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A Novel Approach to Determine In-Flight Particle Oxidation for Thermal Spraying Processes

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Abstract

A careful substrate preparation and the physical properties of the coating particles are decisive for the quality and envisaged properties of the deposited layer. Temperature, size, rate and velocity represent the classical quantities, which can be measured in situ using various diagnostics. Nonetheless, another quality-determining parameter is the degree of oxidation which could not be measured in situ (up to now) by established diagnostics and must therefore be qualitatively derived from the above-mentioned quantities or subsequently be measured by means of destructive methods. Within this work, a diagnostic approach to determine in-flight particle oxidation has been outlined and tested. The presented measurement method detects the entire particle plume from different directions using a 2D two-color pyrometry and allows for the calculation of spatially resolved 3D temperature and intensity distributions based on a tomographic evaluation method. By additionally using measurements of the particle velocities and particle sizes, the surface emissivity of the particles along the spraying direction can be calculated, which in turn allows quantitative conclusions on the degree of particle oxidation. Investigations on the wire arc spraying process have shown that particle oxidation degrees could be determined and tend to correlate well with oxide contents in finished coatings.

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Abbreviations

λ :

Wavelength

\(T\) :

Particle temperature

ε(λ, T):

Emissivity

\(M_{{\lambda {\text{s}}}} \left( {\lambda , T} \right)\) :

Spectral exitance, a function of wavelength and particle temperature

\(Q\left( T \right)\) :

Quotient for temperature calculation

\(K = \frac{hc}{{k_{T} }}\) :

Constant (Planck’s constant times speed of light divided by Boltzmann constant)

\(I_{{i,{\text{tot}}}}\) :

(Total) intensity registered by the ith camera

\(i\) :

Integer value describing the camera number (1 or 2)

\(p\left( {\phi , a} \right)\) :

Projection value

\(f\left( {x,y} \right)\) :

Spatial distribution function

\(L_{\phi ,a}\) :

Integration straight for the radon transformation

\(a\) :

Angle number, i.e., the number of projections

\(\phi\) :

Projection angle

\(\Delta \phi\) :

Angle step at which tomographic projections are acquired

\(A_{ \bot , k}\) :

Luminous surface of a kth particle

\(t_{C, k}\) :

Dwell time in an observation cross section as defined in Ref 1

\(N\) :

Amount of particles flying through an observation cross section

\(B_{i}\) :

Calibration factor

\(\lambda_{s,e}\) :

Initial and final wavelength of the integration of \(I_{{i,{\text{tot}}}}\)

\(q_{\text{e}}\) :

Quantum efficiency of the detector

\(f_{i}\) :

Transmission function of a spectral filter

\(v_{\text{W}}\) :

Wire feed rate

\(r_{\text{W}}\) :

Wire radius

\(r_{\text{P}}\) :

Particle radius

\(t_{ \exp }\) :

Exposure time of the detector

\(l_{C}\) :

Edge length of a pixel in the image plane

\(v_{\text{lamp}}\) :

Velocity of the calibration lamp movement across the detector

\(C_{\text{oxide}}\) :

Oxide content of particles in flight

\(v_{P, z}\) :

Particle velocity along the spraying direction, defined as z-axis

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Authors and Affiliations

  1. EIT1/Lab for Plasma Technology (LPT), Bundeswehr University Munich, Neubiberg, Germany

    M. Szulc, S. Kirner, G. Forster & J. Schein

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  1. M. Szulc
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Szulc, M., Kirner, S., Forster, G. et al. A Novel Approach to Determine In-Flight Particle Oxidation for Thermal Spraying Processes. J Therm Spray Tech 29, 932–946 (2020). https://doi.org/10.1007/s11666-020-01055-0

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