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Abstrak :
Salah satu cara untuk mengurangi berat struktural roket RX-100 adalah dengan memodifikasi material dan proses pembuatan nosel. Nosel dipilih sebagai sasaran pengurangan berat karena nosel menyumbang 30 % dari keseluruhan berat struktur. Salah satu cara untuk mengurangi berat nosel adalah dengan mengganti lapisan grafit masif, yang digunakan sebagai pelindung panas, dengan lapisan WC (Tungsten Carbide) yang diaplikasikan dengan teknik HVOF (High Velocity Oxigen Fuel) thermal spray. Pada makalah ini akan dibahas karakteristik dasar dari material nosel yang dipakai saat ini. Selain itu, juga akan dibahas modifikasi pengujian kekuatan lekatan lapisan, guna memperoleh alat bantu untuk mempermudah pengujian tanpa mengorbankan tingkat presisi. Hasil penelitian menunjukkan bahwa material yang dipakai sebagai nosel roket RX-100 adalah baja S45C. Modifikasi alat bantu pengujian kekuatan lekat lapisan dilakukan dengan menambahkan rantai, yang meningkatkan fleksibilitas dan kemudahan pengujian tanpa mengorbankan tingkat presisi.

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Modification of Bonding Strength Test of WC HVOF Thermal Spray Coating on Rocket Nozzle. One way to reduce structural weight of RX-100 rocket is by modifying the nozzle material and processing. Nozzle is the main target in weight reduction due to the fact that it contributes 30 % to the total weight of the structur. An alternative for this is by substitution of massive graphite, which is currently used as thermal protector in the nozzle, with thin layer of HVOF (High Velocity Oxy-Fuel) thermal spray layer. This paper presents the characterization of nozzle base material as well as the modification of bonding strength test, by designing additional jig to facilitate testing processes while maintaining level of test accuracy. The results showed that the material used for RX-100 rocket nozzle is confirmed to be S45C steel. Modification of the bonding strength test was conducted by utilizing chains, which improve test flexibility and maintains level of accuracy of the test.

Abstrak :
ABSTRAK
Teknologi Thermal Spray Aluminium TSA telah banyak diaplikasikan pada industri Minyak dan Gas terutama sebagai pelindung terhadap korosi. Sebagai pelindung korosi, sifat mekanis seperti kekuatan ikatan adesif dan kohesif material pelapis berkaitan langsung dengan umur ketahanan terhadap korosi. Pada penelitian ini telah dilakukan pengamatan pengaruh waktu tunda proses pelapisan aluminium terhadap karakteristik sifat mekanis lapisan.Proses pelapisan aluminium pada penelitian ini menggunakan metode Thermal Arc Spray dengan material substrat baja karbon SK5 dan material pelapis kawat aluminium 95.5 , dilakukan secara bertahap dengan memberikan waktu tunda 0 jam tanpa waktu tunda , 4 jam, 24 jam dan 48 jam. Ketebalan lapisan TSA awal 75-125 ?m, dan ketebalan lapisan TSA setelah diberikan waktu tunda sebesar 200-250 ?m. Sampel dilakukan pengujian daya lekat pull-off test , tekuk bending test , kekerasan mikro, pengamatan metalografi menggunakan mikroskup optic dan SEM.Proses pelapisan TSA dengan disertai waktu tunda 4 jam, 24 jam dan 48 jam menghasilkan tingkat porositas yang lebih tinggi pada lapisan dibandingkan dengan tanpa waktu tunda, namun variabel perbedaan waktu tunda tidak mempengaruhi tingkat porositas. Tingkat porositas tersebut berpengaruh pada kekuatan ikatan adesif dan kohesif lapisan. Dari hasil pengujian daya lekat lapisan didapatkan sampel tanpa waktu tunda menghasilkan kekuatan ikatan 8,3 MPa, sedangkan sampel yang diberikan waktu tunda 4 jam, 24 jam dan 48 jam mengalami kegagalan adesif dan kohesif dengan kekuatan daya lekat 8 MPa, 8 MPa, dan 7,9 MPa. Pada sampel dengan waktu tunda, lapisan TSA pertama akan bertindak sebagai permukaan substrat bagi lapisan TSA kedua. Tingkat kekasaran dan profil permukaan lapisan TSA pertama sebesar 126,3 ndash; 153 ?m akan menghasilkan tingkat porositas lapisan TSA keseluruhan yang lebih tinggi dibandingkan proses tanpa waktu tunda.

