Ceramic Composite Coating Injection Guided by Molten Pool Infrared Imaging
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Solution Overview
Problem
Existing methods for fabricating ceramic reinforced metal matrix composite coatings face issues such as decomposition and segregation of ceramic particles, leading to coating cracking due to differences in density and thermal expansion coefficients.
Innovation Solution
A device and method utilizing plasma remelting and injection, where ceramic particles are injected into a molten pool formed by a plasma arc, with the optimal injection position calculated using thermal infrared imaging to minimize segregation and decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional alloy coatings are used, then the coating has good toughness and plasticity, but the wear resistance and corrosion resistance are insufficient
Solution Approach 1:
The patent applies composite materials by combining metal matrix with ceramic reinforcement particles (such as WC, TiC, Al2O3, SiC) to create a composite coating that exhibits both the toughness and plasticity of metal and the wear resistance and corrosion resistance of ceramic, thereby simultaneously improving both properties that were previously contradictory
2Reliability
If ceramic particles are added to metal matrix, then the wear resistance and corrosion resistance improve, but the ceramic particles decompose and segregate during fabrication
Solution Approach 1:
The patent changes the fabrication parameters by using plasma remelting technology with controlled temperature fields and injection parameters. By optimizing the plasma power (20-50 kW), injection pressure (0.2-0.8 MPa), and injection timing, the process prevents ceramic particle decomposition and segregation, achieving uniform distribution while maintaining enhanced wear and corrosion resistance
Solution Approach 2:
The patent replaces traditional mechanical mixing methods with plasma remelting and injection technology. The plasma arc creates a controlled molten pool that facilitates uniform ceramic particle distribution through fluid dynamics and thermal fields, eliminating the segregation issues associated with mechanical mixing
3Strength
If ceramic particles are injected into molten pool, then the coating strength improves, but residual stress increases causing coating cracking
Solution Approach 1:
The patent changes process parameters including plasma power (20-50 kW), injection pressure (0.2-0.8 MPa), and cooling rates to control the solidification process. These parameter optimizations reduce thermal gradients and phase transformation stresses, thereby minimizing residual stress while maintaining high coating strength and preventing cracking
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively prevents segregation and thermal decomposition of ceramic particles, reduces residual stress in the coating, and enhances the coating's wear and corrosion resistance, thereby improving its overall performance.
Implementation Method 1
the plasma generator is configured to generate a plasma arc beam, and the plasma arc beam is used to heat the metal-based substrate and form a molten pool on a surface of the metal-based substrate
Implementation Method 2
The thermal infrared imager is configured to acquire an infrared image of the molten pool
Data Source
AI summary
A device and a method for fabricating a ceramic reinforced composite coating based on plasma remelting and injection. The device includes a plasma cladding assembly, a powder feeding assembly, a metal-based substrate, and a thermal infrared imager. The plasma cladding assembly comprises a plasma gun and a plasma generator. A plasma arc generated is used to heat the substrate and form a molten pool on the substrate. The powder feeding assembly comprises a powder feeder configured to feed ceramic particles to the molten pool through a powder feeding copper tube. The thermal infrared imager is configured to acquire an infrared image of the molten pool and acquire an optimal injection position of the ceramic particles according to the infrared image. The optimal injection position is a midpoint between a trailing edge of the plasma arc emitted on the substrate and a trailing edge of the molten pool.