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

STTR 第二阶段：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: 0724382
• 负责人: Gregory Reimann
• 金额: --
• 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: 2007
• 资助国家: 美国
• 起止时间: 2007-08-01 至 2009-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0724382&HistoricalAwards=false
• 关键词: STTR; Phase; II; Novel; Deposition

This Small Business Technology Transfer (STTR) Phase II research project will develop a robust, commercial ready sensor that enables the first viable implementation of real-time control for plasma spray, reducing the cost for existing spray applications and enabling advanced coating applications that require tighter tolerances. The sensing scheme, based on a high speed solid state array, is superior to existing sensors because it can sense individual particles across the entire plume and can filter out non-molten particles that don't contribute to the coating. For the first time, a sensor will provide the basis for real-time, closed loop control for coating thickness of plasma sprayed parts. The Phase II research will develop production models of the sensor and the related closed loop control module, as well as establish proof of concept for advanced versions of the sensor. Plasma spray is a high-throughput, economical, low environmental impact process that can be used to custom engineer coating microstructures to meet specific performance requirements, primarily in the form of thermal barrier coatings for gas turbines used in power generation and aircraft engine applications as well as emerging applications such as the electrolyte coating for fuel cells. Currently, the plasma spray process is run open-loop with respect to the critical deposition physics that determine coating quality and is characterized by large variations in coating thickness and structure.

这项小型企业技术转移（STTR）第二阶段研究项目将开发一种强大的商业就绪传感器，使等离子喷涂的实时控制首次可行实施，降低现有喷涂应用的成本，并使需要更严格公差的先进涂层应用成为可能。基于高速固态阵列的传感方案优于现有的传感器，因为它可以感知整个羽流中的单个颗粒，并可以过滤掉对涂层没有贡献的非熔融颗粒。该传感器将首次为等离子喷涂件涂层厚度的实时闭环控制提供基础。第二阶段的研究将开发传感器和相关闭环控制模块的生产模型，并为传感器的高级版本建立概念验证。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结构，以满足特定的性能要求，主要以用于发电和飞机发动机应用的燃气轮机热障涂层的形式，以及用于燃料电池的电解质涂层等新兴应用。目前，等离子喷涂过程在决定涂层质量的关键沉积物理方面是开环运行的，其特点是涂层厚度和结构的变化很大。