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ABSTRACT
Thermal Aluminum Spray TSA has been widely applied in oil and gas industries especially as a protection against corrosion. As a corrosion protector, mechanical properties of coating materials such as adhesive and cohesive bond strength are directly related to the life time of corrosion resistance. In this research has been observed the influence of time delay of aluminum coating process on the coating mechanical properties.The aluminium coating process in this research using Thermal Arc Spray as the method with SK5 carbon steel substrat and 95.5 aluminum wire coating material. Coating process has been done in 2 stages with 0 hours, 4 hours, 24 hours and 48 hours time delay. The first layer thickness is 75 125 m, and after a given delay time is 200 250 m. Coated samples were tested by pull off test, bending test, micro hardness and metallographic observation using optical microscope and SEM.TSA within 4 hour, 24 hour and 48 hour time delay coating process produces higher porosity levels in the coating compared without time delay, however delay time difference variable did not affect the porosity level. Furthermore, porosity level will affect the adhesive and cohesive bond strength of the coating. From the Pull off testing, sample without delay time resulting 8,3 MPa bond strength, and samples with 4 hours, 24 hours and 48 hours delay time resulted bond strength of 8 MPa, 8 MPa and 7,9 MPa. For sample with time delay, the first TSA coating layer will act as a substrate surface for the second TSA layer. Thus, the surface roughness level of the first TSA coating layer of 126,3 ndash 153 m will resulting higher porosity for overall TSA coating layer than the process without time delay.

