Ceramic Thermal Spray Coating Surface Smoothing via Slurry Jetting
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Solution Overview
Problem
Existing surface treatment methods for ceramic thermal spray coatings, such as mechanical polishing and jetting, face challenges including damage to fragile ceramic coatings, difficulty in treating complex shapes, and surface pollution due to medium particles sticking to the surface.
Innovation Solution
A novel surface treatment method involving jetting a slurry containing a liquid with low viscosity and polyhedral powder medium particles with a median diameter of 1 to 50 μm, using compressed gas under a pressure of 0.01 to 1.0 MPa, to smooth the surface of ceramic thermal spray coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical polishing is used to smooth the surface of ceramic thermal spray coating, then the surface roughness is reduced, but the fragile ceramic coating is damaged and the substrate may be deformed
Solution Approach 1:
The patent replaces mechanical polishing (direct mechanical contact) with jetting treatment (fluid-based abrasive impact). The jetting system uses compressed gas to deliver abrasive particles at controlled velocities, smoothing the surface without the excessive localized loads that cause substrate deformation and coating damage in conventional mechanical polishing.
Solution Approach 2:
The patent controls the jetting parameters (compressed gas pressure, abrasive particle size distribution, liquid slurry composition, and jetting distance) to optimize surface smoothing while preventing damage. By adjusting these parameters, the process achieves the desired surface roughness reduction without exceeding the structural limits of the fragile ceramic coating.
2Manufacturing precision
If jetting with abrasive medium is used to smooth the surface, then the surface roughness is reduced, but the medium particles stick to the surface causing pollution
Solution Approach 1:
The patent introduces liquid slurry as an intermediary medium between the abrasive particles and the ceramic coating surface. The slurry carries the abrasive particles, controls their impact, and crucially, prevents direct adhesion of abrasive particles to the surface. The liquid component acts as a separator that allows the abrasive action to smooth the surface while the slurry itself can be easily removed without leaving polluting residues.
3Manufacturing precision
If conventional jetting is used on ceramic coatings, then the surface is treated, but the ceramic coating generates heat and electricity and is destroyed by friction
Solution Approach 1:
The liquid slurry serves as a cooling intermediary that absorbs friction heat generated during jetting and prevents it from concentrating in the ceramic coating. This thermal management prevents the coating from reaching temperatures that would cause degradation or destruction, while still allowing the abrasive particles to perform the surface treatment function.
4Manufacturing precision
If mechanical polishing is used on objects with curved surfaces or complex shapes, then the surface can be smoothed, but a large machining center is required and the area that can be treated is restricted
Solution Approach 1:
The patent replaces the requirement for large mechanical polishing machines with a portable jetting system. The jetting process uses compressed gas delivery to achieve surface smoothing without requiring the complex positioning and large workspaces needed for mechanical polishers to access curved and complex surfaces.
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 smooths the surface of ceramic thermal spray coatings, reducing the nascent surface-occupied area ratio and preventing the formation of fragile crushed layers, while being suitable for large or complex-shaped objects.
Implementation Method 1
jetting a slurry containing a liquid having a viscosity at a temperature of 20° C. of 10 mPa/s or lower and a powder medium having a polyhedral structure and having a median diameter (D50) of from 1 to 50 μm with a content of the powder medium of from 1 to 50 vol %, against a surface of a ceramic thermal spray coating, using a compressed gas under a pressure of from 0.01 to 1.0 MPa, to smooth the surface
Data Source
AI summary
To provide a surface treatment method for smoothing the surface of a ceramic thermal spray coating, and a ceramic thermal spray coating subjected to the surface smoothing treatment.A surface treatment method for a ceramic thermal spray coating, which comprises jetting a slurry containing a liquid having a viscosity at a temperature of 20° C. of 10 mPa/s or lower and a powder medium having a polyhedral structure and having a median diameter (D50) of from 1 to 50 μm with a content of the powder medium of from 1 to 50 vol %, against a surface of a ceramic thermal spray coating, using a compressed gas under a pressure of from 0.01 to 1.0 MPa, to smooth the surface of the ceramic thermal spray coating.