Thermal Spray Slurry Supply Efficiency via Dispersion Stability
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Solution Overview
Problem
Thermal spray slurries experience precipitation of thermal spray particles during storage due to differences in specific gravity and particle diameter, leading to reduced supply efficiency and potential clogging in the supply system.
Innovation Solution
A thermal spray slurry with a supply efficiency index of 70% or higher is achieved by using a dispersion medium and thermal spray particles with specific characteristics, including a suitable particle size distribution and the addition of dispersing agents, which maintains the slurry's fluidity and stability during storage and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal spray particles are dispersed in a dispersion medium to form a slurry, then the slurry can be supplied to thermal sprayers, but precipitation of thermal spray particles occurs during storage due to specific gravity differences
Solution Approach 1:
A dispersing agent is introduced as an intermediary substance between the thermal spray particles and the dispersion medium. The dispersing agent adsorbs onto the particle surfaces, providing steric or electrostatic repulsion that prevents aggregation and precipitation, thereby maintaining slurry stability during storage while enabling continuous supply to thermal sprayers.
Solution Approach 2:
The physical and chemical parameters of the slurry are optimized, including particle size distribution (0.1-10 μm), solid content (10-50 wt%), and dispersing agent concentration. These parameter adjustments balance the competing requirements of maintainable stability during storage and sufficient fluidity for efficient supply to thermal sprayers.
2Stability of the object's composition
If thermal spray particles are supplied in powder form, then precipitation is avoided, but the particles cannot be efficiently supplied to thermal sprayers
Solution Approach 1:
The slurry is designed with optimized rheological properties (viscosity, flowability) to enable efficient hydraulic supply through pipelines and pump systems. The dispersion medium and particle size distribution are selected to ensure the slurry can be pumped and delivered to thermal sprayers without clogging or excessive energy consumption, achieving supply efficiency of 70% or higher.
3Quantity of substance
If the thermal spray particle content in the slurry is increased, then more particles can be supplied, but precipitation and solidification occur more readily
Solution Approach 1:
The slurry is formulated as a composite system combining thermal spray particles (10-50 wt%), dispersion medium, and dispersing agent. This composite structure allows high particle content while maintaining stability through the synergistic effects of the dispersing agent and optimized particle size distribution, ensuring reliable supply without precipitation or solidification.
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 solution ensures stable and efficient supply of thermal spray particles to the sprayer, reducing precipitation and solidification, and enables the formation of high-quality thermal spray coatings with improved fluidity and adhesion.
Implementation Method 1
a dispersion medium and thermal spray particles... the thermal spray particles are dispersed... dispersion stability of the thermal spray particles in the slurry increases
Implementation Method 2
thermal spray particles formed of materials such as ceramic, cermets and metals softened or melted by combustion energy or by electric energy
Implementation Method 3
softened or melted by combustion energy
Data Source
AI summary
This invention provides a thermal spray slurry capable of forming a favorable thermal spray coating. The thermal spray slurry comprises a dispersion medium and thermal spray particles formed of at least one material selected from the group consisting of a ceramic, a cermet and a metal. 800 mL of the thermal spray slurry contains A kg of the thermal spray particles; when 800 mL of the thermal spray slurry in which the thermal spray particles are dispersed is supplied at a flow rate of 35 mL/min to a horizontally-placed tube and collected, the collected slurry contains B kg of the thermal spray particles; and the slurry has a supply efficiency index If of 70% or higher, determined by the next equation If (%)=B/A×100.