Spraying is a surface treatment technique whereby the heat source such as an arc or gas flame melts the spraying material and the compressed gas injects it to form a coating on the metal surface. Unlike surface alloying, the coating component is never or rarely diluted by the base metal because it melts none or very little of the base material.
In order to coat mechanical components with mechanical abrasions or casting defects on their surface, the self-propagating high-temperature synthesis method (SHS) is incorporated into the oxygen-acetylene flame spaying. Compared to plasma spraying, oxygen-acetylene flame spraying is cheap, but it is not available for materials with high melting points due to its low flame speed and flame temperature. However, combining the oxygen-acetylene flame spraying with the SHS method is the solution.
Therefore, there have been many studies to spray Al-Fe2O3 materials with good internal friction performance, low cost and high melting points by combining the oxygen-acetylene frame spraying and the SHS method. However, they dealt only with the spraying process and the structures and properties of coating layers in the system, but not reactive thermodynamic analyses.
The desired reaction during spraying and the formation of the structure can be found by reaction thermodynamic analysis. Hence, Jegal Tok Song, a researcher at the Faculty of Materials Science and Technology, has formed an Al2O3-Fe composite coating layer with Fe2O3 and Al powder, cheap belongings to the SHS reaction system, and performed a reactive thermodynamic analysis and a simulation of a spraying process.
First, he verified the possibility of reaction by calculating the adiabatic temperature of the system and the Gibbs free energy of theoretically possible reactions. Then, he performed a differential thermal analysis to determine the temperature for reactions. Finally, he determined the optimum spraying conditions by using Fluent.
The results of his study can also be applied to other reaction systems that involve SHS methods for spraying.
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