Transcript SERDP Plasma ID update

SERDP Plasma ID update
21st HCAT Program Review
Toronto, September 26, 2002
Keith Legg 847-680-9420
Program objective

Develop plasma spray for smooth, low porosity
coatings for IDs

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standard, small particle, nanoagglomerates
Evaluate new miniature guns for minimal spray
diameter
Keith Legg 847-680-9420
How it all fits together
Praxair Indianapolis
Sulzer Metco
NRC
All guns
Equipment
Sulzer Metco F-300
Praxair 2700 miniature
Characterize performance
– velocity and temperature
profiles
Sulzer Metco F-100
30kW, 1.5” ID
20 kW 4” ID
Sulzer Metco F-210
12kW, 2.5” ID
Powder
Standard WC-Co
Tribaloy 400
Standard WC-Co powders
All powders
Small particles
WC-Co small
particles
Nano-agglomerate WC-Co
Optimize spray conditions
Do small
particles
provide better
quality?
Best conditions for large parts
– landing gear outer cylinders
Characterize coatings and
coated tubes
Do nanoparticles give better
particles? – OSH issues
Evaluate OSH issues of
nanopowders
Nano-agglomerates
Issues
How small a diameter can
we coat?
And with what type of
powder?
Consider other materials
Keith Legg 847-680-9420
Findings so far

Nanoagglomerate WC-Co is not really commercially
available

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Minimum ID that can be coated with good properties is
2.5 - 3”
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
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therefore cannot be used
coatings are high rate, so ideal for landing gear and utility
actuators
Sulzer Metco may evaluate new, smaller F 300 gun
T 400, WC-12Co, WC self-fluxing
(WC12Co)33Ni9Cr3.5Fe2Si2B2.5C now optimized

Latest WC-Co and self-fluxing look very good
Keith Legg 847-680-9420
Sample holder
Pull test
Metallography
Corrosion
Almen
Wear
Sulzer F 210
Praxair SG 2700
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Measurement of porosity


NRC standard polishing
procedure (Jean-Gabriel
Legoux)
Cutting

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b)
high speed diamond
wheel
Mounting


a)
vacuum infiltration
Polishing
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SiC grind
9m diamond, 3m
diamond
OP-A acidic alumina
a) vacuum mount, b) Bakelite hot mount (smears)
6.4% porosity
2.7% porosity
Sa mple
IM I
Std
production
5- 3
14.3
5.6
12- 4
7.5
0.1
12- 6
7.5
0.5
13- 2
7.9
0.4
14- 1
7.2
1.9
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Issues to be resolved
T400 coating
Tube
3” ID
0.0165” thick
600 ” Ra

overspray
7” long
0.0115” thick
300 ” Ra
Tube rotates, spray head goes in and out
Keith Legg 847-680-9420
ID vs OD spray microstructure
WC-Co 38m powder, 60
OD spray, 3% porosity

WC-Co 38m powder, 60
ID spray, 9% porosity
Overspray incorporates into coating as go down tube

Additional air jets to blow overspray powder away under test at
Praxair
Keith Legg 847-680-9420
Are guns different?

Sulzer Metco gun has additional gas sources to cool
gun
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appears to be effective in blowing out more overspray
Will be checking the different guns and making mods
to gas flow as necessary
NRC has made “FumeSpector” dust storm monitor
Keith Legg 847-680-9420
To be done next few months
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Minimize overspray incorporation
Spray test samples using holder
Property and performance testing
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metallography, adhesion, Almen,
wear, abrasion, corrosion, fatigue
Keith Legg 847-680-9420