Thermal spray deposition of fine powder particles via melting, liquid suspension and solid states

The coating microstructure and quality are strongly related to the starting feedstock powder features. Spraying of the fine powder particles is a suitable solution to enhance the coating microstructure and overcome the defects of conventional spray coatings, such as large pores, cracks and voids. However, the poor rheological properties, low flowability, and easy agglomeration of the fine powders are big challenges.

In Advanced Coating Technology Research Center of AIST, we are focusing on spraying of the fine ceramic particles by different spraying techniques. This study will introduce one of our recent development of spraying the fine ceramic particles directly by a newly developed dc plasma spraying system. Furthermore, the talk discuss the results with other fine particles spraying techniques of axial suspension plasma spraying (ASPS) and plasma assisted aerosol deposition (so called Hybrid Aerosol Deposition; HAD).

This work was conducted in part by High-value added ceramic products manufacturing technologies project supported by Innovative design/manufacturing technologies, a part of SIP (Cross-ministerial Strategic Innovation Promotion Program; managed by NEDO), CSTI (Council for Science, Technology and Innovation).