• Resources Recycling
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• v.9 no.4
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• pp.16-27
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• 2000

In order to produce raw material powder of advanced magnetic material by spray roasting process, newly modified spray roasting system was developed in this work. In this spray roasting system, raw material solution was effectively atomized and sprayed into the reaction furnace. Also, uniform temperature distribution inside reaction furnace made thermal decomposition process fully completed, and produced powder was effectively collected in cyclone and bag filter. This system equipped with apparatus which can purify hazard produced gas. In this study complex acid solution was prepared by dissolution of mill scale and ferro-Mn into the acid solution, and the pH of this complex acid solution was controlled about to 4. It was conformed that mill scale and ferro-Mn containing a lot of impurities such as $SiO_2$, P and Al could be used as raw material by reducing the impurities content of complex acid solution below 20 ppm. Complex oxide powder of Fe-Mn system was produced by spraying purified complex acid solution into the spray roaster through nozzle, and the variations of produced powder characters were studied by changing he reaction conditions such as reaction temperature, the injection velocity of solution and air, nozzle tip size and concentration of solution. The morphology of produced powder had spherical shape under the most experimental conditions, and concentration of solution. The morphology of produced powder has spherical shape under the most experimental conditions, and the composition and the particle size distribution were almost uniform, which tells the excellence of this spray roasting system. The grain size of most produced powder was below 100 nm. From the above results, it will be possible to produce ultra fine oxide powder from the chloride of Fe, Mn, Ni, Cu and rare earth by using this spray roasting system, and also to produce ultra fine pure metal powder by changing reaction atmosphere.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.33 no.4
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• pp.153-157
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• 2023

In order to manufacture a semiconductor circuit, etching, cleaning, and deposition processes are repeated. During these processes, the inside of the processing chamber is exposed to corrosive plasma. Therefore, the coating of the inner wall of the semiconductor equipment with a plasma-resistant material has been attempted to minimize the etching of the coating and particle contaminant generation. In this study, we mixed AlF₃ powder with the solid-state reacted yttrium oxyfluoride (YOF) in order to increase plasma-etching resistance of the plasma spray coated YOF layer. Effects of the mixing ratio of AlF₃ with YOF powder on crystal structure, microstructure and chemical composition were investigated using XRD and FE-SEM. The plasma-etching ratios of the plasma-spray coated layers were calculated and correlation with AlF₃ mixing ratio was analyzed.

• Korean Chemical Engineering Research
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• v.48 no.1
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• pp.75-79
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• 2010

The precursor powders with thin wall structure were prepared by spray pyrolysis from the spray solution with ethylenediaminetetraacetic acid, citric acid and $NH_4Cl$ flux. The $BaMgAl_{10}O_{17}:Eu$ phosphor powders formed from the spray solution without organic additives and flux material had sizes of $1{\sim}5{\mu}m$ and hollow structure with high thickness at post-treatment temperature of $1,200^{\circ}C$. However, $BaMgAl_{10}O_{17}:Eu$ phosphor powders formed from the spray solution with ethylenediaminetetraacetic acid, citric acid and $NH_4Cl$ flux had fine size and plate-like shape. The mean crystallite sizes of the phosphor powders with fine sizes were 23, 35, and 33 nm when the content of $NH_4Cl$ flux were 0, 6, 35 wt% of phosphor. The photoluminescence intensity of the phosphor powders formed from the spray solution with the optimum amount of $NH_4Cl$ flux as 35 wt% was 215% of that of the phosphor powders formed from the spray solution without flux material.

• Korean Journal of Metals and Materials
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• v.47 no.11
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• pp.728-733
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• 2009

Cu based amorphous ($Cu_{54}Zr_{22}Ti_{18}Ni_{6}$) powders were deposited onto Al 6061 substrates by cold spray process with different powder preheating temperatures (below glass transition temperature: $350^{\circ}C$, near glass transition temperature: $430^{\circ}C$ and near crystallization temperature: $500^{\circ}C$). The microstructure and macroscopic properties (hardness, wear and corrosion) of Cu based amorphous coating layers were also investigated. X-ray diffraction results showed that cold sprayed Cu based amorphous coating layers of $300{\sim}350{\mu}m$ thickness could be well manufactured regardless of powder preheating temperature. Porosity measurements revealed that the coating layers of $430^{\circ}C$ and $500^{\circ}C$ preheating temperature conditions had lower porosity contents (0.88%, 0.93%) than that of the $350^{\circ}C$ preheating condition (4.87%). Hardness was measured as 374.8 Hv ($350^{\circ}C$), 436.3 Hv ($430^{\circ}C$) and 455.4 Hv ($500^{\circ}C$) for the Cu based amorphous coating layers, respectively. The results of the suga test for the wear resistance property also corresponded well to the hardness results. The critical anodic current density ($i_{c}$) according to powder preheating temperature conditions of $430^{\circ}C$, $500^{\circ}C$ was lower than that of the sample preheated at $350^{\circ}C$, respectively. The higher hardness, wear and corrosion resistances of the preheating conditions of near $T_{g}$ and $T_{x}$, compared to the properties of below $T_{g}$, could be well explained by the lower porosity of coating layer.

• Proceedings of the Materials Research Society of Korea Conference
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• 1992.05a
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• pp.14-14
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• 1992

During the past five years a very successful effort has been made to improve existing and develop new aluminium alloys. The progress achieved has been possible because of the development of new production methods, such as powder metallurgy and spray/deposition. These methods make use of rapid solidification process which alloys compositions other than those achieved by conventional ingot metallurgy. The ingot metallurgy of the 2000 and 7000 series used thus far, as well as the age hardening Al-Li alloys, show several disadvantages caused by the production process. Such problems are primarily coarse intermetallic constituent phases, coarse grains and macrosegregation, resulting in low fracture toughness. The present contribution reports results of an experimental investigation performed on a modern high strength spay deposited aluminium alloy of the Al-Zn-Mg-Cu (7075 and the modified 7150X) type. Results are given in terms of its microstructural characterization by using X-ray diffractomertry and transmission electron microscopic. The mechanical propierties of those alloys in the as-extruded and extruded+aged condition were evaluated by using microhardness Vickers, tensile test and fracture toughness measurements.

