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All sourcesNASA NTRSDOE OSTI
NASA NTRS2022

MSL MMRTG Power Modeling for Lifetime Performance Predictions

The Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) has been providing power to the Mars Science Laboratory (MSL) rover, Curiosity, for surface operations since 2012. The Jet Propulsion Laboratory (JPL) has employed the Life Performance Prediction Model (LPPM) to generate predictions and outputs based upon flight data from the rover and experimental data from the thermoelectric (TE) couples. In order to make these predictions, LPPM requires various spacecraft inputs relevant to RTG performance such as fin root temperature, load voltage, general purpose heat source (GPHS) inventory, etc., combined with couple data such as thermoelectric properties, interface degradation, and sublimation properties. With tens of thousands of hours of flight data to date, LPPM can not only track performance to date, but also make predictions on the power output of the MMRTG through the 17-year end-of-design-life (EODL). These predictions are useful for mission planners and surface operators who rely on the MMRTG for power in order to perform the critical science necessary during the mission. This paper will showcase the power data extracted from the flight electronics, comparing it to the predictions and outputs generated from LPPM.

Pinkowski, Stanley↗
DOE OSTI2020

Inflation and Dark Energy from spectroscopy at $\mathcal{z} > 2$

The expansion of the Universe is understood to have accelerated during two epochs: in its very first moments during a period of Inflation and much more recently, at $\mathcal{z} < 1$, when Dark Energy is hypothesized to drive cosmic acceleration. The undiscovered mechanisms behind these two epochs represent some of the most important open problems in fundamental physics. Most of the processes involved during Inflation impact observations on the very largest spatial scales. Traditionally, these have been accessed through observations of the Cosmic Microwave Background (CMB). While very powerful, the CMB originates from a 2D surface and the finite number of modes that it contains will largely be measured by experiments over the next decade. Observations of large 3D volumes with large-scale structure (LSS) access similar scales and will dramatically increase the number of available modes. For example, LSS observations in the range $2 \lesssim z \lesssim 5$ can more than triple the volume surveyed at $z \lesssim 2$, and, together with the sufficiently high galaxy number in this interval, strongly motivates a future spectroscopic survey that exploits this opportunity. In addition, tomography allows mapping the growth of structure with redshift, which provides robust constraints on Dark Energy and neutrino masses while relaxing restrictive assumptions such as a power-law primordial power spectrum. Finally, cross-correlation with external tracers, such as CMB lensing, Intensity Mapping or the Lyman-$\alpha$ forest, immunises the constraints to the systematics that make measurement challenging and further improves the precision through ‘sample variance cancellation’ and degeneracy breaking.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Self-Anchored Platinum-Decorated Antimony-Doped-Tin Oxide as a Durable Oxygen Reduction Electrocatalyst

The lifetime of commercial Proton Exchange Membrane Fuel Cells (PEMFCs) is circumscribed by the insufficient durability of commercial catalysts. The use of metal oxide supports in place of carbon significantly increases electrocatalyst durability. Herein, following density functional theory (DFT) predictions of improved Platinum (Pt) stability on antimony doped tin oxide (ATO) supports, we synthesized ATO whose morphology and crystal structure was engineered using a Pt anchoring technique. X-ray photoelectron spectroscopy (XPS) indicated that the Pt anchor sites aided in the reduction of Pt precursors to Pt on the ATO surface. X-ray absorption near-edge spectroscopy (XANES) revealed the existence of strong-metal-support interactions (SMSI) between Pt and ATO. The combination of SMSI and high control over Pt dispersion enabled the Pt/Pt-aerogel-ATO (Pt supported on aerogel ATO with Pt anchor sites) electrocatalyst to achieve 2x the area specific activity of Pt/C in ex-situ testing. In a H 2 /air PEMFC Pt/Pt-aerogel-ATO cathodes enabled 20% higher peak power density and <1/6 the loss of active surface area as compared to Pt/C. Notably, in a PEMFC under rigorous potential cycling, the Pt/Pt-aerogel-ATO retained its initial peak power density as opposed to a 58% loss for Pt/C. Further, cost models indicate that Pt/Pt-aerogel-ATO is 26% less expensive than Pt/C over its useful lifetime.

