Objective
The objectives of the project are as follows:
a study of spray drying, including characterisation of starting powders and powders produced;
a study of the plasma densification process in air, underwater, and in a controlled atmosphere;
the production of these characteristics on the plasma spray process and the coating properties;
the reproducibility and reliability of the powder production.
Yttria powder and magnesia stabilised zirconia powder have been processed by spray drying. A densification process of the agglomerated particles shows a dense structure with a smooth spherical surface. Parameters and spraying criteria for coating production have been developed. The microstructure of the deposits meets the aerospace standards. With round robin tests, ceramographic methods are developed to obtain reproducible results in coating characterisation. The coatings produced are tested and characterised by thermal behaviour, corrosion, internal stresses, thermal shock and bond strength properties.
In the field of production of thermal barrier coatings from ceramic zirconia powders, the following research has been conducted:
a study of spray drying, including the characterization of the starting and resulting powders;
a study of the plasma densification in air, under water and in a controlled atmosphere;
characterization of densified powders;
coating production by optimization of spraying and correlation with powder characteristics;
development of ceramographic methods to obtain reproducible results;
characterization of coatings by standard metallographic and X-ray techniques, as well as the measurement of physical properties and their correlation with powder characteristics;
testing of coating properties (corrosion, bond strength, thermal shock, etc) and correlation with powder characteristics.
It is possible to produce dense, globular composite powders with the desired particle size distribution. The production routes can be applied to powders other than zirconia composites.
A new production route has been developed for the production of globular dense composite zirconia powders which can be produced in a predefined particle size range. Spray drying and plasma densification of the spray dried powders are the major steps with the powders produced by underwater plasma densification and transferred arc densification exhibiting particularly good flowability. This outstanding flowability makes the powders very suitable for plasma spraying of thermal barrier coatings.
The coatings produced using these powders have been investigated with respect to their structure and their mechanical and thermal properties, and have been shown to be at least as good as those produced using commercially available powders.
THE AIM OF THIS STUDY IS TO ADAPT THE PLASMA SPRAY TECHNIQUE TO IC ENGINES BY STUDYING CAREFULLY THE MATERIAL POINT OF VIEW. THE SPECIFIC INNOVATIC VALUE OF THIS PROJECT WILL BE THREEFOLD:
1) THE PRODUCTION OF POWDERS WITH KNOWN CHARACTERISTICS;
2) THE INFLUENCE OF THESE CHARACTERISTICS ON THE SPRAYING PROCESS AND THE COATING PROPERTIES LIKE CORROSION BEHAVIOUR, MECHANICAL PROPERTIES;3) THE REPRODUCIBILITY AND RELIABILITY OF THE POWDER PRODUCTION.
IF THIS PROJECT SUCCEEDS THE RESULTS WILL BE A BREAK THROUGH NOT ONLY IN THE PRODUCTION OF CHEAPER THERMAL BARRIERS COATINGS BUT ALSO IN THE DEVELOPMENT OF SMALL AND MEDIUM SIZE DIESEL ENGINES WITH LESS COOLING, BETTER PERFORMANCE AND EFFICIENCY UP TO 5 %.
IN ORDER TO ACHIEVE THESE OBJECTIVES, IT IS PROPOSED:
A) A STUDY OF SPRAY DRYING, INCLUDING CHARACTERIZATION OF STARTING POWDERS AND PRODUCED POWDERS;
B) A STUDY OF THE PLASMA DENSIFICATION PROCESS, IN AIR, UNDER WATER AS WELL AS IN A CONTROLLED ATMOSPHERE;
C) CHARACTERIZATION OF DENSIFIED POWDERS (CHEMICAL AND PHYSICAL ANALYSIS);D) COATING PRODUCTION BY OPTIMIZATION OF THE SPRAYING PROCESS AND CORRELATING WITH THE POWDER CHARACTERISTICS;
E) DEVELOPMENT OF CERAMOGRAPHIC METHODS TO OBTAIN REPRODUCIBLE RESULTS (ROUND ROBIN TEST);
F) CHARACTERIZATION OF THE COATINGS WITH STANDARD METALLOGRAPHIC AND X-RAY TECHNIQUES, AS WELL AS THE MEASUREMENT OF PHYSICAL PROPERTIES, AND CORRELATE WITH POWDER CHARACTERISTICS;
H) THE PRODUCTION OF PROTOTYPE AMOUNTS (BATCHSIZE 25 TO 50 KG) OF POWDER FOR COMPONENT TESTING.
AFTER H) COMPONENT SPRAYING AND COMPONENT TESTING WILL FOLLOW, TOGETHER WITH AN ECONOMIC EVALUATION.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology materials engineering composites
- engineering and technology materials engineering coating and films
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Multi-annual funding programmes that define the EU’s priorities for research and innovation.
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Calls for proposals are divided into topics. A topic defines a specific subject or area for which applicants can submit proposals. The description of a topic comprises its specific scope and the expected impact of the funded project.
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Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Coordinator
5943 AD Lomm
Netherlands
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.