The document discusses plasma spraying technology, a method of surface engineering that enhances the durability of materials by applying thermal coatings. It outlines the principles of plasma generation, the working setup, key parameters affecting the process, and various applications of the technology. The conclusion highlights the technology's advantages, such as improved component life and reduced corrosion, while noting its high setup costs and unsuitability for small scale operations.

1. Plasma Spraying
•Presented by
Mr. Aditya Uday
Tembhekar
•Guided by
Prof. M.D.
Shinde
SNJB’s Late Sau. Kantabai
Bhavarlalji Jain College of
Engineering, Chandwad
Department of Mechanical Engineering
1 May 2017 1
A Seminar On

2. Contents
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Abstract
Introduction
 Literature Review
 Thermal Coatings
 Introduction to Plasma
 Principle of Working
 Working Setup
 Factors Affecting the Process
Applications, advantages ,disadvantages
 Conclusion

3. Abstract
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Department of Mechanical Engineering
• The age of second world war
• Decaying- corrosion- oxidation
• Surface engineering
• Coating
• Plasma Spraying Technology
• Non traditional Coating

4. introduction
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 Versatile technology
 Arc formation
 Injection of powder
 Melting of powder
 Impact on substrate
 Coating

5. 1 May 2017 5
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Literature Review
Sr
Author’s
Name
Year Contents
1
Dr.
Satrugna
Das
2007
•Study on aluminium, Aluminide Coatings
•Factors affecting the parameters
•Coatings Microstructures
2
Christian
Moreau
2014
•Air Plasma Spray Technology
•Arc dynamics
•Dynamics of Splat formation
3
C. Kannan
et al
2014
•Numerical methodology nozzle
•Analysis on parameters
•CFD analysis
4
Hemant
Panchal
2016
•Review on different thermal coating
processes
•Different Plasma guns

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Thermal coatings
Overlay
Diffusion
Thermal

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What is plasma…?
 4th state of matter
 Artificially generated with neutral
gases
 Irving Longmuir 1920
 Quasi Neutrality with no charge
 Thermal plasmas
 Range 3000-20000K
 Atmospheric Plasmas

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Principle of working
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9. 1 May 2017 9
Working Setup
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Fig. Components of Plasma Coating

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Sr Parameters Range
1 Torch input
power
10-20
KW
2 Plasma gas (Ar)
flow rate
85 LPM
3 Secondary gas
(H 2 ) flow rate
25 LPM
4 Powder feed
rate
50 g/min
5 Powder carrier
gas(N2) flow
rate
38 LPM
6 Torch to base
distance
100 mm
plasma Torch

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Factors Affecting the process
1. Substrate Conditions 2. Arc Power
3. Mass Flow 4. Spraying Angle
Angle Effect
30
0
-60
0
Porosity Increases
Beyond 60
0
Porosity Unaffected

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5. Torch To base Distance 6. Gas Pressure

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7. Substrate Cooling
8. Preheating of Substrate
9. Powder Injection
•Continuous Spraying
•Thermal Stress Development
•Air Spray cooling

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η = (Gc / Gp) x 100 %
10. Deposition Efficiency

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Textile/ Paper/
Printing
Automotive
Industry
Hydraulic/
Aircraft
Applications

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Disadvantage
Unemployment
High Set up Cost
Not Suitable for Small
Scale
Advantage
Reduces Corrosion
Rate
Life of Component
Shiny and glazed look
Low Running Cost
Fully Automated

17. Conclusion/summary
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• Highly Developing and Mature
Technology
• Reduces decaying- corrosion-
oxidation
• Increases the life of component
by reducing replacement cost
• Improves case hardness
• Quality of coating affected by
the different parameters

18. Department of Mechanical Engineering
1. Sagar Amin, Hemant Panchal, International Journal of Current Trends in Engineering & Research
(IJCTER) e-ISSN 2455–1392 Volume 2 Issue 4, April 2016 pp. 556 - 563 Scientific Journal
Impact Factor : 3.468
2. Bhanu Pratap, A review on thermal spray coating, International Journal of Scientific & Engineering
Research, Volume 6, Issue 5, May-2015 ISSN 2229-5518.
3. C. Kannan, A review on thermal Spray coating processes, IJMER, ISSN: 2249–6645, www.ijmer.com,
Vol. 4, Iss.3, Mar. 2014.
4. Dr. Satrugna Das, thesis, study of plasma spray alumina-aluminide composite coating on metals,
National Institute of technology-Rourkela-India, March-2007.
5. C. Moreau, A Perspective on Plasma Spray Technology, Springer, Concordia University, Montreal,
Canada, Dec.2014.
6. Arul raj, S Ramachandran, International Journal of Innovative Research in Science, Engineering and
Technology (An ISO 3297: 2007 Certified Organization) Vol. 4, Issue 1, January 2015, ISSN (Print) :2347
- 6710
7. Manjunatha M, R.S. Kulkarni, M. Kriahnan “ investigation of HVOF thermal sprayed Cr3C2 – NiCr
cermet carbide coating on erosive performance of AISI 316 molybdenum steel “ Procedia Materials
Science 5 ( 2014 ) 622 – 629
8. R. J. Goldston and P. H. Rutherford, Introduction to Plasma Physics, London: Institute of Physics
Publishing, 1995.
9. http://www.wikiwand.com/pt/Globo_de_plasma,05/02/2017,7:30am
10.http://rgplasma.ir/plasmaspray.html, 15/02/2017, 7:15am
11.http://www.samtc.com/technology56.html, 20/02/2017, 5:30pm
References

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You...!