25 ENERGY STORAGE↗
DOE OSTI2020

Subtask 1.5 – CO2 Injection Monitoring with an Optimized Scalable, Automated, Semipermanent Seismic Array

The scalable, automated, semipermanent seismic array (SASSA) method is a flexible and relatively cost-effective surface geophysical method for regular time-lapse monitoring of the movement of injected carbon dioxide (CO2) in a reservoir for CO2 enhanced oil recovery (EOR) or geologic CO2 storage operations. It has the advantages of a low-environmental-footprint while monitoring regions of a reservoir from the surface without the need for a regular grid distribution of receivers. Automated data collection is possible. As only time-lapse amplitude changes at the reservoir level due to CO2 movement within the reservoir are monitored, the turnaround time to deliver results from the SASSA method can be short, without the need for long, time-consuming data-processing workflows. As data is collected and processed, incremental information can be provided to the field operator. The Energy & Environmental Research Center (EERC) conducted a SASSA field test from September 2018 to November 2020 in a portion of the Bell Creek Field in Montana, which implemented new CO2 EOR field activities during the study period. Lessons learned from a proof-of-concept study were incorporated to improve the data quality of the SASSA method and demonstrate the viability of the technology. The EERC implemented several enhancements to improve data quality, including 1) an iterative survey design, which allowed placing the receivers in strategic locations where the movement of the CO2 in the reservoir could be tracked with minimum interference by the cultural noise in the study area; 2) the use of powerful seismic sources in the form of surface orbital vibrators, and 3) data acquisition during optimal periods. History-matched reservoir simulation was performed to predict gas saturation and pressure response induced by CO2 injection in the study area. The results were compared with the SASSA-measured responses to CO2 injection as a partial validation technique. A match between the two methods was observed for most of the SASSA points predicted to have intersected a CO2 saturation change. The validated results provide confidence that the SASSA method can be used independently as a CO2 saturation monitoring technique. As data are collected and processed, incremental information can be provided to the field operator. The critical components of the SASSA workflow for a successful application of the method are the following: Iterative survey design with information about CO2 injection activities from the oilfield operator. A detailed CO2 injection plan is the key driver to select the strategic monitoring location of the SASSA sensors. After this information is incorporated in the initial distribution of sources and receivers in the study area, high-resolution satellite images are used to identify ground locations not affected by cultural noise sources, such as power lines, pipelines/flow lines, or roadways. In the next iteration of the survey design, a scouting trip to the study area is needed to understand more details of the noise sources identified in the previous step and the intensity of the field activities that can also generate noise during the monitoring. Integrating the information from the scouting trip into the survey design to select the optimum source and receiver locations is the final step. Noise attenuation. The variety of noise types during seismic monitoring of an oil field is enormous. Tailored noise characterization and processing at a node-by-node level can enhance the performance and sensitivity of the SASSA technique. Future advancements that could improve the efficiency and application of the SASSA technology include: Gaining a better understanding of the noise field produced by the seismic source to aid the choice of receiver location. Surface noise from the source can overwhelm the small signal changes due to CO2 that the SASSA method measures. Improved data-processing workflow to automatically analyze and adapt to dynamic noise conditions associated with industrial settings. This subtask was funded through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE- FE0024233.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1993

Theoretical studies of the radar properties of the icy Galilean moons of Jupiter

The icy Galilean satellites of Jupiter - Europa, Ganymede, and Callisto - have unusual radar scattering properties compared with those of the terrestrial planets or Earth's Moon. There are three main features of the data that distinguish these targets: (1) the radar cross-section normalized by the geometrical cross-section is an order of magnitude larger than that of any terrestrial planet; (2) the reflected power is almost evenly distributed between two orthogonal polarizations with more power being returned in the same circular polarization as was transmitted whereas virtually all of the power returned from the terrestrial planets is contained in the opposite circular polarization to the one that was transmitted; and (3) the echo power spectra have a broad shape indicating a nearly uniformly radar-bright surface in contrast to the spectra from the terrestrial planets that contain a strong quasi-specular component from the vicinity of the sub-radar point and very little reflected power from the rest of the surface. The normalized radar cross-sections decrease as the areal water ice coverage decreases from Europa to Ganymede to Callisto. Recently, radar echoes from the polar caps of Mars and Mercury, and from Saturn's satellite Titan imply similarly strong cross-sections and have classically unexpected polarization properties and it is also thought that this is due to the presence of ice on the surface. A model called the radar glory model is analyzed and it is shown that the main features of the radar echoes calculated from this model agree well with the observations from all three icy Galilean satellites. This model involves long radar paths in the ice below the surface and special structures in which the refractive index decreases abruptly at a hemispherical boundary. It is not known whether such structures exist or how they could be created, but possible scenarios can be imagined such as the formation of an impact crater followed by deposition of a frost layer followed by a resurfacing event in which a layer of solid ice is placed above the layer of frost. Regardless of the exact geophysical processes required to create such structures, the superior ability of this model to account for all of the important observations with very few adjustable parameters and with no ad hoc assumptions is a compelling argument in support of at least the electromagnetic model. The key features of the electromagnetic model are multiple subsurface scattering events, total internal reflection, and a low degree of randomness imposed on a deterministic geometry that strongly favors backscattering.

