• Journal of Power System Engineering
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• v.2 no.3
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• pp.41-48
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• 1998

This study was aimed at development of fabrication process of functionally graded materials(FGM), consisting of metal and ceramic by thermal spraying method. NiCrAIY/$Al_2O_3$ FGM were made by using plasma spraying onto the SS400 carbon steel substrate. And mechanical properties such as microhardness, thermal shock resistance and adhesive strength of the coating layer were investigated. Adhesive strength was evaluated by acoustic emission method. It was resulted that NiCrAIY/$Al_2O_3$ FGM made by thermal spraying method showed excellent thermal shock resistance and adhesive strength compared to the other lamellar structures of sprayed coatings and that AE is useful tool to evaluate the defect of thermal sprayed coating layer.

• Journal of Welding and Joining
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• v.20 no.2
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• pp.109-115
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• 2002

In the case of using high temperature by coating ceramic/metal, large stress was produced due to difference of thermal expansion coefficient between those. And then lead to delamination. In order to relaxation of the stress A1$_2$O$_3$/SS316 composite powders with $10wt.%Al_2O_3$ compositional gradient and $10wt.%Al_2O_3$ agglomerated powder were made by spray drying method. These powders were sintered to improve the strength and to be plasma sprayed in order to fabricate the FGC(functionally graded coating). The influence of gun power, working distance and Ar pressure on the microstructure of the coating layer was studied in order to optimize the plasma spray conditions. It was proven that the optimum conditions were 40kw gun power, 5cm working distance and $100ft^3/h$ Ar flow for both powders. FGC with 10 compositional steps was fabricated and the total thickness was 1.3mm. FGC was heat treated at $1100^{\circ}C$for 10hours to evaluate the heat resisting characteristics.

• Journal of Welding and Joining
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• v.27 no.6
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• pp.43-48
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• 2009

In this study, Cu-based bulk metallic glass (BMG) coatings were deposited by atmospheric plasma spraying (APS) process with different process conditions (with- and without hydrogen gas). As adding the hydrogen gas, thermal energy in the plasma flame increased and induced difference in the melting state of the Cu-based BMG particles. The microstructure and mechanical properties of the coatings were analyzed using a scanning electron microscope (SEM) with an energy dispersive spectroscopy (EDS) and nano-indentation tester in the light of phase analysis. It was elucidated by the nano-indentation tests that un-melted region was a mainly amorphous phase which showed discrete plasticity observed as the flow serrations on the load.displacement (P - h) curves, and the curves of solidified region showed lower flow serrations as amorphous phase mingled with crystalline phase. Oxides produced during the spraying process had the highest hardness value among the phases and were well mixed with other phases resulted from the increase in melting degree.

• Journal of the Korean Society for Industrial and Applied Mathematics
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• v.15 no.3
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• pp.223-231
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• 2011

During spray coating, especially in an air plasma spray (APS), pores, cracks, and splat boundaries are developed and those factors exert influence on thermomechanical properties such as elastic modulus, thermal conductivity, and coefficient of thermal expansion. Moreover, the thermo mechanical properties are crucial elements to determine the thermoelastic characteristics, for instance, temperature distribution, displacements, and stresses. Two types of thermal barrier coating (TBC) model, the dense and porous microstructures, are taken into account for the analysis of microstructural characterizations. $TriplexPro^{TM}$-200 system was applied to prepare TBC samples, and the METECO 204 C-NS powder is adopted for the relatively porous microstructure and METECO 204 NS powder for the dense microstructure in the top coat of TBCs. Governing partial differential equations were derived based on the thermoelastic theory and approximate estimates for the thermoelastic characteristics were obtained using a finite volume method for the governing equations.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.8
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• pp.248-255
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• 2020

