Plasma

Coating
Agnes Gusvianty 1206244251
Ina Emawati 1406532816
Muhammad Haekal Sena Akbar
1406532646
Coating

Covering a material surface

with another material as Coating surface
protection

Base Material
Why
To enhance a materials
surface mechanics
Need a surface that;
1.Wear-resistant
2.Corrosion-resistant
 Electrochemi
cal

Coating
Chemic Thermochem
Process ical
al
es

Thermocoatin
g
Comparison of The Coating
Processes
Thermal Spray
Thermal Spray
A group of coating processes where the
coating is deposited on a prepared
substrate by applying a stream of particles,
metallic or nonmetallic, which flatten more
or less forming platelets, called splats, with
several layers of these splats forming the
coating

Any material on almost any substrate

General Process of Thermal
Spray
Components
An energetic gas flow
An appropriate gun
Devices for feeding, accelerating, heating, and directing the flow of a
thermal spray material toward the substrate.

Feedstock
Powder, wire, rod, or cord.
Fed at a velocity allowing the spray gun to melt them

Auxiliary gas feed

To accelerate atomized molten material into the spray gun

Controlled atmosphere or a soft vacuum

In air, coating oxidation occurs, increasing with the temperature
Members of the thermal spray family of
processes are typically grouped into
three major categories: flame spray,
electric arc spray, and plasma arc spray,
with a number of subsets falling under
each category.
 Selection of the appropriate
thermal spray method is typically
determined by:
Desired coating material
Coating performance
requirements
Economics
Part size and portability
Plasma Spray

The term "plasma" was first used

by Langmuir in the 1928, when he
tried to describe the gas condition
in the positive column of a gas
discharge at low pressure. Plasma
is a partly or fully ionized gas.
Plasma Spraying Process

A) The formation of the plasma jet and its

interaction with the environment
B) The entry powder into the plasma and
powder interaction with plasma
C) The process of forming a coating.
Why Plasma Spraying?
Wide applicability to a large range of
materials including refractory
materials like ceramics, high
deposition rate (up to a few
kilograms per hour) and rather
simple operation.
Plasma Spray
It is based on the injection of a powder
into a plasma jet formed by electrical to
thermal energy released in a plasma
torch
The particles are accelerated and heated
in the plasma jet
Particles becomes molten and when it
impacts the substrate surface, it forms
splats making lamellae structure
The piling up of the splats or lamellae
strcuture is the coating deposition result
Factors Affecting Coating Properties

(1) the formation of the plasma jet

(2) injection and processing of the
powder material in the plasma jet
(3) impact and solidification of the
particles on the substrate
Plasma Jet
Formation
Conventional Plasma Torch ;
Simple design DC Plasma Torches
(rod-shaped tungsten cathode and
water-cooled nozzle).
Uses mixture of hight atomic weight
(Ar) and high thermal cond (He) gases
Low arc voltage (<70V)
Drawbacks of Conventional
Plasma Torch

Arc instability
Electrode erosion due to heat
Radial injection of the powder

material
Plasma-Powder Interaction
Plasma spray uses coating
material in the form of powder
Powder injected to plasma torch
and accelerated
Accelerated powder bombards the
substrate surface
Plasma-Powder Interaction

If powder grain size is too small, it is mixed with

liquid
Process Parameters :
1. Powder feeder; pounds/hour, kg/hour, must be
suitable to provide uniform input
2. Powder Injector; must have good permeability to
allow optimum powder passage
3. Spraying environment; air may interfere the
exposure of powder to the plasma leading to
oxidation of injected particle.
How Powder is Injected

Wanted trajectory : B (central)

Unwanted trajectory : A (rejection) and C (breaking through)
 Different trajectory due to difference in properties of
each powder material
The variety trajectories of particles within the plasma
depends on material properties of powder particles,
particle sizes and different flow rates of the carrier gas
Coating Surface Formation
Material impingement on substrate
surface comes from a ranging velocity
then spreads
Dynamic of the splats formation
affects the properties of coating
surface
 Splashing and Breakup of Splats

