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In situ monitoring of cracking behaviors of plasma-sprayed coatings by the laser acoustic emission technique

Published online by Cambridge University Press:  31 January 2011

Koichi Taniguchi ,
Manabu Enoki ,
Makoto Watanabe ,
Seiji Kuroda  and
Kaita Ito
Koichi Taniguchi
Affiliation:
Department of Materials Engineering, The University of Tokyo, Tokyo 153-8902, Japan
Manabu Enoki*
Affiliation:
Department of Materials Engineering, The University of Tokyo, Tokyo 153-8902, Japan
Seiji Kuroda
Affiliation:
Hybrid Materials Center, National Institute for Materials Science, Tsukuba, Ibaraki 305-0044, Japan
Kaita Ito
Affiliation:
Department of Materials Engineering, The University of Tokyo, Tokyo 153-8902, Japan; and Hybrid Materials Center, National Institute for Materials Science, Tsukuba, Ibaraki 305-0044, Japan
*
a) Address all correspondence to this author. e-mail: [email protected]
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Abstract

Multichannel acoustic emission (AE) measurements by four laser interferometers were developed and applied during a plasma-spray coating process that is known as being a high-temperature process and an extremely noisy environment in both mechanical and electrical domains. The AE signals could be successfully detected during the cooling period after the deposition, and it was clearly indicated that a higher preheating temperature resulted in the improvement of bonding between splats and/or at the interface of the coating and the substrate. The maximum principal stress generated during the deposition process was calculated by the transient heat and stress analysis and the obtained AE events. The critical stress for crack initiation of the alumina coating on a steel substrate with an NiCr bond coat layer was estimated as 30∼45 MPa. The developed techniques were shown to be a potential tool for in situ monitoring of the thermal spray process, by which an increase in the reliability of thermal spray coatings can be expected.

Keywords

Acoustic emissionCoatingSpray deposition
Type
Articles
Information
Journal of Materials Research , Volume 24 , Issue 10 , October 2009 , pp. 3182 - 3189
Copyright
Copyright © Materials Research Society 2009

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