Sensors & Electronics
Electronics & Systems
Controls for Improved Material Deposition (379)
Problem: Need improved controls for metal coating process to allow more effective exploitation of specialized coatings.
Project Activity Scope (from Technical Overview Chart): Interaction Mechanisms through Controls and Measurements.
PNNL Solution:
- Specialized surface coatings can offer superior material performance.
- Electrospark Deposition (ESD) can meet diverse needs.
- Applications limited by process issues.
- Process evaluation and analysis.
- Controls for effective operation.
- Develop automated ESD coating system.
- Demonstrated superior ESD system operation.
- Expansion of practical ESD coating applications.
Capabilities Employed to Meet Client Needs: Developed electrospark deposition coatings for various applications; performed metallurgical characterization of deposited films; tailored source material metallurgy to meet specific applications requirements; established need for improved process control to improve ESD film consistency; conducted tests and data analysis to determine key process control parameter(s); established easily measured process parameter as basis for process control; developed data analysis algorithm to indicate deviation from desired operating conditions; developed audio tone indicator to aid operator in maintaining desired film properties; conducted successful demonstrations; delivered prototype units for practical field evaluation of manual systems; developed and demonstrated an automated ESD workstation including control software; successfully demonstrated performance for various part geometries (e.g., flat plates, cylinders, irregular surfaces, etc.); established intellectual property position.
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Contact: Jeff Bailey
