Thomas W. Coyle

Spray-Formed, Metal-Foam Heat Exchangers for High Temperature Applications

Open pore metal foams make efficient heat exchanger because of their high thermal conductivity and low permeability. This study describes a novel method of using wire-arc spraying to deposit Inconel 625 skins on the surface of sheets of 10 and 20 pores per linear inch nickel foam. The skins adhere strongly to the foam struts, giving high heattransfer rates. Tests were done to determine the hydraulic and thermal characteristics of the heat exchangers and correlations developed to calculate Fanning friction factor and Nusselt number as a function of Reynolds number for airflow through the foam. Measured heat-transfer coefficients for the foam heat exchangers are greater than those of straight flow channels at the same flow rate. A ceramic thermal barrier coating was deposited on one face of the heat exchanger using plasma spraying. The coating and heat exchanger survived prolonged exposure to the flame of a methane-air burner. DOI: 10.1115/1.4001049

Thermomechanical behavior of nanostructured plasma sprayed zirconia coatings

Retaining nonmelted nanoparticles of zirconia in nanostructured coatings has been a challenge in the past. Recently an air plasma spray process was developed to produce coatings that retain up to 30–35% by volume nonmelted particles, resulting in a unique structure. The creep/sintering behavior of such thermal barrier coatings deposited from nanostructured feedstock has been measured and compared with deposits produced from hot oven spherical particles (HOSP). Both feedstocks contain 6–8 wt.% Y2O3 as a stabilizer. Flexure and compression creep testing were conducted under several different loads and temperatures to obtain creep exponents and parameters.

Microstructure of vacuum plasma-sprayed boron carbide

In the present study, boron carbide was deposited on Ti-6%Al-4%V alloy by vacuum plasma spraying. Chemical and phase compositions of the initial starting powder and the as-sprayed deposit were characterized using hot gas extraction, x-ray photoelectron spectroscopy, Raman spectroscopy, x-ray diffraction, and transmission electron microscopy. Mechanical properties of the deposition were assessed by microhardness and nanohardness indentation. The microstructure consisted of equiaxed boron carbide grains, microcrystalline particles, and amorphous carbon regions. The amount of boron oxide and amorphous carbon in the coating was increased compared with the initial powder. The measured microhardness was slightly higher than values reported previously (1033±200 HV). There was significant variation in measured nanohardness (−100 + 39 GPa) from point to point caused by multiple phases, splat boundaries, and porosity in the deposited structure. Carbon segregation to grain boundaries and/or splat boundaries in boron carbide was observed directly using spatially resolved electron energy loss spectroscopy method.

A New High-Temperature Ultrasonic Transducer for Continuous Inspection

A novel design of piezoelectric ultrasonic transducer is introduced, suitable for operation at temperatures of up to 700 °C-800 °C. Lithium niobate single crystal is chosen as the piezoelectric element primarily due to the high Curie temperature of 1200 °C. A backing element based on a porous ceramic is designed for which the pore volume fraction and average pore diameter in the ceramic matrix can be controlled in the manufacturing process; this enables the acoustic impedance and attenuation to be selected to match their optimal values as predicted by a one-dimensional transducer model of the entire transducer. Porous zirconia is selected as the ceramic matrix material of the backing element to obtain an ultrasonic signal with center frequency of 2.7-3 MHz, and 3-dB bandwidth of 90%-95% at the targeted operating temperature. Acoustic coupling of the piezocrystal to the backing element and matching layer is investigated using commercially available high-temperature adhesives and brazing alloys. The performance of the transducer as a function of temperature is studied. Stable bonding and clear signals were obtained using an aluminum brazing alloy as the bonding agent.

Microstructure and failure mechanism in As-deposited, vacuum plasma-sprayed Ti-6Al-4V alloy

The microstructure, phase composition, and chemical composition of vacuum plasma-sprayed Ti-6Al-4V alloys were examined in detail using a variety of techniques, including x-ray diffraction, x-ray photoelectron spectroscopy, and transmission electron microscopy. The observed chemistry and structure were related to the conditions under which the deposit was formed and the phase equilibria in the Ti alloy system. The porosity of the deposit was in the range of 3 to 5%. A slight decrease in the Al content and a slight increase in the amount of oxygen and hydrogen was found relative to the starting powder. Within individual splats, a columnar solidification structure can be seen. However, the as-deposited material is ≥90% α′ martensite that is present in the form of fine lathes on the order of 500 nm in width surrounded by residual β-phase. This herringbone structure obscures to some extent the preexisting columnar structure of the as-solidified β-phase. The material fails at low elongations (∼1%) when tested in tension, with a macroscopic stress-strain curve, which appears to be quite brittle. Examination of the fracture surface, however, reveals a ductile failure mode within individual splats, which is consistent with the structure described above. Sections perpendicular to the fracture surface show that failure occurs at the weak splat boundaries through the development and growth of voids between splats.