Eshleman, Von R.↗
DOE OSTI2015

A projection-free method for representing plane-wave DFT results in an atom-centered basis

Plane wave density functional theory (DFT) is a powerful tool for gaining accurate, atomic level insight into bulk and surface structures. Yet, the delocalized nature of the plane wave basis set hinders the application of many powerful post-computation analysis approaches, many of which rely on localized atom-centered basis sets. Traditionally, this gap has been bridged via projection-based techniques from a plane wave to atom-centered basis. We instead propose an alternative projection-free approach utilizing direct calculation of matrix elements of the converged plane wave DFT Hamiltonian in an atom-centered basis. This projection-free approach yields a number of compelling advantages, including strict orthonormality of the resulting bands without artificial band mixing and access to the Hamiltonian matrix elements, while faithfully preserving the underlying DFT band structure. The resulting atomic orbital representation of the Kohn-Sham wavefunction and Hamiltonian provides a gateway to a wide variety of analysis approaches. We demonstrate the utility of the approach for a diverse set of chemical systems and example analysis approaches.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1994

Low Earth orbit durability evaluation of protected silicone for advanced refractive photovoltaic concentrator arrays

The need for efficient, cost effective sources of electrical power in space has led to the development of photovoltaic power systems which make use of novel refractive solar concentrators. These concentrators have been conceived in both point-focus and linear-focus designs. Current concentrator lenses are fabricated from flexible silicones with Fresnel facets along their inside surface. To insure the efficient operation of these power systems, the concentrator lenses must be durable and the silicone material must remain specularly transmitting over a reasonable lifetime in low Earth orbit (LEO) and other space environments. Because of the vulnerability of silicones to atomic oxygen and ultraviolet radiation in LEO these lenses have been coated with a multi-layer metal oxide protective coating. The objective of this research was to evaluate the LEO durability of the multilayer coated silicone for advanced refractive photovoltaic concentrator arrays with respect to optical properties and microstructure. Flat metal oxide coated silicone samples were exposed to ground-laboratory and in-space atomic oxyqen for durability evaluation.

Degroh, Kim K.↗
NASA NTRS1993

CFD code calibration and inlet-fairing effects on a 3D hypersonic powered-simulation model

A three-dimensional (3D) computational study has been performed addressing issues related to the wind tunnel testing of a hypersonic powered-simulation model. The study consisted of three objectives. The first objective was to calibrate a state-of-the-art computational fluid dynamics (CFD) code in its ability to predict hypersonic powered-simulation flows by comparing CFD solutions with experimental surface pressure dam. Aftbody lower surface pressures were well predicted, but lower surface wing pressures were less accurately predicted. The second objective was to determine the 3D effects on the aftbody created by fairing over the inlet; this was accomplished by comparing the CFD solutions of two closed-inlet powered configurations with a flowing-inlet powered configuration. Although results at four freestream Mach numbers indicate that the exhaust plume tends to isolate the aftbody surface from most forebody flowfield differences, a smooth inlet fairing provides the least aftbody force and moment variation compared to a flowing inlet. The final objective was to predict and understand the 3D characteristics of exhaust plume development at selected points on a representative flight path. Results showed a dramatic effect of plume expansion onto the wings as the freestream Mach number and corresponding nozzle pressure ratio are increased.

Huebner, Lawrence D.↗
NASA NTRS1993

CFD Code Calibration and Inlet-Fairing Effects On a 3D Hypersonic Powered-Simulation Model

A three-dimensional (3D) computational study has been performed addressing issues related to the wind tunnel testing of a hypersonic powered-simulation model. The study consisted of three objectives. The first objective was to calibrate a state-of-the-art computational fluid dynamics (CFD) code in its ability to predict hypersonic powered-simulation flows by comparing CFD solutions with experimental surface pressure data. Aftbody lower surface pressures were well predicted, but lower surface wing pressures were less accurately predicted. The second objective was to determine the 3D effects on the aftbody created by fairing over the inlet; this was accomplished by comparing the CFD solutions of two closed-inlet powered configurations with a flowing- inlet powered configuration. Although results at four freestream Mach numbers indicate that the exhaust plume tends to isolate the aftbody surface from most forebody flow- field differences, a smooth inlet fairing provides the least aftbody force and moment variation compared to a flowing inlet. The final objective was to predict and understand the 3D characteristics of exhaust plume development at selected points on a representative flight path. Results showed a dramatic effect of plume expansion onto the wings as the freestream Mach number and corresponding nozzle pressure ratio are increased.

