Modelling and Control of Plasma Deposition for Enhanced Materials Production

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The objective of the research is to develop a closed loop control system for induction plasma deposition in order to improve manufactured material quality and also expand the processing capabilities. Such a system will also provide new capabilities to examine the structure/performance relations achievable by plasma deposition. The research is focused on the following areas: 1) experimental verification of a low order model of the process and its refinement, 2) development of control structure, control implementation, and preliminary processing/materials property studies, and 3) extension to related systems. Plasma torches are used to melt and accelerate metallic and/or ceramic particles in order to form dense coatings at high production rates. Plasma deposition is used in a variety of different applications including corrosion, thermal and wear resistance coatings, near net shape manufacture, and production of metal matrix composites. Successful modeling and control of the process will reduce variations in material quality in induction plasma deposition processes.