Book/Dissertation / PhD Thesis

FZJ-2017-08316

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Numerical Simulation of Plasma Spray-Physical Vapor Deposition

Wang, P. (Corresponding author)FZJ*

2017
Forschungszentrum Jülich GmbH Zentralbibliothek, Verlag Jülich
ISBN: 978-3-95806-282-5

Please use a persistent id in citations: http://hdl.handle.net/2128/16257

Abstract: The modeling of the plasma spray process is driven by the intention of further increasing the understanding the growth mechanisms of columnar thermal barrier coatings (TBC). The major parameters associated with the deposition process in the experiment are the power input, plasma gas composition, and chamber pressures resulting in distinct microstructures. Therefore, the objective of this study was to simulate the plasma jet and the growth of columnar TBCs. Five main topics were examined: (1) thermodynamic and transport properties for different plasma mixtures (35Ar-60He, 35Ar-60He-10H$_{2}$, and 100Ar-10H$_{2}$)depending on the pressure and the temperature; (2) vacuum plasma spray (VPS); (3) plasma-spray physical vapor deposition (PS-PVD); (4) built-up of columnar coatings using the Monte-Carlo method; (5) validation by experiments. Investigations of thermodynamic and transport properties gave the basis for the understanding of the plasma process and provide data of the following plasma jet modeling. The plasma jet modeling used three types of plasma mixture (35Ar-60He atpressures ranging from 200 Pa-10000 Pa, 35Ar-60He-10H$_{2}$ at a pressure of 200 Pa, and100Ar-10H$_{2}$ at a pressure of 200 Pa) was carried out by ANSYS Fluent 17, the results were compared to photographs of the plasma jets. Taking into account the influence of non-equilibrium, the plasma composition and spectral line intensities were calculated. Results of the measured and calculated intensities proved that non-equilibrium exists. Finally, a two-dimensional Monte Carlo simulation was used to investigate the formation of columnar growth in plasma spray-physical vapor deposition process (PS-PVD). The surface diffusion in the coating was neglected because of the high deposition rate. The detailed examination of the morphology, the orientation, the porosity level of the columns is given, which is compared to the microstructures produced by a PS-PVD process.

Note: Universität Bochum, Diss., 2017

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Contributing Institute(s):

1. Werkstoffsynthese und Herstellungsverfahren (IEK-1)

Research Program(s):

1. 899 - ohne Topic (POF3-899) (POF3-899)
2. HITEC - Helmholtz Interdisciplinary Doctoral Training in Energy and Climate Research (HITEC) (HITEC-20170406) (HITEC-20170406)

Appears in the scientific report 2017

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Database coverage:
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