• Korean Journal of Materials Research
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• v.27 no.7
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• pp.374-380
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• 2017

Properties of coatings produced by warm spray were investigated in order to utilize this technique as a repair method for Al tire molds. $Al-(0-10%)Al_2O_3$ composite powder was sprayed on Al substrate by warm spraying, and the microstructure and mechanical properties of the composite coating layer were investigated. For comparative study, the properties of the coating produced by plasma spray, which is a relatively high-temperature spraying process, were also investigated. The composite coating layers produced by the two spray techniques exhibited significantly different morphology, perhaps due to their different process temperatures and velocities of particles. Whereas the $Al_2O_3$ particles in the warm sprayed coating layer maintained their initial shape before the spray, flattened and irregular shape $Al_2O_3$ particles were distributed in the plasma sprayed coating layer. The coating layer produced by warm spray showed significantly higher adhesive strength compared to that produced by plasma spray. Hardness was also higher in the warm sprayed coating layer compared to the plasma sprayed one. Moreover, with increasing the fraction of $Al_2O_3$, hardness gradually increased in both spray coating processes. In conclusion, an $Al-Al_2O_3$ composite coating layer with good mechanical properties was successfully produced by warm spray.

• Journal of Ocean Engineering and Technology
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• v.15 no.3
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• pp.69-74
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• 2001

This paper was to investigate of a adhesiveness for the plasma sprayed coating materials did salt spray by acoustic emission method in tensile loadings. The powders used for the coating were nickel aluminum composite powder Ni-4.5wt.%Al and titanium dioxide powder $TiO_2$. These powders were coated on a carbon steel S45C by plasma spray method. The result solution was a 5% NaCl and the slat spray times were 2, 5 and 10 hours respectively. The salt solution penetrated into the surface of the substrate through pore of the coating layer built in the process of plasma spay. Corrosion productions formed on the surface of substrate. The adhesiveness between the substrate and the coating layer is weaken by corrosion and the exfoliation initiated chiefly at the corrosion surface of the substrate. The AE events and energy of the corroded coating specimens decreased as the salt spray times increased.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2001.05a
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• pp.344-349
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• 2001

This paper was to investigate of a adhesiveness for the plasma sprayed coating materials did salt spray by acoustic emission method in tensile loadings. The powders used for the coating were nickel aluminum composite powder Ni-4,5wt.%Al and titanium dioxide powder Ti02. These powders were coated on a carbon steel S45C by plasma spray method. The salt solution was a 5% NaCl and the salt spray times were 2, 5 and 10 hours respectively. The salt solution penetrated into the surface of the substrate through pore of the coating layer built in the process of plasma spay. Corrosion productions formed on the surface of substrate. The adhesiveness between the substrate and the coating layer is weaken by corrosion and the exfoliation initiated chiefly at the corrosion surface of the substrate. The AE events and energy of the corroded coating specimens decreased as the salt spray times increased.

• Journal of the Korean institute of surface engineering
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• v.48 no.6
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• pp.275-282
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• 2015

The cost for maintenance (replacement cost) of Ni-superalloy components in plant industry is very expensive because of high unit price of INCONEL 718. A development of repairing technology using kinetic spray process can be very helpful for reducing the maintenance cost. However, it is very difficult to produce well-deposited INCONEL 718 layer showing high interfacial bond strength via kinetic spraying. Thus, INCONEL 718 was deposited on SCM 440 substrate and the interfacial properties were investigated, in order to elucidate the cause of hindrance to the bonding between INCONEL 718 layer and SCM 440 substrate. As a result, it was revealed that the dominant obstacle to the interfacial bonding was excessive compressive residual stress accumulated in the coating layer, resulting from low plastic-deformation susceptibility of INCONEL 718. Nevertheless, the bonding state was enhanced by the post heat-treatment through relieving the residual stress and generating a diffusion/metallurgical bonding between the INCONEL 718 deposit and SCM 440 substrate.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2016.11a
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• pp.136-136
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• 2016

Commonly used oil-based polymer resin has environmental and safety issues. Many researches for replacing the harmful solvent-borne resins to water-borne resins have been investigated to purify harmful environmental resources and follow the export and import of hazardous materials regulations. In this research, ultrasonic spray coatings of aqueous polymer resin were studied to fabricate thin insulating layer (${\sim}{\mu}m$) on the rectangular copper wire. It needs to have appropriate wettability between resin and substrate during the ultrasonic spray coating process to coat aqueous polymer uniformly. Furthermore, stabilities of coating solution and fabricating process are required to form thin insulating layer on the substrate. In here, physical characteristics such as viscosity of 6 types of commercial polymer dispersions and emersions were analyzed to confirm compatibility for ultrasonic spray coating process. These resins were dissolved in isopropyl alcohol, used for true solvent, and were diluted with ethanol, utilized for diluent. Also, solubilities, dispersion characteristics, and viscosities of these diluted polymer resin solutions were confirmed. Dispersion characteristic and viscosity of coating solution affects jetting of ultrasonic spray coating and these jetting characteristics influence morphologies of insulating layer. In conclusion, we have known that aqueous polymer solution should have outstanding dispersion characteristic and certain range of viscosity to fabricate thin polymer insulating layer uniformly with ultrasonic spray coating.

