Dust Explosion Characteristics of Aluminum, Titanium, Zinc, and Iron-Based Alloy Powders Used in Cold Spray Processing
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. Sakata, K. Tagomori, N. Sugiyama, S. Sasaki, Y. Shinya, T. Nanbu, Y. Kawashita, I. Narita, K. Kuwatori, T. Ikeda, R. Hara, and H. Miyahara (Submitted July 30, 2013; in revised form November 3, 2013) Compared to conventional thermal spray coating, cold spray processing typically employs finer, smallerdiameter metal powders. Furthermore, cold-sprayed particles exhibit fewer surface oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is important to consider the potential for dust explosions or fires during cold spray processing, for both industrial and R&D applications. This work examined the dust explosion characteristics of metal powders typically used in cold spray coating, for the purpose of preventing dust explosions and fires and thus protecting the health and safety of workers and guarding against property damage. In order to safely make use of the new cold spray technology in industrial settings, it is necessary to manage the risks based on an appropriate assessment of the hazards. However, there have been few research reports focused on such risk management. Therefore, in this study, the dust explosion characteristics of aluminum, titanium, zinc, carbonyl iron, and eutectoid steel containing chromium at 4 wt.% (4 wt.% Cr-eutectoid steel) powders were evaluated according to the standard protocols JIS Z 8818, IEC61241-2-3(1994-09) section 3, and JIS Z 8817. This paper reports our results concerning the dust explosion properties of the above-mentioned metal powders.
Keywords
aluminum, carbonyl iron, cold spray, dust explosion, eutectoid steel, risk assessment, scanning electron microscopy, titanium, x-ray diffraction, zinc
1. Introduction Over the last decade, cold spray technology has been studied as a new means of applying high-quality coatings, and various applications of this technology have been developed. During the cold spray process, feedstock powders are not melted and thus lower temperatures are
This article is an invited paper selected from presentations at the 2013 International Thermal Spray Conference, held May 13-15, 2013, in Busan, South Korea, and has been expanded from the original presentation. K. Sakata, K. Tagomori, N. Sugiyama, S. Sasaki, and Y. Shinya, Fujikikosan Corp., Kitakyushu, Japan; T. Nanbu and Y. Kawashita, Nissan Motor Co., Ltd., Yokosuka, Japan; and I. Narita, K. Kuwatori, T. Ikeda, R. Hara, and H. Miyahara, Kyushu University, Fukuoka, Japan. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
applied, which means that the coating particles typically undergo less oxidation than particles in a conventional thermal spray process. During the operation of lowpressure cold spray equipment, fine metal particles (less than 76 lm in diameter) are often used as the feedstock powder and, according to BS 2955, particles with diameters below 76 lm are technically considered ‘‘dust’’ (Ref 1). It is well known within the thermal spraying industry that, when dust particles are suspended in air and con
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