• 한국분말재료학회지
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• 제29권2호
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• pp.123-131
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• 2022

The purpose of this study is to improve the mechanical properties and develop manufacturing technology through self-soluble alloy powder flame spray coating on the surface of a run-out table roller for hot rolling. The roller surface of the run-out table should maintain high hardness at high temperatures and possess high wear, corrosion, and heat resistances. In addition, sufficient bonding strength between the thermal spray coating layer and base material, which would prevent the peel-off of the coating layer, is also an important factor. In this study, the most suitable powder and process for roll manufacturing technology are determined through the initial selection of commercial alloy powder for roll manufacturing, hardness, component analysis, and bond strength analysis of the powder and thermal spray coating layer according to the powder.

• Journal of Welding and Joining
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• 제14권6호
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• pp.101-108
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• 1996

In this study, WC-l7wt% Co composite powder for thermal spray was fabricated by spray drying method. The agglomerated composite powder had spheroidal morphology and the particle size distribution was 20~60${\mu}{\textrm}{m}$. WC and Co were distributed homogeneously. However, the strength of the spray-dried agglomerate was low due to the pores within the agglomerate. Therefore, the spray-dried agglomerate was broken down during HVOF thermal spray and the microstructure was inhomogeneous with many pores within the coating layer. And the decomposition of WC to W and $W_{6}$ $C_{2.54}$ was accelerated. The strength and flowability of the agglomerate were greatly improved by sintering heat treatment(110$0^{\circ}C$, 1 hour, hi atmosphere), and then the coating layer showed dense and homogeneous microstructure with well-developed splats. The hardness of the coating layer was H $v_{300}$ = 1072.2.2.

• 한국분말야금학회:학술대회논문집
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• 한국분말야금학회 1997년도 추계학술강연 및 발표대회 강연 및 발표논문 초록집
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• pp.25-25
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• 1997

• 한국재료학회지
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• 제24권7호
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• pp.357-362
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• 2014

Thermal barrier coatings(TBCs) are being applied in many industrial fields such as thermal power generation, aviation and seasonal fields. $ZrO_2-Y_2O_3$(8%) thermal spray coating powders are commercially used as thermal-barrier coating materials to protect against oxidation and corrosion of heat-resistant alloys at elevated temperatures. Currently, $ZrO_2-Y_2O_3$(8%) thermal-spray powder is made using the industrial co-precipitation process, which is very complex and requires a lot of time. In this study, orthorhombic $ZrO_2$ and $Y_2O_3$ powders were fabricated by mechanical mixing, which is more economical than the co-precipitation process. A tetragonal, yttria-stabilized zirconia(YSZ) coating-layer was produced by plasma spraying, using orthorhombic $ZrO_2-Y_2O_3$(8%) powder. Our experimental results indicate that $ZrO_2-Y_2O_3$(8%) mixed powder can be used economically in industry because it is no longer necessary to make this powder by liquid and gas-phase methods.

• 한국분말재료학회지
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• 제28권6호
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• pp.478-482
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• 2021

The effect of the process conditions of high-velocity oxygen fuel (HVOF) thermal spray coating on the porosity of the coating layer is investigated. HVOF coating layers are formed by depositing amorphous FeMoCrBC powder. Oxygen pressure varies from 126 to 146 psi and kerosene pressure from 110 to 130 psi. The Microstructural analysis confirms its porosity. Data analysis is performed using experimental data. The oxygen pressure-kerosene pressure ratio is found to be a key contributor to the porosity. An empirical model is proposed using linear regression analysis. The proposed model is then validated using additional test data. We confirm that the oxygen pressure-kerosene pressure ratio exponentially increases porosity. We present a porosity prediction model relationship for the oxygen pressure-kerosene pressure ratio.

• Journal of Welding and Joining
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• 제7권2호
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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.

• 한국재료학회지
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• 제21권2호
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• pp.106-110
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• 2011

A high thermal conductive AlN composite coating is attractive in thermal management applications. In this study, AlN-YAG composite coatings were manufactured by atmospheric plasma spraying from two different powders: spray-dried and plasma-treated. The mixture of both AlN and YAG was first mechanically alloyed and then spray-dried to obtain an agglomerated powder. The spray-dried powder was primarily spherical in shape and composed of an agglomerate of primary particles. The decomposition of AlN was pronounced at elevated temperatures due to the porous nature of the spray-dried powder, and was completely eliminated in nitrogen environment. A highly spherical, dense AlN-YAG composite powder was synthesized by plasma alloying and spheroidization (PAS) in an inert gas environment. The AlN-YAG coatings consisted of irregular-shaped, crystalline AlN particles embedded in amorphous YAG phase, indicating solid deposition of AlN and liquid deposition of YAG. The PAS-processed powder produced a lower-porosity and higher-hardness AlN-YAG coating due to a greater degree of melting in the plasma jet, compared to that of the spray-dried powder. The amorphization of the YAG matrix was evidence of melting degree of feedstock powder in flight because a fully molten YAG droplet formed an amorphous phase during splat quenching.

• 한국세라믹학회지
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• 제40권5호
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• pp.460-467
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• 2003

기계적 합금화법에 의해 준비된 복합분말을 이용하여 용사공정에 의해 알루미늄 모재에 Al-SiC$_{p}$ 복합재료 코팅층을 형성하였다. 24h milling 후 복합화된 분말을 제조할 수 있었으며, 이 분말을 용사하여 복합재료 코팅층을 형성할 수 있었다. 코팅층의 두께 및 기공율과 공정변수와 관계를 분석하였으며, 경도의 증가를 확인하였다. 또한 TEM분석에 의해 Al-Si-C-O 화합물의 존재를 확인하였다.

• 한국세라믹학회지
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• 제53권5호
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• pp.557-562
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• 2016

Pyrophyllite granule powders for thermal spray coating were successfully prepared through spray drying process. To produce a stable slurry, commercial pyrophyllite powder of $45{\mu}m$ in size was ball-milled for reduction of the size to $2{\sim}3{\mu}m$ and a dispersant was added to control the viscosity. Dense and spherical granules (average granule size : $59{\mu}m$) were prepared under conditions of 12,500 rpm for rotation velocity of the atomizer and 100 cps for slurry viscosity. The granules were then heat treated at $1,200^{\circ}C$ for proper handling strength and flow properties. The final granules had an apparent density of $0.725g/cm^3$ and a flow rate of 2.5 g/sec, which represent excellent properties to be used as the granule powder for thermal spray coatings.

• 한국분말재료학회지
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• 제7권2호
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• pp.63-70
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• 2000

Thermal spray coating process has proven to be effective at producing hard, dense, wear resistance coatings on the relatively mild substrates. Among several spraying techniques, HVOF (High Velocity Oxygen Fuel) and plasma coating processes, which are preferentially used for the wear resistance application such as capstans, have been applied in this study. The effects of pre-treatment, it-process and post-treatment parameters on the wear and mechanical properties of WC+12%Co, Cr3C2 and Al2O3 powder coatings have been investigated and correlated with the microstructures. The results indicated that the carbide coating was more preferable to the oxide coatings and the post-treatments consisting of vacuum annealing and sealing on carbide coatings led to significant improvements in wear resistance, adhesive strength and coating phase stabilization over the other processing techniques in this application.