• Proceedings of the KWS Conference
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• 2007.11a
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• pp.282-284
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• 2007

The superconductor characteristics of BSCCO spray films by Heat treatment was studied. $Bi_2Sr_2CaCu_2O_x$(Bi-2212) is high-Tc superconductor(HTS) coatings have been prepared by Heat treatment. Where high current carrying capabilities are required and therefore thick film and bulk material are called for, the Bi2Sr2Ca1Cu2O8-d(Bi-2212)compound has evoleved as one of the most promising. and the Bi-2212 HTS coating layer is synthesized through the peritectic reaction between Sr-Ca-Cu oxide coating layer and Bi-Cu oxide coating layer by partial melting process. The superconducting characteristics depends on the spray distance which was related to the spray particle melt. The Bi-2212 HTS layer consists of the whisker growth and secondary phase in 2212 layer were observed.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.10
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• pp.88-95
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• 2006

Cold gas dynamic spray is a relatively new coating process by which coatings can be produced without significant heating during the process. Cold-spray uses supersonic gas flow to carry metallic powders to the substrate. Its low process temperature can minimize thermal stress and also reduce the deformation of the substrate. Most researches on cold-spray have focused on micro scale coating, but in this study macro scale deposition was conducted. Properties of aluminum layer by cold-spray deposition such as coefficient of thermal expansion (CTE), modulus of elasticity. hardness, and electric conductivity were measured. The results showed that properties of aluminum layer by cold-spray deposition were different from properties of pure aluminum and aluminum alloy.

• Korean Journal of Materials Research
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• v.34 no.2
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• pp.79-84
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• 2024

Thin films of yttria-stabilized zirconia (YSZ) nanoparticles were prepared using a low-temperature deposition and crystallization process involving successive ionic layer adsorption and reaction (SILAR) or SILAR-Air spray Plus (SILAR-A+) methods, coupled with hydrothermal (175 ℃) and furnace (500 ℃) post-annealing. The annealed YSZ films resulted in crystalline products, and their phases of monoclinic, tetragonal, and cubic were categorized through X-ray diffraction analysis. The morphologies of the as-prepared films, fabricated by SILAR and SILAR-A+ processes, including hydrothermal dehydration and annealing, were characterized by the degree of surface cracking using scanning electron microscopy images. Additionally, the thicknesses of the YSZ thin films were compared by removing diffusion layers such as spectator anions and water accumulated during the air spray plus process. Crack-free YSZ thin films were successfully fabricated on glass substrates using the SILAR-A+ method, followed by hydrothermal and furnace annealing, making them suitable for application in solid oxide fuel cells.

• Journal of Powder Materials
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• v.27 no.4
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• pp.333-338
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• 2020

In this study, we fabricate a thin- and dense-BCuP-5 coating layer, one of the switching device multilayers, through a plasma spray process. In addition, the microstructure and macroscopic properties of the coating layer, such as hardness and bond strength, are investigated. Both the initial powder feedstock and plasma-sprayed BCuP-5 coating layer show the main Cu phase, Cu-Ag-Cu₃P ternary phases, and Ag phase. This means that microstructural degradation does not occur during plasma spraying. The Vickers hardness of the coating layer was measured as 117.0 HV, indicating that the fine distribution of the three phases enables the excellent mechanical properties of the plasma-sprayed BCuP-5 coating layer. The pull-off strength of the plasma-sprayed BCuP-5 coating layer is measured as 16.5 kg/㎠. Based on the above findings, the applicability of plasma spray for the fabrication process of low-cost multi-layered electronic contact materials is discussed and suggested.

• Transactions of the Korean hydrogen and new energy society
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• v.21 no.3
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• pp.201-206
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• 2010

In present work, $La_{0.8}Ca_{0.2}CrO_3$ (LCC) ceramic interconnect layer for SOFC was prepared by using thermal plasma spray coating process. The LCC powders were synthesized by Pechini method and calcined at the temperature of $1000^{\circ}C$. The prepared LCC powder was characterized by x-ray diffraction (XRD), scanning electron microscopy (SEM), particle counter, BET analysis, respectively. In addition, basic and essential properties of LCC layer coated by thermal plasma spray coating process such as the morphology of surface and cross section for coated layer, gas leak rate, and electrical conductivity were analyzed and discussed. Based on these experimental results, it can be concluded that the LCC layer coated by thermal plasma spray coating process can be suitable as a ceramic interconnect of SOFC operated at $800^{\circ}C$.