Key process variables for APS (Atmospheric Plasma Spray)
07-02-2006, 01:34 PM,
#1
Key process variables for APS (Atmospheric Plasma Spray)
The following messages were copied and pasted from www.gordonengland.co.uk/cgi-bin/board/sefmessages/8554.html to illustrate how to bring life back into a read only archived message.


Quote:Posted by becky (132.244.246.24) on 11:49:59 25/05/06

Hello.
When spraying APS coatings, which paramters do you all consider to be the most important variables that need to be monitored for the purposes of statisical process control?
Any help much appreciated.
Becky.

Quote:Posted by Gordon England (62.252.0.12) on 01:02:42 02/06/06

In Reply to: key process variables for APS posted by becky

Hi Becky
Not too sure what you mean by statisical process control, but I would say all the process parameters need to be monitored.
Regards Gordon

* https://www.gordonengland.co.uk/tsc.htm#Factors

Quote:Posted by becky (132.244.246.24) on 09:57:52 02/06/06

In Reply to: Re: key process variables for APS posted by Gordon England

Thanks for the response Gordon.
I would like to understand how SPC could be used to controlling the process. By utilising run charts to assess performance, it should be possible to identify potential problems before they become problems and enable you to avert a non-conforming coating before it is too late. Just as an example ~ wear on nozzles. How often should nozzles be changed? How can you monitor their wear such that they are replaced before they degrade and start affecting / contaminating a coating? What techniques do people use to detect wear etc etc. In a shop floor environment, not all factors can be watched by an operator, (maybe possible in a lab environment) so if only three (for the sake of argument) can be monitored, what three 'key process variables' would be best to monitor.
Any help from anyone greatly received.

Quote:Posted by Gordon England (62.252.0.12) on 21:49:22 02/06/06

In Reply to: Re: key process variables for APS posted by becky

Hi Becky
I would first choose voltage readings. On most modern constant current power supplies, voltage is dictated by the resistance of the plasma gases and nozzle/electrode geometry. Voltage is not normally a set parameter (assuming plasma gas flows are the primary setting). Voltage readings straying from normal range will indicate problems (nozzle/electrode wear, water/gas leaks, plasma gas flow problems).
Next would be powder feed rate and then gas flow rates (including carrier gas).
Best regards Gordon


Quote:Posted by becky (132.244.246.24) on 10:26:29 06/06/06

In Reply to: Re: key process variables for APS posted by Gordon England

Thank you Gordon, that is very helpful.
If the 'set' voltage is recorded on a run chart and then actual voltages are recorded, we should be able to ascertain if the process is starting to shift. This will be an interseting excercise.
Should the peak voltage during the cycle be measured, or at a particular time / times / point in the process? What do you think?
I'll also start taking the other readings that you have suggested and see if we can refine our process. Your help is very much apprecaited.
Kind regards
Becky.
Quote:Posted by Gordon England (62.252.0.12) on 14:20:52 06/06/06

In Reply to: Re: key process variables for APS posted by becky

Hi Becky
Monitoring voltage alone with no reference to other parameter settings would probably be a waste of time. Assuming you are monitoring a spray system where all settable parameters are kept constant (you spray same coating all the time)then monitoring voltage over time for any individual nozzle/electrode hardware set-up would be useful. It is important that you are able to relate voltage with the other parameter settings particularly plasma gas flows, current, etc. and hardware.
An interesting point is that a few set voltage to a specific point and keep this constant, so that they always maintain a constant power output. In this case plasma gas make-up and flow become the variable.
Hope this helps.
Regards Gordon

Quote:Posted by Wojciech (62.233.197.106) on 09:21:40 12/06/06

In Reply to:Re: key process variables for APS posted by Gordon England

Hi,
I was working on a plasma spraying symulation software, and on the process analising. We were interested in influence of variable process parameters on coatings properties.
We assumed that most important variables are:
- Power
- Torch-substrate distance
- Powder feed rate
- Carrier gas flow
Other important parameters I think would be:
- Torch scan speed
- Plasma gas composition
(- Point of powder injection - Angle of powder injection)
You might find interesting that the experiments were planned/analised using 'full factorial design'.
Regards,
Wojciech
Reply
12-30-2006, 11:02 AM, (This post was last modified: 02-08-2008, 04:54 PM by Gordon.)
#2
RE: Key process variables for APS (Atmospheric Plasma Spray)
Gordon Wrote:The following messages were copied and pasted from www.gordonengland.co.uk/cgi-bin/board/sefmessages/8554.html to illustrate how to bring life back into a read only archived message.


