splat morphology of hvof thermally sprayed nylon matt chalker milan ivosevic dr. richard cairncross
TRANSCRIPT
Splat Morphology of HVOF Splat Morphology of HVOF Thermally Sprayed NylonThermally Sprayed Nylon
Matt ChalkerMatt Chalker
Milan IvosevicMilan Ivosevic
Dr. Richard CairncrossDr. Richard Cairncross
GoalsGoals
Learn About Thermal Spray Learn About Thermal Spray ProcessesProcesses
Learn Modeling Software Flow-3DLearn Modeling Software Flow-3DCreate Video of Morphing Nylon Create Video of Morphing Nylon
SplatsSplatsDetermine Time Table for Splats from Determine Time Table for Splats from
Impact to SolidificationImpact to Solidification
Thermal SprayThermal Spray
Old Coating TechniqueOld Coating TechniqueMelting substance, spraying molten Melting substance, spraying molten
substance onto substratesubstance onto substrateMany processes, each suited for different Many processes, each suited for different
applicationsapplications
HVOF Thermal Spray of PolymersHVOF Thermal Spray of Polymers
HVOF Developed for CeramicsHVOF Developed for CeramicsPolymers attempted recentlyPolymers attempted recentlyCombustion occurs inside chamberCombustion occurs inside chamberThermal Conductivity lowThermal Conductivity lowTemperature/Phase Gradient DevelopsTemperature/Phase Gradient Develops
Potential ApplicationsPotential Applications
Solventless PaintSolventless PaintGood Corrosion ResistanceGood Corrosion ResistanceGood Abrasion QualitiesGood Abrasion QualitiesGreat in Marine EvironmentsGreat in Marine EvironmentsGood Protection for Off-Shore Oil Rigs or Good Protection for Off-Shore Oil Rigs or
BridgesBridges
HVOF Spraying ParametersHVOF Spraying Parameters
Material - Pure Nylon-11 D-60Material - Pure Nylon-11 D-60 Substrate - Glass 1”x1”x1/16”Substrate - Glass 1”x1”x1/16” Spray Distance – 9” Spray Distance – 9” Max Transverse Velocity, 1 PassMax Transverse Velocity, 1 Pass HVOF Nozzle Length – 6”HVOF Nozzle Length – 6” Nozzle I.D. – 5/16”Nozzle I.D. – 5/16” OO22 Flow – 310 scfh Flow – 310 scfh
HH22 Flow – 695 scfh Flow – 695 scfh Powder Feed Setting – 0.8 rpmPowder Feed Setting – 0.8 rpm Powder Gas Flow – 80 scfhPowder Gas Flow – 80 scfh
Video of Splat MorphingVideo of Splat Morphing
• Splats not always dome shapedSplats not always dome shaped• Splats become “Fried Eggs” under Splats become “Fried Eggs” under
certain conditionscertain conditions• Domes instead of “Fried Eggs” if Domes instead of “Fried Eggs” if
substrate pre-heatedsubstrate pre-heated
Preliminary TasksPreliminary Tasks
Construct Heater and InsulationConstruct Heater and InsulationCalibrate HeaterCalibrate HeaterConfigure Set-UpConfigure Set-UpObserve Test-Splats MeltingObserve Test-Splats MeltingDetermine Temperature at Lens of Determine Temperature at Lens of
MicroscopeMicroscope
Substrate Heater RequirementsSubstrate Heater Requirements
Small, Must be fairly compactSmall, Must be fairly compact Insulation to Protect MicroscopeInsulation to Protect MicroscopeClip or Mount to Hold SlidesClip or Mount to Hold SlidesRaised Structure to conform to MicroscopeRaised Structure to conform to MicroscopeVariable Temperature ControlVariable Temperature Control Insulated Electrical ContactsInsulated Electrical Contacts
Notes from VideoNotes from Video
Flow begins at a recorded temperature Flow begins at a recorded temperature lower than Nylon’s melting temperaturelower than Nylon’s melting temperature
Melting Temperature approximately 180Melting Temperature approximately 180ooCCFlow at approximately 140Flow at approximately 140ooCCThe smaller splats flow before the larger The smaller splats flow before the larger
splatssplatsThe lower features on the eggs flow early The lower features on the eggs flow early
as wellas well
Low Temperature FlowLow Temperature Flow
Second Cycle Melting Temperature Second Cycle Melting Temperature differentdifferent
Experimental error could be a factorExperimental error could be a factorThermocouple cement not thermally Thermocouple cement not thermally
conductive enoughconductive enough
Future ExperimentationFuture Experimentation
Confirm Temperature using Different Confirm Temperature using Different ThermocouplesThermocouples
Confirm Temperature using OvenConfirm Temperature using OvenCompare Results to DSC ResultsCompare Results to DSC ResultsCreate Model of Results in Flow-3DCreate Model of Results in Flow-3DUse Previous Results to Create TimelineUse Previous Results to Create Timeline