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Spray Parameters and Coating Microstructure Relationship in Suspension Plasma Spray TiO2 Coatings

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posted on 2025-03-07, 11:18 authored by Garima Mittal, Nigar Gul Malik, Arunima Bhuvanendran Nair Jayakumari, David Martelo, Namrata Kale, Shiladitya PaulShiladitya Paul
In recent years, there has been growing interest in thermal spray techniques using suspension or solution-based coatings. These techniques offer precise control over particle size and microstructure, improving feedstock flowability and allowing for high-quality coating customization. Spray parameters, such as stand-off distance (SOD) and feedstock flow rate, can alter the performance and characteristics of these coatings. Geothermal power plant heat exchangers often face issues like corrosion, scaling, and fouling. The literature suggests that these issues could be mitigated, at least in part, by the use of spray coatings. In this study, TiO2 coatings were applied on a carbon steel substrate using suspension plasma spray (SPS) to enhance the performance of geothermal heat exchanger materials. The impact of SOD (50, 75, and 100 mm) and feedstock flow rate (10, 20, and 30 mL/min) on these coatings was examined through various techniques, including scanning electron microscope (SEM), profilometry, X-ray diffraction (XRD), and adhesion testing. The results demonstrated that coatings deposited using a 10 mL/min feedstock flow rate were well adhered to the substrate due to the efficient melting of the coating material, but as the SOD and feedstock flow rate increased due to poor thermal and kinetic energy exchange between the torch and feedstock particles, adhesion between the coating and substrate decreased.

History

Author affiliation

College of Science & Engineering Engineering

Published in

Coatings

Volume

13

Issue

12

Pagination

1984 - 1984

Publisher

MDPI AG

eissn

2079-6412

Language

en

Deposited by

Dr Shiladitya Paul

Deposit date

2025-02-03

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