Simulation of surface roughness during the formation of thermal spray coatings

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Description

The formation of a thermal spray coating was analyzed to identify methods to reduce the surface roughness of the coating. A new methodology was developed which uses a string of equally spaced node points to define the shape of the coating surface and to track the shape change as the thermal spray mass is deposited. This allows the calculation of arbitrary shapes for the coating surface which may be very complex. The model simulates the stochastic deposition of a large number of thermal spray droplets, where experimental data is used for the mass flux distribution on the target surface. This ... continued below

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58 p.

Creation Information

Kanouff, M.P. July 1, 1996.

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  • Sandia National Laboratories
    Publisher Info: Sandia National Labs., Livermore, CA (United States)
    Place of Publication: Livermore, California

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Description

The formation of a thermal spray coating was analyzed to identify methods to reduce the surface roughness of the coating. A new methodology was developed which uses a string of equally spaced node points to define the shape of the coating surface and to track the shape change as the thermal spray mass is deposited. This allows the calculation of arbitrary shapes for the coating surface which may be very complex. The model simulates the stochastic deposition of a large number of thermal spray droplets, where experimental data is used for the mass flux distribution on the target surface. This data shows that when the thermal spray mass impinges on the target surface, a large fraction of it (over-spray) splashes off the target and is re-deposited with a small spray angle, resulting in a large coating roughness. This analysis was used in a parameter study to identify methods for reducing the coating roughness. Effect of the shape of the profile for the pre-roughened substrate was found to be small. Decreasing the droplet size by a factor of 2 decreased the roughness by 13%. Increasing the spray angle for the over-spray by a factor of 2 decreased the roughness by 50%, and decreasing the amount of over- spray by a factor of 2 decreased the roughness by 51%.

Physical Description

58 p.

Notes

OSTI as DE97050515

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  • Other Information: PBD: Jul 1996

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  • Other: DE97050515
  • Report No.: SAND--96-8224
  • Grant Number: AC04-94AL85000
  • DOI: 10.2172/412965 | External Link
  • Office of Scientific & Technical Information Report Number: 412965
  • Archival Resource Key: ark:/67531/metadc678459

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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Creation Date

  • July 1, 1996

Added to The UNT Digital Library

  • July 25, 2015, 2:20 a.m.

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  • April 12, 2016, 8:29 p.m.

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Kanouff, M.P. Simulation of surface roughness during the formation of thermal spray coatings, report, July 1, 1996; Livermore, California. (digital.library.unt.edu/ark:/67531/metadc678459/: accessed November 19, 2017), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.