Porous ceramics as backing element for high-temperature transducers

A new application of porous ceramics as the attenuative backing element in high-temperature transducers is introduced. By introducing pores of different volume fractions and various sizes into the ceramic matrix, acoustic impedance and attenuation can be controlled to match their optimal values as predicted by a simple numerical model of the entire transducer, coupled with a model of the attenuative effect of the pores. This concept was applied to the design and manufacture of porous 3mol% Yttria-stabilized zirconia (YSZ) backing elements for a 2.8-MHz lithium niobate (LiNbO3) piezoelectric crystal, with a targeted operating temperature of 700°C to 800°C. Acoustic measurements revealed that the actual acoustic impedance and attenuation of the porous samples matched well with their predicted values. The design and fabrication process can be employed in manufacturing backing elements for a variety of transducers with specified center frequency and signal bandwidth.

Preparation of Lanthanum Zirconate Coatings by the Solution Precursor Plasma Spray

Solution precursor plasma spray (SPPS) can synthesize powders and deposit the coatings synchronously. The lanthanum zirconate coatings are deposited by SPPS in the present study, and the dense coating can be obtained through changing the precursor solution. The addition of urea can change the heat exchange process for some precursor mixtures. However, almost no effect can be found on the microstructure of powder and coating by the addition of urea. The extra heat energy caused by the addition of urea is so small, as compared with the heat input by the present plasma jet, so that the heating effect can be ignored. The porosity of coatings increase when the LaCl3·7H2O instead of La(NO3)3·6H2O reacts with Zr(CH3CO2)4.

Numerical Study of Suspension Plasma Spraying

A numerical study of suspension plasma spraying is presented in the current work. The liquid suspension jet is replaced with a train of droplets containing the suspension particles injected into the plasma flow. Atomization, evaporation, and melting of different components are considered for droplets and particles as they travel toward the substrate. Effect of different parameters on particle conditions during flight and upon impact on the substrate is investigated. Initially, influence of the torch operating conditions such as inlet flow rate and power is studied. Additionally, effect of injector parameters like injection location, flow rate, and angle is examined. The model used in the current study takes high-temperature gradients and non-continuum effects into account. Moreover, the important effect of change in physical properties of suspension droplets as a result of evaporation is included in the model. These mainly include variations in heat transfer properties and viscosity. Utilizing this improved model, several test cases have been considered to better evaluate the effect of different parameters on the quality of particles during flight and upon impact on the substrate.

Optimization of Grit-Blasting Process Parameters for Production of Dense Coatings on Open Pores Metallic Foam Substrates Using Statistical Methods

Open pore metallic foam core sandwich panels prepared by thermal spraying of a coating on the foam structures can be used as high-efficiency heat transfer devices due to their high surface area to volume ratio. The structural, mechanical, and physical properties of thermally sprayed skins play a significant role in the performance of the related devices. These properties are mainly controlled by the porosity content, oxide content, adhesion strength, and stiffness of the deposited coating. In this study, the effects of grit-blasting process parameters on the characteristics of the temporary surface created on the metallic foam substrate and on the twin-wire arc-sprayed alloy 625 coating subsequently deposited on the foam were investigated through response surface methodology. Characterization of the prepared surface and sprayed coating was conducted by scanning electron microscopy, roughness measurements, and adhesion testing. Using statistical design of experiments, response surface method, a model was developed to predict the effect of grit-blasting parameters on the surface roughness of the prepared foam and also the porosity content of the sprayed coating. The coating porosity and adhesion strength were found to be determined by the substrate surface roughness, which could be controlled by grit-blasting parameters. Optimization of the grit-blasting parameters was conducted using the fitted model to minimize the porosity content of the coating while maintaining a high adhesion strength.

Titanium Dioxide Coating Prepared by Use of a Suspension-Solution Plasma-Spray Process

Abstract Titanium dioxide coatings were prepared from titanium isopropoxide solution containing nano TiO2 particles by use of a plasma-spray process. The effects of stand-off distance on coating composition and microstructure were investigated and compared with those for pure solution precursor and a water-based suspension of TiO2. The results showed that the anatase content of the coating increased with increasing stand-off distance and the rate of deposition decreased with increasing spray distance. Anatase nanoparticles in solution were incorporated into the coatings without phase transformation whereas most of the TiO2 in the precursor solution was transformed into rutile. The microstructure of preserved anatase particles bound by rutile improved the efficiency of deposition of the coating. The amount of anatase phase can be adjusted by variation of the ratio of solution to added anatase TiO2 nanoparticles.