High-power hybrid plasma spraying of large yttria-stabilized zirconia powder

To testify to the advantage of large ceramic powder spraying, numerical simulations and experimental studies on the behavior of large yttria-stabilized zirconia (YSZ) powder in a high-power hybrid plasma spraying process have been carried out. Numeric predictions and experimental results showed that, with the high radio frequency (RF) input power of 100 kW, the most refractory YSZ powder with particle sizes as large as 88 μm could be fully melted and well-flattened splats could be formed. A large degree of flattening (ξ) of 4.7 has been achieved. The improved adhesive strength between the large splat and the substrate was confirmed based on the measurement of the crack density inside of the splats. A thick YSZ coating >300 μm was successfully deposited on a large CoNiCrAlY-coated Inconel substrate (50×50×4 mm in size). The ultradense microstructure without clear boundaries between the splats and the clean and crack-free interface between the top-coat and the bond-coat also indicate the good adhesion. These results showed that highpower hybrid plasma spraying of large ceramic powder is a very promising process for deposition of highquality coatings, especially in the application of thermal barrier coatings (TBCs).     

On the development and characterization of a firebrand generator

A unique experimental apparatus has been constructed in order to generate a controlled and repeatable size and mass distribution of glowing firebrands. The present study reports on a series of experiments conducted in order to characterize the performance of this firebrand generator. Firebrand generator characterization experiments were performed at the Fire Research Wind Tunnel Facility (FRWTF) at the Building Research Institute (BRI) in Tsukuba, Japan. The firebrand generator was fed with three different initial firebrand geometries, two different sized cylinders and one size of disks. Cylinders were used to simulate firebrand fluxes from vegetation, such as trees, while disks were used to simulate a firebrand flux from burning structures. Samples of these geometries were constructed from wood dowels, fed into the firebrand generator, ignited, and the glowing firebrands generated were collected using an array of water filled pans. The pans were filled with water in order to quench combustion. The collected firebrands were subsequently dried and the size and mass distribution was measured. These experiments were performed over a range of wind tunnel speeds, with no wind speed present to 9 m/s, to determine the lofting distance of the firebrands generated. Finally, the size and mass distribution produced from the firebrand generator are compared to those produced from burning trees. Results of the study are presented and discussed.