• Korean Journal of Materials Research
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• v.30 no.7
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• pp.350-358
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• 2020

A variety of composite powders having different aluminum and carbon contents are prepared using various organic solvents having different amounts of carbon atoms in unit volume as ball milling agents for titanium and aluminum ball milling. The effects of substrate temperature and post-heat treatment on the texture and hardness of the coating are investigated by spraying with this reduced pressure plasma spray. The aluminum part of the composite powder evaporates during spraying, so that the film aluminum content is 30.9 mass%~37.4 mass% and the carbon content is 0.64 mass%~1.69 mass%. The main constituent phase of the coating formed on the water-cooled substrate is a non-planar α₂ phase, obtained by supersaturated carbon regardless of the alloy composition. When these films are heat-treated at 1123 K, the main constituent phase becomes γ phase, and fine Ti₂AlC precipitates to increase the film hardness. However, when heat treatment is performed at a higher temperature, the hardness is lowered. The main constitutional phase of the coating formed on the preheated substrate is an equilibrium gamma phase, and fine Ti₂AlC precipitates. The hardness of this coating is much higher than the hardness of the coating in the sprayed state formed on the water-cooled substrate. When hot pressing is applied to the coating, the porosity decreases but hardness also decreases because Ti₂AlC grows. The amount of Ti₂AlC in the hot-pressed film is 4.9 vol% to 15.3 vol%, depending on the carbon content of the film.

• Journal of Powder Materials
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• v.27 no.3
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• pp.210-218
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• 2020

A T-800 (Co-Mo-Cr) coating material is fabricated using Co-Mo-Cr powder feedstock and laser cladding. The microstructure and melted Al erosion properties of the laser-cladded T-800 coating material are investigated. The Al erosion properties of the HVOF-sprayed MoB-CoCr and bulk T-800 material are also examined and compared with the laser-cladded T-800 coating material. Co and lave phases (Co₂MoCr and Co₃Mo₂Si) are detected in both the laser-cladded T-800 coating and the bulk T-800 materials. However, the sizes of the lave phases are measured as 7.9 ㎛ and 60.6 ㎛ for the laser-cladded and bulk T-800 materials, respectively. After the Al erosion tests, the erosion layer thicknesses of the three materials are measured as 91.50 ㎛ (HVOF MoB-CoCr coating), 204.83 ㎛ (laser cladded T-800), and 226.33 ㎛ (bulk T-800). In the HVOF MoB-CoCr coating material, coarse cracks and delamination of the coating layer are observed. On the other hand, no cracks or local delamination of the coating layer are detected in the laser T-800 material even after the Al erosion test. Based on the above results, the authors discuss the appropriate material and process that could replace conventional bulk T-800 materials used as molten Al pots.

• Transactions of Materials Processing
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• v.21 no.5
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• pp.330-335
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• 2012

Roll formed steel bolts are electrodeposited with Zn-Ni to protect themselves from corrosion. However, white storage stain or white rust(corrosion) is found on Zn-Ni electrodeposited surface of steel bolts when they are exposed to moisture. In this paper a new process is introduced to protect Zn-Ni electrodeposited steel bolt from white storage stain or white rust for a long time under the salt spray test and high humidity test conditions. The better corrosion resistance could be gotten by the additional process of Ni-P electroless deposition and heat treatment to conventional manufacturing method of Zn-Ni coated steel bolt. The corrosion resistance of Zn-Al powder slurry coated steel bolt showed better than that of Zn-Ni electrodeposited one.

• Journal of Welding and Joining
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• v.7 no.2
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• pp.25-34
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• 1989

The purpose of this work is to coat ZrO$_{2}$ - 8Y$_{2}$O$_{3}$ ceramic on the Al cast alloy(AC-8A) by using the plasma spray method. Two types of coatings which were composed of two and three layer coating were examined. Each coating powder was analyzed for shape and size distribution and X-ray diffraction pattern. For the coated layers, microstructural analysis and performance estimation which was composed of static thermal test, thermal cyclic test and thermal shock test were conducted.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.29 no.6
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• pp.298-307
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• 2019

Two types of CaO-Al₂O₃-SiO₂ (CAS) glass powder applied spray coating on the surface of sintered Al₂O₃ were researched for sintering behavior; (1) Si-rich, glass containing high content SiO₂, (2) Ca-rich, containing high content CaO. Foaming of bubbles remaining inside the Ca-rich glass was produced at a viscosity of approximately 10⁷~10⁹ poise, resulting in decreasing shrinkage (interfering with sintering) and increasing surface roughness. In case of Si-rich glass, there was no serious foaming bubbles phenomenon like Ca-rich below 1000℃, however cristobalite crystals with low density occurred at 1200℃ and then produced re-foaming of bubbles, resulting in abnormal sintering behavior. These phenomenon is considered to be a decrease in viscosity due to an increase in the Ca content of the glass according to the formation of low-density cristobalite crystals. Therefore, in case of CAS glass, it is necessary to consider the increase of surface roughness and the sintering interference because of foaming bubbles phenomenon at low temperature sintering. Especially, when containing high SiO₂ content, abnormal foaming phenomenon due to crystallization at high temperature should be predicted.