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A Process Model for Laser Surface Treatment of Plasma Sprayed Coatings

[+] Author Affiliations
J. Wu, J. Choi, S. Zhang, G. Hilmas

University of Missouri at Rolla

Paper No. IMECE2004-59969, pp. 447-455; 9 pages
doi:10.1115/IMECE2004-59969
From:
  • ASME 2004 International Mechanical Engineering Congress and Exposition
  • Heat Transfer, Volume 3
  • Anaheim, California, USA, November 13 – 19, 2004
  • Conference Sponsors: Heat Transfer Division
  • ISBN: 0-7918-4711-X | eISBN: 0-7918-4178-2, 0-7918-4179-0, 0-7918-4180-4
  • Copyright © 2004 by ASME

abstract

Advanced ceramics are not easily fabricated and consolidated by the plasma spray technique because of their extremely high melting temperature. Zirconium diboride (ZrB2 ) has been successfully plasma sprayed, but the coatings are quite porous. The high levels of porosity are usually a result of unmelted ZrB2 particles that have been incorporated into the coating during deposition. Applying a laser surface treatment to reduce both the porosity and the coating surface roughness, and to improve the coating quality, is of great interest. A laser based surface treatment technique provides a well-controlled heat input, with minimal or no distortion. In this study, a two dimensional mathematical model is developed to investigate the effects of laser power, beam diameter and level of porosity on the coating quality, incorporating melting, solidification, and evaporation phenomena. A continuum model is used to solve Navier-Stokes equations for both solid and liquid phases. Volume-of-Fluid (VOF) is incorporated to track the free surface. The surface force is incorporated as a body force instead of a boundary condition. The porosity level and surface roughness before and after the laser surface treatment are simulated and compared with experimental results.

Copyright © 2004 by ASME

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