Abstrak :
Contents : - Quo Vadis Thermal Spraying ? - HVOF-Sprayed Quasicrystal Composite Coatings for Bearing Applications - Functional Ceramic and Metallurgical Coatings on Magnesium Components - Study on Zircon-Based Ceramic Coating for High Temperature Oxidation Resistant Application - Tungsten Coatings for Divertor Wings - Double Doped Ceria Electrolyte Synthesized by Solution Plasma Spraying with Induction Plasma Technology - Replacement for Hard Chrome Plating in Printing Machinery - A contribution to Engine pistons Life Time Improving by Means of Thermal Spray Coatings - Plasma Spraying of Tin on to a Monocrystalline Lithium Fluoride Window - Fabrication and Properties of TiO2 Plioto-Catalytic Coatings by Thermal Spraying with TiO2-AI Agglomerated Powder - XRD and Rietveld Quantitative Pliase Analysis of Radio Frequency Suspension Plasma Sprayed Nano-hydroxyapatite Powders - HVOF Sprayed Hydroxyapatite Coatings: Powders' Melting State and Mechanical Properties - In Vitro Changes on High-Pressure Plasma Sprayed Hydroxyapatite (HA) Caotings - Corrosion Resistant Coatings for Gas Turbine Exhaust Stack Applications - Ceramic Abradable Coatings for Applications up to 1100°C - Production of Superplastic Foils by Thermal Spraying - The Internal Plasma Spraying on Powerful Technology for the Aerospace and Automotive Industries - A Contribution to the Production and Characterization of HVOF coatings for Application in the Petrochemical Field - Process Modelling to Optimise the Structure of Hollow Zirconia Particles for use in Plasma Sprayed Thermal Barrier Coatings - Comparative Study of Different Sealing Methods for Thick Thermal Barrier Coatings - Influence of a Multi-Gas Mixture on the on the Performance of a HPPS Plazjet System for a Thermal Barrier Coating - Effect of Bond Coat Processes and Surface Characteristics on the Failure Mechanism of Thermal Barrier Coatings - Thermal Shock Characteristics of Functionally Graded Thermal Barrier Coatings - Kinetics of Thermally Grown Oxide at Interface Between Thermal Barrier Coatings and MCrAlY Bond Coatings - Reaction Diffusion Behavior of Thermally Sprayed MCrAlY Coatings on Ni-Based Super Alloys - Optimization of Shop Practices for Thermal Barrier Coatings - Removal of Thermal Barrier Coatings from Turbine Blades: A Comparison of Machanical and Chemical Methods - Induction Plasma Synthesis of MoSi2 Ultrafine Powders - Improvements in HVOF Sprayed Cermet Coatings Produced from SHS Powders - Composites Made of Metal Foams With Thermally Sprayed Coatings - Plasma Spray Dissociation ZrSiO4 As The Basis of Forming ZrO2-Mullite Composites from a ZrSiO4 + AI2O3 Mixture - HVOF Sprayed Hydroxyapatite/Titania Composite Coatings - Manufacture of SiC Composite Coatings by HVOF - Hight Temperature Behaviour of Plasma Sprayed ZrB2-SiC Composite Coatings - Abradable Coatings for Low-Temperature Applications - Developments of Plasma Sprayed Ceramic Coatings - Properties of Al203 coatings sprayed by HFPD - On the Tailoring of Spray Dried Thermal Spray Powders - Spray Powders and Coatings on the Basis of Titanium Suboxides - A Comparative Study of the Deposition of Chromium Carbide Based Metal Matrix Composites by Axial Plasma Spray, Air Plasma Spray and High Velocity Oxygen Fuel - Heating Effect of Flame Impingement on polymer Coatings - Mechanical Properties of Thermal Spray PEEK Coatings - Characterization and Mechanical Properties of Flame Sprayed Hydroxyapatite/Polymer Composite Coatings - Structure and Thermal Conductivity of Flame Sprayed Polyamide 11 Coatings Filled with AI2O3, AIN and BN Ceramics - Surface Modification of Recycled PET Plate by Particle Implantation and Deposition with Plasma Spraying - Sprayed Composite Coating of High Performance Thermoplastics - Processing and Characterization of Nanostructured Cermet Coatings - Synthesis and Properties of Multimodal WC-12 Co Coatings - Structure and Properties of HVOF Sprayed Amorphous Polymer Matrix Nanocomposite Coatings - Properties of HVOF Sprayed Multi-Scale Polymer/Silica Nanocomposite Coatings - Control of the Injection of an Alumina Suspension Containing Nanograins in a dc Plasma - Cold Sprayed Nanostructured WC-Co - Low Pressure Plasma Spraying of Sol-Gel Al203/SiC Nanocomposite Coatings - Effects of Shock Waves on Impact Velocity of Cold Spray Particles - Optimization of the Cold Spray Process - Kinetic Powder Compaction Applying the Cold Spray Process A Study on Parameters - Experimental Study of Interaction of Supersonic Gas Jet With a Sub

Abstrak :
Thermal spray is a coating process that provides functional surface to protect or improve the performance of a substrate or component. Almost any kind and form of material can be thermally sprayed which is why thermal spray is used worldwide to provide protection from corrosion, wear, and heat, to restore and repair components, and for a variety of other applications. This reference handbook is the complete guide to thermal spray technology. It covers principles, processes, types of coatings, applications, performance, and testing/analysis. Developed under the guidance of the Thermal Spray Society Training Committee, the handbook provides an excellent introduction and guidebook for those who are new to thermal spray. It also provides enough in-depth coverage and data that it should be of great value to specifiers and users of thermal spray coatings and to thermal spray experts who need additional background in certain areas.

