Process control for thermal-spray deposition of thermoset coatings using computer simulation

Journal article


Hu, X, Bao, Y, Gawne, DT and Zhang, T (2016). Process control for thermal-spray deposition of thermoset coatings using computer simulation. Progress in Organic Coatings. 101, pp. 407 - 415.
AuthorsHu, X, Bao, Y, Gawne, DT and Zhang, T
Abstract

Thermal spraying is a green solvent-free process with the potential of applying polymer coatings to large components in-house or on-site without the need for prolonged drying. Almost no systematic research has been undertaken on thermally spraying thermoset coatings owing to the complexity and difficulty of managing the curing process. An adequately cured thermoset coating could not be deposited by thermal spraying owing to insufficient cumulative time above the cure temperature. Preheating and post-heating the substrate under a constant heat source were not successful as they led to non-uniform curing, residual stress and the risk of overheating. This study develops and validates a computer model that simulates the deposition of thermoset coatings on metal substrates using thermal spraying and high-energy infrared irradiation. The model uses readily-available commercial software and enables precise control of the coating process to improve energy efficiency and coating quality. Further research showed that evenly cured coatings could be achieved by using variable heat fluxes and controlled utilization of inward conduction from the outer surface layers. Self curing during cooling was significant and maybe employed to increase energy efficiency. The thickness of the metal substrate was shown to be an important variable as it acts as a heat sink and, for heavy sections, can substantially increase energy consumption. The results indicate a need for sufficiently accurate process control and provide a suitable methodology for the deposition of thermoset coatings.

KeywordsThermal spraying, organic coatings, computer simulation, process control
Year2016
JournalProgress in Organic Coatings
Journal citation101, pp. 407 - 415
PublisherElsevier
ISSN1873-331X
Digital Object Identifier (DOI)doi:10.1016/j.porgcoat.2016.09.008
FunderSeventh Framework Programme
Publication dates
Print17 Sep 2016
Publication process dates
Deposited22 Sep 2016
Accepted06 Sep 2016
Accepted author manuscript
License
CC BY-NC-ND 4.0
Permalink -

https://openresearch.lsbu.ac.uk/item/8722x

  • 3
    total views
  • 33
    total downloads
  • 1
    views this month
  • 3
    downloads this month

Related outputs

The influence of nanostructure on the mechanical properties of 3D printed polylactide/nanoclay composites
Paspali, A, Bao, Y, Gawne, D, Piestert, F and Reinelt, S (2018). The influence of nanostructure on the mechanical properties of 3D printed polylactide/nanoclay composites. Composites Part B: Engineering. 152, pp. 160-168.
Effect of melting parameters during synthesis on the structure and properties of tin fluoride phosphate glasses
Iturrarana, N, Huraux, K, Bao, Y, Gawne, D and Guilment, J (2018). Effect of melting parameters during synthesis on the structure and properties of tin fluoride phosphate glasses. Journal of Non-Crystalline Solids. 489, pp. 64-70.
Effect of tin fluoride content on the structure and properties of phosphate glass – polyamide 11 hybrids
Serio, L, Gawne, DT and Bao, Y (2017). Effect of tin fluoride content on the structure and properties of phosphate glass – polyamide 11 hybrids. European Polymer Journal.
Effect of composition on the mechanical properties of 3d printed polymer nanocomposites
Paspali, A, Bao, Y, Gawne, DT and Piestert, F (2017). Effect of composition on the mechanical properties of 3d printed polymer nanocomposites. 25th Annual International Conference on Composite/Nano Engineering (ICCE 25). Rome, Italy 16 - 22 Jul 2017 London South Bank University.
Microporosity and delamination mechanisms in thermally sprayed borosilicate glass coatings
Gao, J, Bao, Y and Gawne, DT (2016). Microporosity and delamination mechanisms in thermally sprayed borosilicate glass coatings. Surface & Coatings Technology. 304 (25 Oct), pp. 195 - 202.