Predicted nickel splat shapes at two different substrate temperatures. Left: 290
C; right: 400 C.
 EFFECT OF SOLIDIFICATION

From the figure, lower substrate temperature

causes more splashes and breakups of
splash
It is because lower substrate temperature
means higher temperature difference
between the particle and substrate
Hence, faster solidification process.
Delaying solidification by raising
the substrate temperature results in disk-
shape splats with no break-up.
 Gases may be entrapped under an impacting
drop, resulting in generation of small voids under
the splat.
Caused by rapid increase in gas pressure between
an impacting droplet and the substrate.
The rise in pressure deforms the drop and results
in gas entrapment.

Effect of Surrounding Gas

EFFECT OF UNDERCOOLING
Solidificationof splats on substrate
surface may not be in equilibrium
Resulting in undercooling
This cause the spread of the splats to
become smaller
 What can negatively affect mechanical
properties of coating?
1. Porous in splats
2. Highly-flattening splats
3. Bad contact between splats ad surface
4. Irregularity of splats shapes
 Emerging Plasma Spray
Technologies

To minimize the defects in coating

microstructure such as porous
Two emerging technologies ;
1. Suspension and solution plasma
spraying
2. Very low pressure plasma spray
 Suspension and Solution
Plasma Spraying
The coating material comes as a liquid
consisting either of ;
1. nano-sized particles in aqueous or
organic solvent (called suspension)
2. made by dissolving metal salts or
organometallic precursors, or liquid metal
precursors, in a solvent (called solution)
Suspension and Solution Plasma Spraying
In the case of suspension, particles are
present in the liquid prior to its injection
in the plasma jet
In the case of solution, particles are
formed in flight in the plasma jet and
eventually deposit onto the substrate
Some Special Features

Low specific density of the liquid

injected in the plasma jet and small
inertia of the fine particles
Fast deceleration of the fine particles
that impose shorter spray distances
that come with higher heat flux to
substrate
The coating exhibits a rather dense
and homogeneous fine structure
Very Low Pressure Plasm a Spraying

uses a highpower plasma torch

operated in a lower pressure
chamber (>1,000 Pa)
Traditional low-pressure
plasma spraying uses (5,000
20,000 Pa)
Very Low Pressure Plasma Spraying

Results in the formation of a low-

density elongated plasma jet issuing
from the plasma torch
The plasma density, velocity and

temperature are related to the

operation pressure and have a
significant effect on the coating
microstructure
 Feedstock can be ; fine powders, and also liquid
suspension, solutions and even gaseous
precursors
Deposition may be in the form of vapor
condensation or very fine molten particles or
mixed mode
 Some Special
Features

Able to deposit uniform coatings
on large substrates
It is found that, lower pressure
makes higher velocity and
temperature of plasma jet
higher deposition rate than in
PVD/CVD
THANK YOU
References
1. Vardelle, Armelle, et al. 2014. A Perspective on Plasma Spray
Technology. Springer Science+Business Media New York.
2. Rui Jovana, Miroljub Vilotijevi, Duan Boi, Karlo Rai. 2012.
UNDERSTANDING PLASMA SPRAYING PROCESS AND
CHARACTERISTICS OF DC-ARC PLASMA GUN (PJ-100).
Association of Metallurgical Engineers of Serbia.
3. ASM International Handbook of Thermal Spray.
4. Mostaghimi, Javad and Sanjeev Chandra. 2002. Splat formation in
plasma-spray coating process. Centre for Advanced Coating
Technologies, University of Toronto.
5. P. Fauchais and A. Vardelle. 2012. Thermal Sprayed Coatings Used
Against Corrosion and Corrosive Wear, Advanced Plasma Spray
Applications. InTech.