Abstrak :
Contents : - Numerical and Microstructural Investigations of the Bonding Mechanisms in Cold Spraying - High Strain Rate Deformation Phenomena in Explosive Powder Compaction and Cold Gas Spraying - Optimizing the Cold Spray Process - Modeling of Particle-Substrate Adhesive Interaction Under the Cold Spray Process - A Systematic Approach to Material Eligibility for the Cold Spray Process - Particle-Substrate Interactions in Cold Gas Dynamic Spraying - Evaluation Of Coatings Produced Via Kinetic And Cold Spray Processes - Potential Applications of Cold-Spray Technology in Automotive Manufacturing - Development of Cold Gas Sprayed Coatings - Cold Spray Copper Application for Upper Stage Rocket Engine Design - Kinetic Spray of Aluminum Metal Matrix Composites For Thermal Management Applications - Effect of Spray Angle on Deposition Characteristics in Cold Spraying - Cold Spraying – Equipment and Application Trends - Automated Cold Spray System: Description of Equipment and Performance Data - Helium Recovery: Design Considerations for Cold Spray Systems - Cold Spray Technology: An Industrial Perspective - Production Coating Cost Comparison - Thermal Spray Solutions For Diesel Engine Piston Rings - Low-Cost High-Performance Coatings Produced by Internal Plasma Spraying for the Production of High Efficiency Engines - Development of Thermal Spray for Automotive Cylinder Bores - 316L – an Alternative to NiCr Bondcoats for Cr2O3-Coatings on Anilox Rolls - Plasma-Sprayed Ceramic Coatings for Molten Metal Environments - Influence of Powder Size in Aluminum Oxide Coatings for Use in the Semiconductor Industry - Intermediate Temperature SOFC Based on Fully Integrated Plasma Sprayed Components - Investigation of the Photocatalytic Efficiencies of Plasma Sprayed Tio2-Fe3O4 Coatings - Protection of Titanium Alloy Surfaces by Thermal Spraying and Laser Treatment - Fabrication of TiO2 Photocatalytic Coatings on PET by Thermal Spraying - Photocatalytic Decomposition of Ammonia by Thermal Sprayed TiO2 Coatings - Optimization of Axial Injection Conditions in a Supersonic Induction Plasma Torch: Application to SOFCs - Methodology for Meeting Standards and Environmental Requirements in Thermal Spraying Hardfacing and Sand Blasting Erosion Resistance of Arc Spray Composite Coatings at High Temperature on Boiler Tubes of Pulverized Coal Fired Power Station - Assessing the Feasibility of Using Diamond as a Reinforced Phase in Metal Matrix Composite Coatings - New Carbide Based Materials for HVOF Spraying - Advanced Oxide Ceramic Coatings for Applications Demanding High Wear Resistance - Development and Application of WC-Cr3C2-Ni Coating with High Impact Resistance - Preparation and Characterization of Powders and Coatings Containing Solid Lubricants - Properties of Plasma and D-Gun Sprayed Metal-Matrix-Composite (MMC) Coatings Based on Ceramic Hard Particle Reinforced Fe-, Ni-aluminide Matrix - Ceramic Coating of Alloy 625 using Controlled Atmosphere Plasma Spraying for Sea Water Corrosion Protection - The Influence of Matrix Phase Viscosity on the Plasma-Spray Deposition Of Silicon-Nitride Composite Coatings - Influence of Rare Earth Elements on the Corrosion Resistance of Fe-Cr-Ni Thermal Sprayed Coatings - Process Temperature-Hardness-Wear Relationships for HVOF-Spraye Nanostructured and Conventional Cermet Coatings - A Parametric Study of an HVOF Process for the Deposition of Nanostructured WC-Co Coatings - Abrasion and Sliding Wear of Nanostructured Ceramic Coatings - Fatigue and Fracture Resistance of Nanostructured Composite System: Chrome Carbide – Hard Oxide Aluminum – Aluminum - Abrasion Wear Behaviour of Plasma and HVOF Sprayed Al2O3-SiC Nanocomposite Coatings - Effect of Powder Composition on the Microstructure and Wear Properties of Sprayed Cast Iron Coatings - Influence of Thermal Spray Process on the Corrosion Behavior of High-Density - Stainless Steel Coatings in Simulated Marine Environment - A New Spray Coating Process for Manufacture of Stainless Steel Clad Construction Steel with Resistance to Corrosion by De-icing Salts & Seawater - HVOF Reactive Spraying of Mechanically Alloyed Ni-Ti-C Powders - Marine Exposure Tests of Thermal Sprayed Coatings in Japan - Development of Dense Corrosion Resistant Coatings By an Improved HVOF Spraying Process - Protection of Steel Components Against Marine Corrosion by Thermally Sprayed Anodic Coatings - Development and Implementation of HVOF WC/Co/Cr Coating as Alternative to Electrolytic Hard Chrome Plate in Landing Gear Applications

