Thermal Spray Processing: Process Diagnostics and Control by Artificial Intelligence

热喷涂加工：人工智能的过程诊断和控制

• 批准号: RGPIN-2020-04614
• 负责人: Moreau, Christian
• 金额: $ 2.84万
• 依托单位: Concordia University
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2020
• 资助国家: 加拿大
• 起止时间: 2020-01-01 至 2021-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=717165
• 关键词: Thermal; Spray; Processing; Process; Diagnostics

Thermal spray is a family of processes used to manufacture high performance metallic and ceramic coatings that are used in a wide variety of industrial applications. They involve feeding the material in powder form into a flame or plasma that projects it in molten form at high speed against the part to be coated. Thermal spray coatings are particularly important in aerospace, energy and natural resources, key contributors to the Canadian economy. The research program that will be performed over the next five years with this NSERC Discovery Grant award will focus on an emerging and very powerful thermal spray technology named Suspension Plasma Spray (SPS). In SPS, the ceramic coating material is applied in the form of micron- and submicron-size particles. This allows the microstructure of the coatings, and hence their thermal, electric and physical characteristics, to be highly customized to meet very specific and diverse end-user requirements including specific “functionality”. It thus has the potential to substantially increase the use and value of thermal spray. Thermal spray is an inherently complex process, and SPS has two characteristics that distinguish it from current more mature processes; the very small particle size and the fact that the particles are injected when suspended in a liquid. This research program will develop the fundamental knowledge about the various phases of the SPS process to allow precise and reliable tailoring and control of the process to produce highly customized coating microstructures. This involves a combination of theoretical and experimental research, the latter using modern equipment in the thermal spray laboratory at Concordia University and electron microscopes at Concordia and other local universities. The knowledge generated will allow the development of customised sensors that will be used in industrial scale applications. For the first time, modern Artificial Intelligence (AI) techniques will be used to tailor the SPS coating microstructure and properties with the objective of implementing such a control strategy in industry. A culturally and gender diverse group of students and other Highly Qualified Personnel (HQP) will be directly involved in both theoretical and practical research and given specific responsibilities under the supervision of three professors. Students will also attend national and international conferences to present their work, and be given “soft skills” training, preparing them for future careers. SPS has the potential to make major contributions to the Canadian economy, and to sustainability and the environment. Applications include higher performing thermal and environmental barrier coatings for aircraft engines, critical to reducing fuel consumption and environmental impact of passenger aircraft; membranes for applications such as water purification; separation of gasses including carbon dioxide; and coatings for hydrogen electrolysis.

热喷雾是一种用于制造高性能金属和陶瓷涂料的工艺系列，这些涂料用于各种工业应用。它们涉及将粉末形式的材料喂入火焰或等离子体中，该材料以高速向要涂层的零件以高速进行熔融形式的材料。在航空航天，能源和自然资源，加拿大经济的主要贡献者中，热喷涂涂料尤其重要。 NSERC Discovery Grant奖将在未来五年内执行的研究计划将重点介绍一种名为Suspension Clasma Spray（SPS）的新兴且非常强大的热喷雾技术。在SPS中，陶瓷涂料材料以微米和亚微米大小的颗粒的形式施加。这允许涂料的微观结构，因此可以高度定制其热，电和物理特性，以满足非常具体和多样化的最终用户要求，包括特定的“功能”。因此，它有可能大大增加热喷雾的使用和价值。 热喷雾是一个固有的复杂过程，SPS具有两个将其与当前更成熟过程区分开的特征。非常小的粒径以及悬浮在液体中时注入颗粒的事实。该研究计划将开发有关SPS流程各个阶段的基本知识，以允许对流程进行精确且可靠的剪裁和控制以生成高度定制的涂料微观结构。这涉及理论和实验研究的结合，后者在康科迪亚大学的热喷雾实验室中使用现代设备以及康科迪亚和其他当地大学的电子显微镜。产生的知识将允许开发定制的传感器，这些传感器将用于工业规模应用。现代人工智能（AI）技术将首次用于量身定制SPS涂层微观结构和属性，目的是在行业中实施这种控制策略。 在文化和性别多样化的学生和其他高素质的人员（HQP）中，将直接参与理论和实践研究，并在三位教授的监督下赋予特定责任。学生还将参加国家和国际会议以展示他们的工作，并接受“软技能”培训，为未来的职业做准备。 SPS有可能为加拿大经济以及可持续性和环境做出重大贡献。应用包括飞机发动机的高性能和环境屏障涂料，对于降低燃油消耗和客机的环境影响至关重要；用于净水等应用的膜；包括二氧化碳在内的气体分离；和氢电解的涂层。