Plasma Spraying of Functionally Graded Materials: Measured and Simulated Results

2000 ◽  
Author(s):  
J.R. Fincke ◽  
R.L. Williamson ◽  
C.H. Chang
Keyword(s):  
Functionally Graded Materials ◽  
Gas Flow ◽  
Particle Temperature ◽  
Computer Code ◽  
Functionally Graded ◽  
Turbulent Dispersion ◽  
Particle Model ◽  
Graded Materials ◽  
Measured Velocity ◽  
Discrete Particle Model

Abstract Thermal spray processing of functionally graded materials requires that the spray patterns of different particle types coincide at impact and that each particle type arrives with the appropriate temperature and degree of melting. Measurements of particle velocity, temperature, and size along with spray pattern characteristics have been obtained for co-injected NiCrAlY and zirconia powder. The plasma and particle flow fields were also simulated with a pseudo 3-D model using the LAVA computer code. The model assumes that the gas flow is axisymmetric while the particles are treated in a fully 3-D manner. A stochastic discrete-particle model that includes turbulent dispersion dictates particle behavior. The simulation produced reasonably accurate velocities and particle trajectories, although, particle temperature is consistently over predicted. Comparisons between the calculated and measured velocity and temperature statistical distributions and calculated molten fractions are discussed.

Solidification Processing of Functionally Graded Materials by Sedimentation

1999 ◽  
Author(s):  
J. W. Gao ◽  
S. J. White ◽  
C. Y. Wang
Keyword(s):  
Functionally Graded Materials ◽  
Volume Fraction ◽  
Particle Volume Fraction ◽  
Computer Code ◽  
Functionally Graded ◽  
Particle Volume ◽  
Particle Sedimentation ◽  
Graded Materials ◽  
Free Zone ◽  
Free Region

Abstract A combined experimental and numerical investigation of the solidification process during gravity casting of functionally graded materials (FGMs) is conducted. Focus is placed on the interplay between the freezing front propagation and particle sedimentation. Experiments were performed in a rectangular ingot using pure substances as the matrix and glass beads as the particle phase. The time evolutions of local particle volume fractions were measured by bifurcated fiber optical probes working in the reflection mode. The effects of various processing parameters were explored. It is found that there exists a particle-free zone in the top portion of the solidified ingot, followed by a graded particle distribution region towards the bottom. Higher superheat results in slower solidification and hence a thicker particle-free zone and a higher particle concentration near the bottom. The higher initial particle volume fraction leads to a thinner particle-free region. Lower cooling temperatures suppress particle settling. A one-dimensional solidification model was also developed, and the model equations were solved numerically using a fixed-grid, finite-volume method. The model was then validated against the experimental results, and the validated computer code was used as a tool for efficient computational prototyping of an Al/SiC FGM.

Plasma Processing of Functionally Graded Materials Part I: Process Diagnostics

1997 ◽  
Author(s):  
W.C. Smith ◽  
T.J. Jewett ◽  
S. Sampath ◽  
W.D. Swank ◽  
J.R. Fincke
Keyword(s):  
Functionally Graded Materials ◽  
Particle Temperature ◽  
Particle Morphology ◽  
Functionally Graded ◽  
Complete Analysis ◽  
Spray Parameters ◽  
Trajectory Data ◽  
Graded Materials ◽  
Particle Species ◽  
Initial Stage

Abstract An investigation into the dependency of the formation of functionally graded materials (FGMs) on process variables was carried out. The initial stage of the investigation involved a complete analysis of the plasma spray parameters used in the fabrication of an FGM constructed of NiCrAlY and partially stabilized zirconia (PSZ). In flight particle temperature, velocity and trajectory data were gathered for individual powders, as well as mixtures of the particle species, over a range of spray parameters. This data was combined with material specific properties such as flowability, apparent density, particle morphology and size distribution. The end result of the studies allowed for size matching of the particle species so as to ensure both species were molten at the nominal spray distance and possessed coincident impact velocities. Following the initial investigation, two spray conditions were selected for further analysis. Individual layers of specific powder mixture ratios were deposited as well as a complete FGM structure. The resulting structures were then compared based on their deposition efficiencies, porosity levels, compositional homogeneity and microstructures.

Dynamic Analysis with Stress Recovery for Functionally Graded Materials: Numerical Simulation and Experimental Benchmarking

2014 ◽  
Vol 2 (1) ◽  
pp. 21
Author(s):  
Carlos Alberto Dutra Fraga Filho ◽  
Fernando César Meira Menandro ◽  
Rivânia Hermógenes Paulino de Romero ◽  
Juan Sérgio Romero Saenz
Keyword(s):  
Numerical Simulation ◽  
Dynamic Analysis ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Stress Recovery ◽  
Graded Materials
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