Plasma Spray Coating Using Embedded Powder Filament
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Solution Overview
Problem
Plasma spraying of fine powders faces challenges such as clumping and uneven application due to the use of gas-fed particles and liquid suspensions, which can cool the plasma jet and pose handling issues, necessitating improved systems and methods for powder application.
Innovation Solution
A method and system for plasma spraying using an elongated filament with embedded powder particles, where the filament is fed into a plasma jet at a controlled rate, allowing the organic binder to burn away and the powder to be plasticized, forming a ceramic coating on a substrate, thereby avoiding clumping and handling issues associated with liquid suspensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If gas-fed particles are used for plasma spraying, then powder can be applied to substrate, but clumping and uneven application occur
Solution Approach 1:
The patent uses a filament as an intermediary carrier to deliver powder particles to the plasma jet. Instead of directly spraying loose powder particles which cause clumping, the powder is embedded within a filament structure that controls its delivery and dispersion, ensuring uniform coating application without aggregation
Solution Approach 2:
The invention segments the powder delivery process by embedding discrete powder particles within a continuous filament matrix. This segmentation allows individual powder particles to be delivered separately and uniformly to the plasma jet, preventing clumping while maintaining controlled application rates
2Quantity of substance
If liquid suspension is used to carry powder, then powder can be transported, but plasma jet is cooled and handling issues arise
Solution Approach 1:
The filament serves as a dry intermediary carrier replacing liquid suspension. It transports powder particles to the plasma jet without introducing liquid that would cool the plasma, maintaining plasma temperature while enabling controlled powder delivery
Solution Approach 2:
The system uses gas flow to feed the filament into the plasma jet, replacing hydraulic (liquid suspension) methods with pneumatic delivery. This approach transports powder without liquid cooling effects while maintaining controlled delivery rates through gas pressure regulation
3Manufacturing precision
If fine powder is sprayed directly, then coating can be applied, but clumping occurs reducing coating quality
Solution Approach 1:
The filament acts as a stabilizing intermediary that holds fine powder particles in a controlled arrangement during delivery. This prevents the natural tendency of fine powders to clump upon contact with the plasma jet, ensuring consistent and reliable coating application
Solution Approach 2:
The powder particles are pre-positioned and stabilized within the filament structure before entering the plasma jet. This preliminary arrangement prevents clumping by ensuring uniform spatial distribution of particles prior to the coating process, improving coating consistency
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 approach enables even application of ceramic coatings without clumping, provides greater shear resistance, and simplifies waste handling, while avoiding the drawbacks of traditional liquid suspension techniques.
Implementation Method 1
application of a filament embedded with one or more powders, such as a fine ceramic powder, to a plasma jet to generate plasticized ceramic particles
Implementation Method 2
generate plasticized ceramic particles which impact a substrate, freeze, and form a ceramic coating
Implementation Method 3
The filament is then fed into a plasma jet at a controlled rate, similar to a wire spray process. Once exposed to the plasma jet, the organic filament burns away
Implementation Method 4
generate plasticized ceramic particles which impact a substrate, freeze, and form a ceramic coating
Implementation Method 5
the ceramic powder is plasticized and accelerated by the plasma jet, and flies through the air to the substrate where it deposits
Data Source
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AI summary
The present disclosure relates to a method for plasma spraying. In one embodiment, a method includes controlling application of a filament (210) embedded with powder particles (215) to a plasma jet (225;325;425) to generate a spray (230;330;430) for coating a substrate (240). The method for plasma spraying can include controlling a plasma source to generate a plasma jet (225;325;425), such that the spray (230;330;430) is formed by powder (215) that is plasticized and output by the plasma jet (225;325;425) to the substrate (240).