Columnar Coating Vaporization via Liquid Corpuscle Injection
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Solution Overview
Problem
Existing methods for producing coatings with columnar structures are inefficient in terms of material evaporation and deposition, limiting their effectiveness in withstanding thermal cycling and maintaining a dense, strain-tolerant microstructure.
Innovation Solution
A method involving the injection of primary corpuscles with a carrier gas into a thermal process jet, where the corpuscles are disintegrated by mechanical and thermal interaction, allowing for complete or partial vaporization and deposition of the coating material as a columnar coating on a substrate, utilizing adjustable process parameters to control the plasma jet properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermal spraying processes are used to produce columnar coatings, then the coating can be deposited on the substrate, but the material evaporation and deposition efficiency is low
Solution Approach 1:
The invention changes the physical state parameter of the coating material from solid particles to liquid droplets before injection into the plasma jet. This parameter change enables more efficient vaporization and deposition, directly addressing the low efficiency problem in conventional thermal spraying processes while reducing production time
2Productivity
If the coating material is injected as solid particles, then the material can be supplied to the plasma jet, but the vaporization is incomplete and deposition efficiency is reduced
Solution Approach 1:
The invention utilizes phase transition by converting solid coating material into liquid droplets through pre-heating before injection into the plasma jet. This phase transition from solid to liquid state enables more complete vaporization and efficient deposition, reducing material loss while improving productivity
3Productivity
If the plasma jet temperature is increased to improve vaporization, then the evaporation efficiency increases, but the risk of coating material oxidation and energy consumption increases
Solution Approach 1:
The invention applies preliminary action by pre-heating the coating material to convert it from solid to liquid state before injection into the plasma jet. This preliminary thermal treatment reduces the energy required during plasma vaporization, lowering overall energy consumption while maintaining high evaporation efficiency
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
This method enables the efficient production of dense, columnar coatings with low porosity and enhanced strain tolerance to thermal cycling, significantly prolonging the coating's lifetime by ensuring reversible stress responses without cracking.
Implementation Method 1
a coating material in the form of primary corpuscles (1) is injected with a carrier gas into a thermal process jet
Implementation Method 2
the particles are dispersed, so that the coating material is completely or partially vaporized by thermal action on the individual particles
Implementation Method 3
the coating material is completely or partially vaporized by thermal action on the individual particles
Implementation Method 4
The primary corpuscles are disintegrated in the process jet by mechanical and thermal interaction
Implementation Method 5
The coating material is converted into a vapor phase in the process jet and deposited as a condensate in the form of a columnar coating on a substrate (100)
Data Source
Figure 1
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AI summary
In a process for producing a coating (10) with a columnar, preferably dense structure, a coating material in the form of primary corpuscles (1) is injected with a carrier gas into a thermal process jet. The coating material is converted into a vapor phase in the process jet and deposited as condensate in the form of a columnar coating on a substrate (100). The primary corpuscles are liquid droplets or are each formed by a cluster of particles (2) held together by cohesive forces of a binding medium or by adhesive forces. The liquid droplets contain a chemical precursor of the coating material in the form of a salt solution, which is converted into secondary corpuscles containing particles (2) by thermal action in the process jet. The primary and secondary corpuscles are disintegrated in the process jet by mechanical and thermal interaction.The particles are dispersed, so that the coating material is completely or partially evaporated by thermal action on the individual particles.