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Atmospheric plasma spraying is a common process for depositing ceramic coatings to prevent wear and corrosion. Raw materials include, for example, alumina, titanium oxide and chromium oxide. Plasma sprayed chromium oxide coating is widely used in anilox rolls, pump seals and wear rings due to its good surface quality, high hardness and wear resistance. However, chromium oxide is difficult to spray due to its high melting point, low thermal conductivity and easy volatilization at high temperature. The volatilization of chromium oxide during the spraying process will produce extremely fine dust particles, which will gather on the workpiece and be trapped inside the coating, reducing the cohesion and mechanical properties of the coating. Dry ice spraying has been used in the field to improve the quality of chromium oxide and many other plasma sprayed coatings by keeping the surface clean and helping heat management. During the spraying process, the chromium oxide coating sprayed by plasma on the TUT is connected to the spraying robot through two different commercial dry ice sprayers using dry ice spray. Several parameters were tested and temperature monitoring was implemented. Metallographic samples were prepared and analyzed by SEM. Hardness, adhesion, permeability and wear tests were also carried out. It is found that dry ice spray has changed the temperature history of the substrate, and the coating has significantly produced unexpected effects. Excessive cooling will reduce the adhesion, cohesion and wear resistance shown in the figure, but adjusting the spraying parameters can better eliminate some adverse effects. Different injection models related to the size of particles leaving the nozzle also have great differences. Although the other injector only sprays small dry ice dust that mainly cools the substrate, the larger particles with greater kinetic energy sprayed by the other injector have a more positive impact on the cohesion of the coating than the samples of non-dry ice spray coating, This increases wear resistance. Plasma spraying is used to manufacture ceramic coatings, especially for wear and corrosion applications. For example, alumina, titanium oxide and chromium oxide are used as starting materials. Plasma sprayed chromium oxide coating is widely used in rolls, seals and wear-resistant tire presses due to its good surface finish, high hardness and wear resistance. However, chromium oxide is a challenging injection molding material due to its high melting temperature and low thermal conductivity. Chromium oxide is also easy to evaporate at high temperature, resulting in the formation of fine chromium oxide dust. The resulting chromium oxide dust is easily left between the coatings, weakening the cohesion and mechanical properties of the coating.
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