Abstrak :
This proceedings volume representing the second International Thermal Spray Conference (May 2004, Osaka, Japan) contains 232 papers and 93 poster presentations. Arrangement is in sections on applications, characterization methods for coating properties, coating technologies for vehicle engines, cold spray, consumables for thermal spraying, corrosion protection, economics and quality, HVOF processes and materials, innovative equipment and process technology, modeling and simulation, nanostructured materials, photocatalytic materials, process diagnostics, protective coatings against wear and erosion, and thermal barrier coatings.

Abstrak :
Baja Tahan Karat 316L memiliki aplikasi yang sangat beragam, mulai dari platform serta instalasi lainnya, terutama pada lepas pantai karena ketahanan korosinya yang tinggi. Namun, pada penggunaannya, baja tahan karat 316L memiliki kemungkinan untuk terjadi korosi sumuran. Korosi sumuran merupakan korosi yang sulit untuk dideteksi sampai akhirnya terjadi kerusakan. Dengan mengaplikasikan pelapisan aluminium pada baja tahan karat 316L maka korosi sumuran dapat dicegah. Selain itu, ketahanan korosi secara umum juga akan meningkat. Metode untuk mengaplikasikan aluminium pada baja tahan karat 316L adalah dengan electric arc thermal spray aluminum. Pengujian kali ini menginvestigasi ketebalan pelapisan paling baik yang memberikan hasil maksimal, dengan tiga parameter yaitu berkisar antara 90-100 µm, 140-150 µm, and 190 – 200 µm. Ketahanan korosi diuji menggunakan metode polarisasi siklik. Hasil studi menunjukkan bahwa ketahanan korosi dan daya lekat paling baik dihasilkan lapisan dengan ketebalan 190 – 200 µm...... In oil and gas industries, 316L Stainless Steel is widely used to construct platforms and other installations because of its high corrosion resistance. However, 316L Stainless Steel is still susceptible to pitting corrosion which is difficult to be detected before failure starts to happen. By applying aluminium coating on stainless steel, pitting corrosion will be prevented. Moreover, the corrosion rate will decrease and the steel’s lifetime will increase. Using Electric Arc Thermal Spray Aluminium as the method to apply the aluminium, one of the most important factor that influence corrosion rate on aluminium coated stainless steel is the thickness itself. This paper investigates the most effective thickness applied to achieve the best quality of the coating, ranging at 90-100 µm, 140-150 µm, and 190 – 200 µm. The corrosion resistance is tested using the data obtained from the cyclic polarization curve. The study shows that the coating thickness of 190 – 200 µm produces the best corrosion resistance and adhesion strength

Abstrak :
Nozzle of RKX l00 rocket contributes 30 % to the total weight of the structure, so that allowing further research on weight reduction. An alternatiye for this is by substitution of massive graphite, which is currently used' as thermal protector in the nozzle, with thin layer of HVOF (High Velocity Oxy-Fuel) thermal spray layer. A series of study on the characteristics of various type of HVOF coating material have been conducted This paper presents the investigation on the HVOF Cr,C3-NiCr thermal spray coating, particularly, the optimization of bonding strength by varying surface roughness of substrates. Characterization includes bonding strength test, microhardness measurement and microstructural analysis by both optical and scanning electron microscopes (SEM). The results showed that grit blasting pressure increases the surface roughness from 4.54 ,urn to 5.72 _um at the pressure of 6 bar. Average microhardness of the coating is 631 VHN_;m.Coating applied to the Surface with roughness of 5.42 ,ann possessed the highest bonding strength of 4 4 MPa. Microstructural observation by using optical microscope and scanning electron microscope (SEM) confirmed dense lamellae structure with variable composition. High coating adherence was found to be due to mechanical interlocking.