Journal of the American Ceramic Society· 2026Q2
Effect of He Addition on the In‐Flight Behavior of ZrSiO 4 Powder and Coating Deposition During DC Arc Plasma Spraying
- 1citations
- Q2SCImago
- 2026year
Short summary
Adding He to Ar+H2 plasma gas reduces ZrSiO4 particle surface pyrolysis during plasma spraying from 42.5% to 12.3% (at 10 vol.% He) while increasing jet velocity, leading to improved coating integrity.
AI-generated from the title and abstract; the full text is not read.
Key points
- He addition to Ar+H2 plasma suppresses ZrSiO4 particle surface pyrolysis during plasma spraying.
- He addition increases plasma jet velocity from 940 m/s to 1271 m/s (at 30 vol.% He).
- Surface pyrolysis conversion rate decreased from 42.5% to 12.3% at 10 vol.% He.
- Excessive He (>=30 vol.%) leads to incomplete melting and monoclinic ZrO2 formation, degrading coating integrity.
AI-generated from the title and abstract; the full text is not read.
Abstract
ABSTRACT Controlling the surface pyrolysis of ceramic powders during high‐temperature plasma spraying is a critical challenge for producing phase‐pure and structurally integral coatings. Here we show that adding He to the conventional Ar+H 2 plasma working gas effectively suppresses the in‐flight surface pyrolysis of ZrSiO 4 particles while maintaining adequate melting for deposition. By combining CFD simulations, optical emission spectroscopy (OES), and coating microstructure analysis, we demonstrate that He addition induces a synergistic “mild cooling and velocity enhancement” effect. As the He volume fraction increases from 0 to 30 vol.%, the electron excitation temperature decreases linearly from 14 202 to 12 412 K, while the maximum jet velocity rises from 940 to 1271 m/s. This shortens the residence time of particles in the high‐temperature zone and reduces the surface pyrolysis conversion rate from 42.5% to only 12.3% at the optimal He content of 10 vol.%. Excessive He addition (≥30 vol.%) leads to incomplete melting and formation of monoclinic ZrO 2 , degrading coating integrity. This work establishes a quantitative relationship among gas composition, particle in‐flight behavior, and coating phase composition and microstructure, providing a surface‐engineering strategy for plasma processing of high‐temperature ceramic powders.
The authors' abstract, as published at the source. Journal of the American Ceramic Society, 2026 · DOI ↗
Continue with a free account
Ask the paper: 3 free questions a day about this paper; save it, get its citation, new summaries every day for your field. Takeaways are Premium.
Continue free on the webSign in with Google or Apple; no card needed. You come back to this paper.
On your phone:
Field: Aerospace Engineering
Aerospace EngineeringEngineering