Plasma Torch Thermal Barrier Deposition
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Solution Overview
Problem
Current methods for depositing thermal barrier materials on substrates, such as plasma spraying and vapor phase deposition, face limitations including porosity, limited lifetime, high thermal conductivity, and high implementation costs, as well as challenges in achieving uniform thickness on complex shapes and low deposition rates.
Innovation Solution
A method using two plasma torches to create a resultant plasma jet that vaporizes powder particles, allowing for a hybrid deposit structure combining low thermal conductivity and good lifetime, with reduced power requirements and no need for a secondary vacuum, enabling higher deposition rates and yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If plasma spraying is used to deposit thermal barrier material, then the deposit has low thermal conductivity due to porous structure, but the deposit has limited lifetime due to microcracks and spalling
Solution Approach 1:
The invention changes the physical state parameter of the deposited material from liquid droplets (plasma spraying) to vapor phase (vapor deposition), which fundamentally alters the deposit morphology from lamellar to columnar, thereby improving lifetime while maintaining thermal insulation
Solution Approach 2:
The invention creates a composite deposit structure with columnar morphology that combines the benefits of low thermal conductivity with improved mechanical properties and resistance to thermal expansion, effectively merging advantages of both plasma spraying and vapor deposition
2Reliability
If electron beam vapor phase deposition is used to obtain good lifetime and erosion resistance, then the deposit has columnar morphology and good mechanical properties, but the thermal conductivity is higher than plasma spray deposits
Solution Approach 1:
The invention replaces the electron beam heating mechanism with a plasma torch heating mechanism, achieving vapor phase deposition without requiring high vacuum conditions, thereby reducing implementation costs while maintaining columnar deposit morphology and low thermal conductivity
3Reliability
If electron beam vapor phase deposition is used to achieve good deposit quality, then the deposit has excellent lifetime and erosion resistance, but the implementation cost is high due to high power requirements and vacuum systems
Solution Approach 1:
The invention substitutes the electron beam system with a plasma torch system, replacing electromagnetic heating with thermal plasma heating, which eliminates the need for high vacuum systems and reduces power consumption, thereby significantly lowering implementation costs while maintaining deposit quality
Solution Approach 2:
The invention uses a plasma torch that operates at atmospheric or near-atmospheric pressure, eliminating the need for expensive and complex high vacuum systems, thereby reducing equipment costs and operational complexity
4Ease of manufacture
If plasma spraying is used for thermal barrier deposition, then the method is simple and cost-effective, but the deposition rate is low and uniform thickness on complex shapes is difficult to achieve
Solution Approach 1:
The invention changes the deposition mechanism from droplet impact (plasma spraying) to vapor condensation (vapor deposition), which enables higher deposition rates and better conformal coating on complex geometries while maintaining cost-effectiveness through plasma torch technology
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 achieves a hybrid deposit with low thermal conductivity, good resistance to erosion, and lower implementation costs, while accommodating thermal expansion and providing improved adhesion and uniformity on complex substrates.
Implementation Method 1
the plasma jet, which reaches a temperature of 20,000 K and a speed of the order of 400 meters per second (m/s) to 1000 m/s entrains and melts the powder particles
Implementation Method 2
The plasma jet is generated by creating an electric arc between the anode and the cathode of a plasma torch, thereby ionizing the gaseous mixture blown through said arc by the plasma torch
Implementation Method 3
Once the material has been vaporized by the electron beam, it condenses on the substrate
Implementation Method 4
The plasma jet is generated by creating an electric arc between the anode and the cathode of a plasma torch, thereby ionizing the gaseous mixture
Implementation Method 5
creating an electric arc between the anode and the cathode of a plasma torch, thereby ionizing the gaseous mixture
Data Source
AI summary
The invention relates to the field of methods of depositing a material on a substrate. It relates to a method of depositing, onto a substrate, a material that acts as a thermal barrier and that prior to deposition is in powder form. The powder is introduced into the plasma jet of a first plasma torch and into the plasma jet of at least one second plasma torch, the first plasma torch and at least the second plasma torch being disposed in an enclosure and oriented in such a manner that their plasma jets cross, so as to create a resultant plasma jet in which the powder is vaporized, the substrate being placed on the axis of the resultant plasma jet.