ADVANCED PLASMA SPRAY APPLICATIONS Edited by Hamidreza Salimi Jazi Advanced Plasma Spray Applications Edited by Hamidreza Salimi Jazi Published by InTech Janeza Trdine 9, 51000 Rijeka, Croatia Copyright © 2012 InTech All chapters are Open Access distributed under the Creative Commons Attribution 3.0 license, which allows users to download, copy and build upon published articles even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. After this work has been published by InTech, authors have the right to republish it, in whole or part, in any publication of which they are the author, and to make other personal use of the work. Any republication, referencing or personal use of the work must explicitly identify the original source. As for readers, this license allows users to download, copy and build upon published chapters even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. Notice Statements and opinions expressed in the chapters are these of the individual contributors and not necessarily those of the editors or publisher. No responsibility is accepted for the accuracy of information contained in the published chapters. The publisher assumes no responsibility for any damage or injury to persons or property arising out of the use of any materials, instructions, methods or ideas contained in the book. Publishing Process Manager Silvia Vlase Technical Editor Teodora Smiljanic Cover Designer InTech Design Team First published March, 2012 Printed in Croatia A free online edition of this book is available at www.intechopen.com Additional hard copies can be obtained from orders@intechopen.com Advanced Plasma Spray Applications, Edited by Hamidreza Salimi Jazi p. cm. ISBN 978-953-51-0349-3 Contents Preface IX Part 1 Plasma Spray for Corrosion and Wear Resistance 1 Chapter 1 Thermal Sprayed Coatings Used Against Corrosion and Corrosive Wear 3 P. Fauchais and A. Vardelle Chapter 2 The Influence of Dry Particle Coating Parameters on Thermal Coatings Properties 39 Ricardo Cuenca-Alvarez, Carmen Monterrubio-Badillo, Fernando Juarez-Lopez, Hélène Ageorges and Pierre Fauchais Chapter 3 Isothermal Oxidation Behavior of Plasma Sprayed MCrAlY Coatings 61 Dowon Seo and Kazuhiro Ogawa Chapter 4 Analysis of Experimental Results of Plasma Spray Coatings Using Statistical Techniques 83 S.C. Mishra Part 2 Plasma Spray in Biomaterials Applications 97 Chapter 5 Plasma Sprayed Bioceramic Coatings on Ti-Based Substrates: Methods for Investigation of Their Crystallographic Structures and Mechanical Properties 99 Ivanka Iordanova, Vladislav Antonov, Christoph M. Sprecher Hristo K. Skulev and Boyko Gueorguiev Chapter 6 Effect of Hydrothermal Self-Healing and Intermediate Strengthening Layers on Adhesion Reinforcement of Plasma-Sprayed Hydroxyapatite Coatings 123 Chung-Wei Yang and Truan-Sheng Lui VI Contents Part 3 Plasma Spray in Nanotechnology Applications 147 Chapter 7 Solution and Suspension Plasma Spraying of Nanostructure Coatings 149 P. Fauchais and A. Vardelle Chapter 8 A Solid State Approach to Synthesis Advanced Nanomaterials for Thermal Spray Applications 189 Behrooz Movahedi Part 4 Plasma Spray in Polymer Applications 219 Chapter 9 Atmospheric Pressure Plasma Jet Induced Graft-Polymerization for Flame Retardant Silk 221 Dheerawan Boonyawan Preface I have been familiar with plasma spraying in one of the leading thermal spray research laboratories in North America; Centre for Advanced Coating Technologies at the University of Toronto since I started my PhD thesis under supervision of Professors Javad Mostaghimi and Thomas W. Coyle in 2001. Having access to various methods of thermal spraying, diagnostic tools, and processes simulation, I gained experiences in process, deposition, characterization, and simulation of various types of thermal spray coatings. One member of the family of thermal spray processes is plasma spraying which has a direct current (dc) arc or radio frequency (RF) discharge as a heat source. The plasma spray torch, generally, consists of a cathode and anode. The anode is usually high purity oxygen free copper and the cathode is made from tungsten. A gas, such as argon or nitrogen or a mixture of these with hydrogen or helium, flows around the cathode and through the anode which serve as a constricting nozzle. A direct current (dc) arc, initiated with a high frequency discharge is maintained between the anode and the cathode. The power of the gun varies between 5 to 250 kW depending on the type of torch and the operation parameters. The plasma gas generated by the arc consists of free electrons, ionized atoms, and some neutral atoms and undissociated diatomic molecules if hydrogen or nitrogen is used. The temperature of the core of the plasma jet may exceed up to 30,000 K. Gas velocity in the plasma spray torch can be varied from subsonic to supersonic using converging-diverging nozzles (between 600 ms-1 with pure Ar and 2300 ms-1 with Ar-H2). In an ideal plasma spray process, powders are fed into the high velocity, high temperature gas jet, generated by a plasma gun, using a feeder system with a specific feeding rate (107–108 particles per second). Feeding powders have a relatively wide size distribution and the melting behavior and momentum of powders will be different. Depending on the powder size distribution and plasma spraying process parameters, the powders are completely or partially melted and accelerated (depending on their masses and trajectories) toward the substrate or mandrel mold. Therefore, the molten or semi-molten powders have various temperature and axial velocity distributions at the deposition point. Finally, the droplets solidify after impacting the substrate with a very high cooling rate (~104–108 ºC/sec) forming lamellae (splats) and build up deposits by laying of splats. X Preface The temperature in the plasma jet core is high enough to melt any material, given sufficient time. Heat transfer in the plasma jet is primarily the result of the recombination of the ions and re-association of atoms in diatomic gases on the powder surfaces and absorption of radiation. Due to the nature of the plasma plume and plasma deposition, plasma spray has received a large amount of attentions from highly trained researchers and engineers to be used in various applications in industries such as, polymer, biomedical, electronic, automobiles, and etc. The current book gives the state-of-the-art researches of new and advanced applications in the fields of plasma spraying. Some new applications of coatings deposited by plasma spraying are comprehensively discussed in Chapter 1. In Chapter 2, a few application of plasma spraying in biomaterials is addressed. Nano powder production and deposition of nanostructure coatings by plasma spraying are investigated in Chapter 13. In Chapter 4, the application of plasma plume in polymer industry for surface modification and treatment is addressed. Dr. Hamidreza Salimi Jazi Isfahan University of Technology, Isfahan, Iran . thermal spray concept, Fauchais et al (2012) Advanced Plasma Spray Applications 6 2.1 Thermal spray processes 2.1.1 Plasma- based processes They comprise d.c. plasma spraying, plasma transferred. ADVANCED PLASMA SPRAY APPLICATIONS Edited by Hamidreza Salimi Jazi Advanced Plasma Spray Applications Edited by Hamidreza Salimi. developments (AS: Powder flame spraying, FS: Wire flame spraying, PS: Air plasma spraying, VPS: Vacuum plasma spraying, C.S.: Cold Spray) Gärtner et al (2006). Wire arc spraying: instead of using