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Title: Feedback enhanced plasma spray tool

Abstract

An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.

Inventors:
; ; ; ; ;
Issue Date:
Research Org.:
Idaho National Lab. (INL), Idaho Falls, ID (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1175558
Patent Number(s):
6967304
Application Number:
10/423,237
Assignee:
Cyber Materials LLC (Auburndale, MA)
Patent Classifications (CPCs):
B - PERFORMING OPERATIONS B05 - SPRAYING OR ATOMISING IN GENERAL B05B - SPRAYING APPARATUS
Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02T - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
DOE Contract Number:  
AC07-99ID13727
Resource Type:
Patent
Country of Publication:
United States
Language:
English
Subject:
47 OTHER INSTRUMENTATION

Citation Formats

Gevelber, Michael Alan, Wroblewski, Donald Edward, Fincke, James Russell, Swank, William David, Haggard, Delon C., and Bewley, Randy Lee. Feedback enhanced plasma spray tool. United States: N. p., 2005. Web.
Gevelber, Michael Alan, Wroblewski, Donald Edward, Fincke, James Russell, Swank, William David, Haggard, Delon C., & Bewley, Randy Lee. Feedback enhanced plasma spray tool. United States.
Gevelber, Michael Alan, Wroblewski, Donald Edward, Fincke, James Russell, Swank, William David, Haggard, Delon C., and Bewley, Randy Lee. Tue . "Feedback enhanced plasma spray tool". United States. https://www.osti.gov/servlets/purl/1175558.
@article{osti_1175558,
title = {Feedback enhanced plasma spray tool},
author = {Gevelber, Michael Alan and Wroblewski, Donald Edward and Fincke, James Russell and Swank, William David and Haggard, Delon C. and Bewley, Randy Lee},
abstractNote = {An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2005},
month = {11}
}

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Works referenced in this record:

Plasma spray processes: diagnostics and control?
journal, October 1999


Diagnostics and control in the thermal spray process
journal, September 2001


In-flight particle surface temperature measurement: Influence of the plasma light scattered by the particles
journal, September 1993


Rapid solidification and microstructure development during plasma spray deposition
journal, December 1996