Advances in Materials Science and Engineering

Research Article

Adaptive Control of the Atmospheric Plasma Spray Process for Functionally Graded Thermal Barrier Coatings

Table 1

Injector locations, particles’ injection speed, particles’ mean z-location, and the mean axial velocity and temperature of particles when they arrive at the substrate. Values of other parameters are: current = 500 A, voltage = 50 V, Ar flow rate = 40 slm, H₂ flow rate = 10 slm, particles’ diameter between 30 and 100 m, mass flow rates of NiCrAlY and ZrO₂ = 20 g/min, and z-locations of powder ports = 8 mm.


Injection type	Case	y-location of injector (mm)		Average injection velocity (m/s)		Mean axial velocity (m/s)		Mean temperature (K)		Averaged z-location of particles (cm)
Injection type	Case	NiCrAlY	ZrO₂	NiCrAlY	ZrO₂	NiCrAlY	ZrO₂	NiCrAlY	ZrO₂	NiCrAlY	ZrO₂

Mixed	AB	6	6	10	10	75.3	105.5	2497	2784	−1.2	−0.86

Separate (ZrO₂ injector fixed)	A1	4	6	10	10	80.9	107.7	2531	2811	−1.14	−0.82
	A2	8	6	10	10	70.2	108.5	2478	2819	−1.27	−0.82
	A3	4	6	8	10	86.4	107.8	2568	2818	−0.87	−0.82
	A4	8	6	12	10	61.4	107.6	2383	2814	−1.68	−0.83

Separate (NiCrAlY injector fixed)	B1	6	4	10	10	74.8	114.1	2501	2855	−1.21	−0.80
	B2	6	8	10	10	74.8	101.1	2486	2779	−1.22	−0.86
	B3	6	4	10	8	73.6	118.1	2464	2887	−1.24	−0.60
	B4	6	8	10	12	76.1	94.6	2503	2720	−1.19	−1.12