A proposed process control chart for DC plasma spraying process. Part II. Experimental verification for spraying alumina

C.B. Ang, A. Devasenapathi, H.W. Ng, Ching Man Yu, Y.C. Lam

Research output: Journal article publicationJournal articleAcademic researchpeer-review

17 Citations (Scopus)


The role of particle injection velocity in influencing the nature of alumina coatings obtained by plasma spraying was studied. Previously reported process chart obtained by computational fluid dynamics (CFD) study on the particle states of alumina with respect to particle injection velocity and size was verified experimentally. For this purpose, alumina particles of three different size ranges with a mean size of 25, 40, and 76 ?m were subjected to different injection velocities. The coating obtained was analyzed for cross-sectional microstructure and thickness by optical microscopy. In addition, the role of particle injection velocity and size in influencing the coating-deposition efficiency was studied. The experimental results agreed well with the CFD results, which had indicated the dependence of particle trajectory in the plasma plume on the particle injection velocity and size leading to the changes in the extent of melting. While a higher coating thickness and deposition efficiency was obtained with 25-?m particles, with further increase in particle size, a reverse trend was observed. This was attributed to the changes in heat-transfer characteristics of the particles with size, which governed the coating buildup and deposition efficiency.
Original languageEnglish
Pages (from-to)401-420
Number of pages20
JournalPlasma Chemistry and Plasma Processing
Issue number3
Publication statusPublished - 1 Sep 2001
Externally publishedYes


  • Alumina
  • Computational fluid dynamics (cfd)
  • Deposition efficiency
  • Injection velocity
  • Plasma spraying

ASJC Scopus subject areas

  • Chemistry(all)
  • Chemical Engineering(all)
  • Condensed Matter Physics
  • Surfaces, Coatings and Films

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