STTR Phase I: Novel Deposition Rate Sensors for Real-Time Thickness Control of Plasma Spray

STTR 第一阶段：用于等离子喷涂实时厚度控制的新型沉积速率传感器

• 批准号: 0539622
• 负责人: Gregory Reimann
• 金额: $ 10万
• 依托单位: Cyber Materials Solutions
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2006
• 资助国家: 美国
• 起止时间: 2006-01-01 至 2006-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0539622&HistoricalAwards=false
• 关键词: STTR; Phase; Novel; Deposition; Rate

This Small Business Technology Transfer (STTR) Phase I project will develop prototypes of two novel, fast deposition rate sensors that will enable implementation of real-time deposition rate control for plasma spray. Plasma spray is currently run open loop with respect to the actual particle states and is characterized by large variations which affect yield and quality. Preliminary research reveals that currently available sensors, which measure average particle temperature and velocity, are not well correlated to deposition rate. The new sensor concepts measure particle flux using a high speed CCD array and molten flux using spectral deconvolution, both of which have been shown to correlate well to deposition rate. These new high speed sensors will provide the basis for implementing real time control that can significantly reduce coating thickness variation, a primary plasma spray performance metric.Plasma spray is a high-throughput, economical, low environmental impact process that can be used to custom engineer coating microstructure to meet specific performance requirements. It is used extensively to coat turbine components with thermal barrier coatings (world wide market of $2.5 B where US has a 35% market share) as well as emerging applications such as the electrolyte coating for fuel cells. The sensor technology proposed in this project, enabling real-time control, will enhance the process capability of plasma spray to achieve greater than 2 sigma capability, enhancing coating quality, reliability and relieving some of the cost pressures faced by domestic manufacturers.

该小型企业技术转让 (STTR) 第一阶段项目将开发两种新型快速沉积速率传感器的原型，这些传感器将能够实现等离子喷涂的实时沉积速率控制。等离子喷涂目前在实际颗粒状态方面是开环运行的，其特点是变化较大，影响产量和质量。初步研究表明，目前测量平均颗粒温度和速度的传感器与沉积速率的相关性并不好。新的传感器概念使用高速 CCD 阵列测量颗粒通量，并使用光谱解卷积测量熔融通量，这两种传感器均已被证明与沉积速率密切相关。这些新型高速传感器将为实施实时控制提供基础，从而显着减少涂层厚度变化（主要的等离子喷涂性能指标）。等离子喷涂是一种高通量、经济、低环境影响的工艺，可用于定制工程涂层微观结构以满足特定的性能要求。它广泛用于为涡轮机部件涂覆热障涂层（全球市场价格为 2.5 B，其中美国拥有 35% 的市场份额）以及新兴应用，例如燃料电池的电解质涂层。该项目提出的传感器技术可实现实时控制，将提高等离子喷涂的工艺能力，达到大于2西格玛的能力，提高涂层质量、可靠性，并缓解国内制造商面临的部分成本压力。