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Development of plasma deposition process and creep study of ceramic and metallic materials in titanium alloy substrate for aerospace applications.

Grant number: 12/24851-7
Support Opportunities:Scholarships in Brazil - Doctorate
Effective date (Start): August 01, 2013
Effective date (End): November 30, 2016
Field of knowledge:Engineering - Aerospace Engineering
Principal Investigator:Danieli Aparecida Pereira Reis
Grantee:Felipe Rocha Caliari
Host Institution: Instituto de Ciência e Tecnologia (ICT). Universidade Federal de São Paulo (UNIFESP). Campus São José dos Campos. São José dos Campos , SP, Brazil


In this proposed doctoral work, we intend to continue the research already initiated relating the effect of thermal barrier coating on the Ti-6Al-4V. These studies considered a ceramic coating with high levels of porosity, cracks and inclusions. The objective of this project is to develop a process for depositing a multilayer of CoNiCrAlY + ZrO2 in Ti-6Al-4V alloy using a plasma torch, aiming to improve coating microstructure to optimize the mechanical properties of the alloy. The parameters thermal conductivity, modulus of elasticity (strain tolerance), growth rate, thickness, crystalline structure, porosity, surface roughness, cohesion and adhesion will be used to evaluate the coating produced. The development of the deposition process is going to be done in the Laboratory of Plasmas and Processes (LPP) of the ITA with a thermal plasma torch. Process parameters such as plasma density, Mach, power, gas flow, gas enthalpy, gas used, the powder injection angle, distance from the spray trajectory and speed of the positioning system of the sample and the characteristics of the powder used will be studied to optimize the coating. After applied the coating on the Ti-6Al-4V, creep tests at temperatures of 500 to 600ºC will be conducted, initially in the form of constant load, and the stress range will be determined via the hot tensile tests. Complete studies in order to develop a process for depositing a multilayer substrate ZrO2 + CoNiCrAlY alloy Ti-6Al-4V, using a plasma torch are scarce. A set of curves will be obtained and experimental parameters relating primary, secondary and tertiary creep stages as a function of applied stress and temperatures. Microstructural characterization via scanning electron and transmission microscopy, as well as atomic force microscopy are valuable tools for the characterization of the coating obtained by plasma deposition process and the operating creep mechanisms (TEM).

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Scientific publications
(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)
CALIARI, F. R.; MIRANDA, F. S.; FILHO, G. P.; ESSIPTCHOUK, A.; REIS, D. A. P.; AZARMI, F; BALANI, K; EDEN, T; HUSSAIN, T; LAU, YC; et al. In-Flight Analysis and Microstructural Evaluation of CoNiCrAlY Coatings Deposited by HVPS. INTERNATIONAL THERMAL SPRAY CONFERENCE AND EXPOSITION (ITSC 2018), v. N/A, p. 4-pg., . (12/24851-7)
CALIARI, F. R.; MIRANDA, F. S.; REIS, D. A. P.; FILHO, G. P.; CHARAKHOVSKI, L. I.; ESSIPTCHOUK, A.. Plasma torch for supersonic plasma spray at atmospheric pressure. Journal of Materials Processing Technology, v. 237, p. 351-360, . (12/24851-7)
CALIARI, F. R.; MIRANDA, F. S.; REIS, D. A. P.; ESSIPTCHOUK, A. M.; FILHO, G. P.. Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy. JOURNAL OF THERMAL SPRAY TECHNOLOGY, v. 26, n. 5, p. 880-889, . (12/24851-7)

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