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1
Content available remote Microplasma-sprayed multilayer coatings for electric heating elements
Kaliuzhnyi Sergii, Alontseva Dayra, Voinarovych Sergey, Kyslytsia Oleksandr, Khozhanov Aleksandr, Łatka Leszek, Faizrakhmanov Zulfat, Bektasova Gulsym
Materials Science Poland
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2022
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Vol. 40, No. 4
158--170
EN
The paper presents new results on the application of microplasma spraying (MPS) for manufacturing electric heating elements (EHEs) consisting of a St3 steel plate (the substrate) with a sprayed electrically insulating Al2O3 sublayer (400±50 μm thick) and TiO2 electric heating tracks (4 mm width; 150±50 μm thickness). Measurements of the temperature of the multilayer coating with a thermal imager enabled determination of the temperature distribution over the surface of the EHE. The electric strength and conductivity tests showed the efficiency of the sprayed EHEs up to a temperature of 200°C. The results of analysis of the causes of material losses during MPS of electric heating tracks (TiO2) are presented, and the optimal parameters for efficient MPS of coatings in the form of narrow tracks on steel substrates are determined. Using regression analyses, the equation for the influence of MPS parameters on the coating transfer efficiency (CTE) is obtained. Process parameters such as the electric current and the plasma-forming gas flow rate have been found to have the greatest influence on the CTE. In the experiment, a high efficiency of the sprayed material during MPS of electric heating tracks of TiO2 powder was established (the maximum CTE reached 89%), which indicates the prospects for using MPS technology in the production of EHEs for DC electric heating and for maintaining the temperature of product surfaces up to 200°C.
2
Content available remote Microplasma spraying of hydroxyapatite coatings on additive manufacturing titanium implants with trabecular structures
Kadyroldina Albina, Alontseva Dayra, Voinarovych Sergey, Łatka Leszek, Kyslytsia Oleksandr, Azamatov Bagdat, Khozhanov Aleksandr, Prokhorenkova Nadezhda, Zhilkashinova Almira, Burburska Svitlana
Materials Science Poland
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2022
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Vol. 40, No. 4
28--42
EN
This paper presents new results of microplasma spraying (MPS) of laboratory-synthesized hydroxyapatite (HA) powder coatings onto trabecular substrates obtained by selective laser melting (SLM) of a certified titanium medical alloy powder. The aim of the study was to establish the possibility of combining the technologies of MPS and additive manufacturing (AM) for the possible production of custom-designed implants with increased surface biocompatibility, as well as to establish the MPS parameters that ensure chemical purity of the HA coating and satisfactory adhesion of the coatings to the substrate. The structural-phase compositions of the initial HA powder and the plasma-sprayed HA coating were studied by X-ray diffraction analysis and transmission electron microscopy, and the adhesion strength of the coating was tested according to the F1147 standard of the American Society for Testing and Materials (ASTM). The main results of the study are the following: the application of the MPS technology for HA coating with an average thickness of 150±50 μm on trabecular substrates obtained by the SLM method has been shown. The parameters of MPS of HA coatings onto titanium implants with a trabecular surface have been established. It is also proved that using the appropriate MPS parameters, it is possible to obtain a HA coating with a 95% level of HA phases, 93% level of crystallinity, and the adhesion strength to the trabecular substrate of 24.7±5.7 MPa, which complies with the requirements of the international medical standard (International Organization for Standardization [ISO] 13779-2:2018). These results are of significance for a wide range of researchers developing plasma spray technologies for the manufacture of biocompatible coatings.
3
Content available remote Fabrication and characterization of Zr microplasma sprayed coatings for medical applications
Voinarovych Sergii G., Alontseva Darya L., Kyslytsia Oleksandr N., Kaliuzhnyi Sergii, Khozhanov Alexandr R., Krasavin Alexander, Kolesnikova Tatiana
Advances in Materials Science
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2021
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Vol. 21, nr 2(68)
93--105
EN
This paper presents new results of studying the influence of parameters of microplasma spraying (MPS) of Zr wire on the structure of Zr coatings. The coating experiments were accomplished in a two level fractional factorial design. Individual particles of sprayed Zr wire and their splats on the substrate were collected under various spraying parameters (amperage, spraying distance, plasma gas flow rate and wire flow rate) and evaluated by Scanning Electron Microscopy (SEM) to establish the effect of particle size and shape on the coating microstructure. The particles were characterized by measurement of their sizes and the obtained results were evaluated in terms of their degree of melting. This was compared with the experimentally observed coating microstructure type and finally correlated to the investigated coating porosity to select the specific MPS parameters of Zr coatings depositing onto medical implants from Ti alloy. It was found that the main parameters influencing the size of the sprayed Zr particles and the porosity of the Zr coatings are the plasma gas flow rate and amperage. It was demonstrated that it is possible to control the porosity of Zr microplasma coatings in the range from 2.8% to 20.3% by changing the parameters of the MPS. The parameters of microplasma spraying of Zr wire were established to obtain medical implant coatings with porosity up to 20.3% and pore size up to 300 μm.