Quote:Posted by becky (132.244.246.24) on 11:49:59 25/05/06

Hello.
When spraying APS coatings, which paramters do you all consider to be the most important variables that need to be monitored for the purposes of statisical process control?
Any help much appreciated.
Becky.

Quote:Posted by Gordon England (62.252.0.12) on 01:02:42 02/06/06

In Reply to: key process variables for APS posted by becky

Hi Becky
Not too sure what you mean by statisical process control, but I would say all the process parameters need to be monitored.
Regards Gordon

* https://www.gordonengland.co.uk/tsc.htm#Factors

Quote:Posted by becky (132.244.246.24) on 09:57:52 02/06/06

In Reply to: Re: key process variables for APS posted by Gordon England

Thanks for the response Gordon.
I would like to understand how SPC could be used to controlling the process. By utilising run charts to assess performance, it should be possible to identify potential problems before they become problems and enable you to avert a non-conforming coating before it is too late. Just as an example ~ wear on nozzles. How often should nozzles be changed? How can you monitor their wear such that they are replaced before they degrade and start affecting / contaminating a coating? What techniques do people use to detect wear etc etc. In a shop floor environment, not all factors can be watched by an operator, (maybe possible in a lab environment) so if only three (for the sake of argument) can be monitored, what three 'key process variables' would be best to monitor.
Any help from anyone greatly received.

Quote:Posted by Gordon England (62.252.0.12) on 21:49:22 02/06/06

In Reply to: Re: key process variables for APS posted by becky

Hi Becky
I would first choose voltage readings. On most modern constant current power supplies, voltage is dictated by the resistance of the plasma gases and nozzle/electrode geometry. Voltage is not normally a set parameter (assuming plasma gas flows are the primary setting). Voltage readings straying from normal range will indicate problems (nozzle/electrode wear, water/gas leaks, plasma gas flow problems).
Next would be powder feed rate and then gas flow rates (including carrier gas).
Best regards Gordon


Quote:Posted by becky (132.244.246.24) on 10:26:29 06/06/06

In Reply to: Re: key process variables for APS posted by Gordon England

Thank you Gordon, that is very helpful.
If the 'set' voltage is recorded on a run chart and then actual voltages are recorded, we should be able to ascertain if the process is starting to shift. This will be an interseting excercise.
Should the peak voltage during the cycle be measured, or at a particular time / times / point in the process? What do you think?
I'll also start taking the other readings that you have suggested and see if we can refine our process. Your help is very much apprecaited.
Kind regards
Becky.
Quote:Posted by Gordon England (62.252.0.12) on 14:20:52 06/06/06

In Reply to: Re: key process variables for APS posted by becky

Hi Becky
Monitoring voltage alone with no reference to other parameter settings would probably be a waste of time. Assuming you are monitoring a spray system where all settable parameters are kept constant (you spray same coating all the time)then monitoring voltage over time for any individual nozzle/electrode hardware set-up would be useful. It is important that you are able to relate voltage with the other parameter settings particularly plasma gas flows, current, etc. and hardware.
An interesting point is that a few set voltage to a specific point and keep this constant, so that they always maintain a constant power output. In this case plasma gas make-up and flow become the variable.
Hope this helps.
Regards Gordon

Quote:Posted by Wojciech (62.233.197.106) on 09:21:40 12/06/06

In Reply to:Re: key process variables for APS posted by Gordon England

Hi,
I was working on a plasma spraying symulation software, and on the process analising. We were interested in influence of variable process parameters on coatings properties.
We assumed that most important variables are:
- Power
- Torch-substrate distance
- Powder feed rate
- Carrier gas flow
Other important parameters I think would be:
- Torch scan speed
- Plasma gas composition
(- Point of powder injection - Angle of powder injection)
You might find interesting that the experiments were planned/analised using 'full factorial design'.
Regards,
Wojciech

I agree with you ,but you have to add ,good extraction+colding gun Questionto make less oxydation
Reply




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