The effects of the coating thickness on the thermal durability and thermal stability of thermal barrier coatings (TBCs) with a gradient coating thickness were investigated using a flame thermal fatigue (FTF) test and thermal shock (TS) test. The bond and topcoats were deposited on the Ni-based super-alloy (GTD-111) using an air plasma spray (APS) method with Ni-Cr based MCrAlY feedstock powder and yttria-stabilized zirconia (YSZ), respectively. After the FTF test at 1100 ℃ for 1429 cycles, the bond coat was oxidized partially and the thermally grown oxide (TGO) layer was observed at the interface between the topcoat and bond coat. On the other hand, the interface microstructure of each part in the TBC specimen showed a good condition without cracking or delamination. As a result of the TS test at 1100 ℃, the TBC with gradient coating thickness was initially delaminated at a thin part of the coating layer after 37 cycles, and the TBC was delaminated by more than 50% after 98 cycles. The TBCs of the thin part showed more oxidation of the bond coat with the delamination of topcoat than the thick part. The thick part of the TBC thickness showed good thermal stability and oxidation resistance of the bond coat due to the increased thermal barrier effect.

• Journal of ILASS-Korea
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• v.13 no.4
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• pp.193-199
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• 2008

Spray coating is a versatile surface modification technology in which coating is built-up based on the successive deposition of micron-scaled particles. Depending on the coating materials, the coatings can meet the required mechanical properties, corrosion resistance, and other properties of base materials. Spraying processes are mainly classified into thermal and kinetic spraying according to their bonding mechanism and deposition characteristics. Specifically, thermal spraying process can be further classified into many categories based on the design and mechanism of the process, such as frame spraying, arc spraying, atmospheric plasma spraying (APS), and high velocity oxygen-fuel (HVOF) spraying, etc. Kinetic spraying or cold gas dynamic spraying is a newly emerging coating technique which is low-temperature and high-pressure coating process. In this paper, overall view of thermal and kinetic spray coating technologies is discussed in terms of fundamentals and industrial applications. The technological characteristics and bonding mechanism of each process are introduced. Deposition behavior and properties of technologically remarkable materials are reviewed. Furthermore, industrial applications of spray coating technology and its potentials are prospected.

• Journal of the Korean Vacuum Society
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• v.7 no.s1
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• pp.179-182
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• 1998

Boron carbide coating has some very attractive properties for nuclear and semiconductor industry. The potential of atmosheric plasma spray as manufacturing methods for $B_4C$ coating was discussed. In this work, the boron carbide coating with low porosity, high microhardness and good life of thermal shock resistance was deposited by the control of spraying distance. The relationship between the properties of $B_4C$ coatings and their spraying distance was studied.

• Proceedings of the KWS Conference
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• 2003.05a
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• pp.111-113
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• 2003

The existing heating unit is indirect-heating method that make use or the nichrome wire or halogen lamp. The indirect-heating method has the demerits of long warming time, high power consumption and many organization parts. In this study, the heating unit of direct-heating method manufactured as being the thermal spray coating of conductive heating material on the surface of heating unit in order to improve the demerits of indirect-heating method. And YSZ added Ni-20Cr that had moderate electrical resistivity was chosen of the conductive heating material.

• Journal of the Korea Institute of Building Construction
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• v.21 no.6
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• pp.539-550
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• 2021

In this study, Zn and Zn-15Al were coated on general carbon steel by plasma arc metal spraying and then immersed in a 3.5wt.% NaCl solution similar to the seawater environment to evaluate the corrosion resistance properties. Through the surface shape analysis test by SEM and XRD, it was found that the Zn coating was porous and needle-shaped, so the penetration of the electrolyte was easy, and thus the corrosion rate was rapid. On the other hand, the Zn-15Al coating had a uniform and dense shape and was shown to suppress corrosion.

• Proceedings of the Korean Institute of Surface Engineering Conference
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• 2003.10a
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• pp.11-11
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• 2003

Electroplated hexavalent chromium coatings have been used in many technical applications since it was invented by G.J. Sargent in 1920. Because of the environmental problems and health risks associated with the use of hexavalent chromium, there has been an extensive search for alternative coatings with properties such as corrosion resistance and wear resistance, at a reasonable cost. However there is no single substitute that meets all the desirable performance characteristics of chromium. Advanced techniques, such as alloy plating, electroless plating, trivalent chromium plating, plasma and thermal spray coating, PVD and ion implantation, have been applied for replacing hexavalent chromium plating.