4
Content available remote Development of technologies for manufacturing medical implants using CNC machines and microplasma spraying of biocompatible coatings
Alontseva Dayra, Azamatov Bagdat, Voinarovych Sergii, Kyslytsia Oleksandr, Koltunowicz Tomasz N., Toxanbayeva Aigerim
Przegląd Elektrotechniczny
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2020
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R. 96, nr 4
154--157
EN
The paper describes the main technological approaches for manufacturing medical implants from titanium alloy using Computer Numerical Control (CNC) machines and microplasma spraying of hydroxyapatite (HA) coatings. New approaches to the formation of coatings with the desired structure and properties and the challenges of developing the technologies for producing modified implants are discussed.
PL
W artykule opisano główne podejścia technologiczne do wytwarzania implantów medycznych ze stopu tytanu przy użyciu maszyn CNC do sterowania numerycznego i mikroplazmowego natryskiwania powłok hydroksyapatytowych (HA). Omówiono nowe podejścia do tworzenia powłok o pożądanej strukturze i właściwościach oraz wyzwania związane z opracowaniem technologii wytwarzania zmodyfikowanych implantów.
5
Content available remote Software development for a new robotic technology of microplasma spraying of powder coatings
Alontseva D., Krasavin A., Nurekenov D., Ospanov O., Kusaiyn-Murat A., Zhanuzakov Y.
Przegląd Elektrotechniczny
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2018
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R. 94, nr 7
26--29
EN
The paper presents the main results of software development for a new robotic technology of microplasma spraying of powder coatings to protect surfaces of industrial parts. The numerical methods have been implemented for modeling temperature fields induced by the radiation treatment of coatings. The proprietary software products have been developed to perform calculations of temperature fields in two-layer heat absorbers under irradiation and to provide the desired trajectory of a plasma source. The laboratory samples with coatings have been obtained.
PL
W artykule przedstawiono główne wyniki opracowywania oprogramowania dla nowej zrobotyzowanej technologii mikroplazmatycznego natryskiwania powłok proszkowych w celu ochrony powierzchni części przemysłowych. Zastosowano metody numeryczne do modelowania pól temperatury indukowanych przez napromienianie powłok. Opracowano autorskie produkty do wykonywania obliczeń pól temperatur w dwuwarstwowych pochłaniaczach ciepła w warunkach napromieniowania i zapewnienia pożądanej trajektorii źródła plazmy. Uzyskano próbki laboratoryjne z powłokami.
6
Content available remote Development of technology of microplasma spraying for the application of biocompatible coatings in the manufacture of medical implants
Alontseva D., Borisov Y., Voinarovych S., Kyslytsia O., Kolesnikova T., Prokhorenkova N., Kadyroldina A.
Przegląd Elektrotechniczny
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2018
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R. 94, nr 7
94--97
EN
This paper describes the equipment design of E. O. Paton Electric Welding Institute and technology of microplasma spraying of coatings from powder and wire materials for applying biocompatible coatings for medical implants. The given equipment was introduced at an experimental robotics complex for microplasma spraying at D. Serikbayev East-Kazakhstan State Technical University By this example the authors discuss the challenges and prospects of the development and implementation of microplasma spraying technology.
PL
W artykule opisano konstrukcję sprzętu w E. O. Paton Electric Welding Institute oraz technologię natryskiwania mikroplazmy powłok z proszków i materiałów drucianych w celu nanoszenia biokompatybilnych powłok na implanty medyczne. Dany sprzęt został wprowadzony do eksperymentalnego kompleksu robotyki do natryskiwania mikroplazmy na Uniwersytecie Technicznym D. Serikbayev East-Kazakhstan. Na tym przykładzie autorzy omawiają wyzwania i perspektywy rozwoju i wdrażania technologii mikroplazmatycznej.
7
Content available remote Optimization of hydroxyapatite synthesis and microplasma spraying of porous coatings onto titanium implants
Alontseva D. L., Abilev M. B., Zhilkashinova A. M., Voinarovych S. G., Kyslytsia O. N., Ghassemieh E., Russakova A., Łatka L.
Advances in Materials Science
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2018
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Vol. 18, nr 3(57)
79--94
EN
The paper presents the main results of development and optimization of the synthesis of hydroxyapatite and the application of the micro-plasma spraying technique for biocompatible coatings. The hydroxyapatite synthesis was optimized using the mathematical modelling method. Synthesized hydroxyapatite was studied by IR spectrometry and X-ray diffraction analysis for assessment of the compatibility of the chemical and phase composition to the bone tissue. The Ca/P ratio of the obtained hydroxyapatite was 1.65, which is close to that of bone tissue (1.67). To increase the adhesion strength of the HA coating to the surface of the titanium implant, it was suggested to apply a titanium sublayer to the implant surface. Microplasma spraying (MPS) of biocompatible coatings from titanium wires and synthesized HA powders onto substrates made of medical titanium alloy has been carried out. Microplasmatron MPN-004 is used to obtain the two-layer coatings for titanium implants. The two layer coating includes a sub-layer of a porous titanium coating with a thickness in range from 200 up to 300 μm and the porosity level of about 30%, and an upper layer of HA about 100 μm thick with 95% level of HA phases and 93% level of crystallinity. The pore size varies from 20 to 100 μm in both coatings. The paper describes the technology and modes of microplasma deposition of two-layer coatings, including the mode of gas-abrasive treatment of the surface of implants made of titanium alloy before spraying. The synthesized HA powder and the Ti/HA coatings were investigated by optical microscopy and scanning electron microscopy with the energy dispersion analysis and the X-ray diffraction analysis.
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