Ua is
unstable :
Potential •If I increases: the potential will be
higher than necessary and will
Ua –I characteristic
lead to the destruction of the
electrodes

Applied U P If we put a resistance is series with

P1 RI the arc:
•The tension available for the
electrodes is now U – RI (straight
P2 line)
•Two set points are now possible:
I P1 (unstable) and P2 (stable)

A stable set point can be controlled with the two variables R and D
 Plasma torch
If we have the control of :
– The composition of the gas phase: Ar, N2, H2; mixtures…
– The flow rate of the gas (m3/hr.)
– The velocity of the gas : controlled by the geometry of the nozzle
We have a plasma torch or reactor instead of an arc

Composition of Ar plasma Composition of N2 plasma

 Plasma torch: heating applications
Examples
 Thermal spraying
Objective: synthesize thick layers (50-200 µm) of metals, ceramics or both

How: by injection of a so-called primary powder (~ 20 µm) into the hot zone of a
D.C. plasma torch.

Spraying processes

→
 Thermal spraying
Industrial sectors of
applications: from space
to aeronautics, milling
rolls…

Applications:
•thermal barrier coatings
(oxides on metals),
•wear resistance,
•hot corrosion
resistance,
•gas (hot) corrosion
resistance,
•Medical applications, …
 Thermal spraying: primary powder
Primary powders:
• Composition: wide variety, metals, ceramics, composites
– metallic powders obtained by atomization (spherical) or crushing (angular)
– Ceramic powders obtained by electro-melting or crushing

• Characteristics: nature, granulometry, shape and aspect

– The control of the characteristic reproducibility is essential
– The powders can be pretreated
Spraying powder Ni 80% Cr 20% atomized

100 X 200 X
 Thermal spraying: primary powder

Zirconium oxide stabilised

with magnesium oxide

some are partially fused ; others angular

100X
 Thermal spraying: primary powder

80% WC-Co 88-12

20% NiCr

100X

100X
 Thermal spraying: powder injection
Powder injection
• Various types of equipment
• Constrains: regularity of
powder flow rate (at short and
long time scale)
• Powder injected via an
auxiliary carrier gas (circuit
and flow rate independent of
the plasma gas).

Calibrated powder injection

equipment
 Plasma torch
• The main part is a convergent nozzle made of water cooled copper connected to
the negative potential of the DC power supply.
• The second electrode is a W cylinder placed along the axis of the nozzle at a
precise distance (adjustable).
• Electricity and cooling water are provided by flexible cables (water at min 10
bars).
• Plasma gas are entering the torch behind the nozzle.
 Plasma torch
• The torch can be used by hand (rare nowadays) or fixed on a moving 3D robot.

• Taking into account cooling requirements, the torch is expected to work in

nominal current condition (for example 300A).The nominal power will depend on
the nature of the plasma gas .(For example 30V ; 9KW with argon and 60V ;
18KW with nitrogen)
 Plasma spraying: coating formation

• During its (short) residence time in the plasma, the primary powder will be heated, totally
or partially melted and accelerated to supersonic velocities.
• At a certain distance (5 to 7 cm) the particles will splash on the substrate as illustrated
below.

• Possible defects are: voids ; oxide inclusions ; unmelted particles

• Note that high roughness of the substrate is needed (mechanical adhesion, no
chemical reaction).
• Multiple passes are necessary for thick coatings
 Plasma spraying: coating formation

Remark: Precise conditions of temperature, velocity and residence time must be

satisfied for a good impact of the particles on the substrate as illustrated (impact test).

melted but temperature partially melted correctly melted

too high temperature too low
 Plasma spraying: coating formation
Bond coat:
•In order to increase adhesion a “bond” coat is first applied to the substrate.
•Typical example: a first layer of special alloy on the metallic substrate (with better
adhesion and similar expansion coefficient ) before a ceramic layer.
•Twin powder distributors are used to progressively change the composition
between pure bond and final layer materials.
•Ex of bond coat: Ni-Cr alloys ; MCrAlY (M=Co or Ni) for Y2O3 stabilized ceria

top

MCrAlY

intermediate diffusion layer

Nickel alloy 200X

 Plasma spraying: process control
Very large number of parameters classified in 4 categories:
• Plasma : nature of the gas ; flow rate ; nozzle geometry ; electric power
• Powder : nature ; shape ; size distribution
• Injection : nature and flow rate of carrier gas ; independent powder flow rate
• Substrate: nature, surface preparation

Guidelines:
– Try to obtain the optimal trajectory of the powder inside the plasma zone in
order to have the desired transfer of heat and velocity.
– The action on the parameters will be dependent of size and density of the
primary powder for a given plasma design (and power)
– Fluctuation of properties and plasma conditions (even at short time scale)
are unavoidable.

Modern equipment:
– Experts systems associated with the spraying are provided by the
manufacturer (more and more sophisticated )