Huebner, Lawrence D.↗
DOE OSTI2014

Deep Geothermal Drilling Using Millimeter Wave Technology (Final Technical Research Report)

Conventional drilling methods are very mature, but still have difficulty drilling through very deep,very hard and hot rocks for geothermal, nuclear waste entombment and oil and gas applications.This project demonstrated the capabilities of utilizing only high energy beams to drill such rocks,commonly called ‘Direct Energy Drilling’, which has been the dream of industry since the invention of the laser in the 1960s. A new region of the electromagnetic spectrum, millimeter wave (MMW) wavelengths at 30-300 giga-hertz (GHz) frequency was used to accomplish this feat. To demonstrate MMW beam drilling capabilities a lab bench waveguide delivery, monitoring and instrument system was designed, built and tested around an existing (but non-optimal) 28 GHz frequency, 10 kilowatt (kW) gyrotron. Low waveguide efficiency, plasma generation and reflected power challenges were overcome. Real-time monitoring of the drilling process was also demonstrated. Then the technical capability of using only high power intense millimeter waves to melt (with some vaporization) four different rock types (granite, basalt, sandstone, limestone) was demonstrated through 36 bench tests. Full bore drilling up to 2” diameter (size limited by the available MMW power) was demonstrated through granite and basalt samples. The project also demonstrated that MMW beam transmission losses through high temperature (260°C, 500oF), high pressure (34.5 MPa, 5000 psi) nitrogen gas was below the error range of the meter long path length test equipment and instruments utilized. To refine those transmission losses closer, to allow extrapolation to very great distances, will require a new test cell design and higher sensitivity instruments. All rock samples subjected to high peak temperature by MMW beams developed fractures due to thermal stresses, although the peak temperature was thermodynamically limited by radiative losses. Therefore, this limited drill rate and rock strength data were not able to be determined experimentally. New methods to encapsulate larger rock specimens must be developed and higher power intensities are needed to overcome these limitations. It was demonstrated that rock properties are affected (weakening then strengthened) by exposure to high temperatures. Since only MMW beams can economically reach rock temperatures of over 1650°C, even exceeding 3000°C, that can cause low viscosity melts or vaporization of rocks. Future encapsulated rock specimens must provide sufficiently large sizes of thermally impacted material to provide for the necessary rock strength, permeability and other analyzes required. Multiple MMW field systems, tools and methods for drilling and lining were identified. It was concluded that forcing a managed over-pressure drilling operation would overcome water influx and hot rock particulates handling problems, while simultaneously forming the conditions necessary to create a strong, sealing rock melt liner. Materials that contact hot rock surfaces were identified for further study. High power windows and gases for beam transmission under high pressures are critical paths for some of the MMW drilling systems. Straightness/ alignment can be a great benefit or a problem, especially if a MMW beam is transmitted through an existing, conventionally drilled bore.

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2015

Platinum Nanoparticle Loading of Boron Nitride Aerogel and Its Use as a Novel Material for Low-Power Catalytic Gas Sensing

We report that a high-surface-area, highly crystalline boron nitride aerogel synthesized with nonhazardous reactants has been loaded with crystalline platinum nanoparticles to form a novel nanomaterial that exhibits many advantages for use in a catalytic gas sensing application. The platinum nanoparticle-loaded boron nitride aerogel integrated onto a microheater platform allows for calorimetric propane detection. The boron nitride aerogel exhibits thermal stability up to 900 °C and supports disperse platinum nanoparticles, with no sintering observed after 24 h of high-temperature testing. The high thermal conductivity and low density of the boron nitride aerogel result in an order of magnitude faster response and recovery times (<2 s) than reported on alumina support and allow for 10% duty cycling of the microheater with no loss in sensitivity. Lastly, the resulting 1.5 mW sensor power consumption is two orders of magnitude less than commercially available catalytic gas sensors and unlocks the potential for wireless, battery-powered catalytic gas sensing.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Occultation Modeling for Radiation Obstruction Effects on Spacecraft Systems

A geometric occultation model has been developed to determine line-of-sight obstruction of radiation sources expected for different NASA space exploration mission designs. Example applications includes fidelity improvements for surface lighting conditions, radiation pressure, thermal and power subsystem modeling. The model makes use of geometric two dimensional shape primitives to most effectively model space vehicles. A set of these primitives is used to represent three dimensional obstructing objects as a two dimensional outline from the perspective of an observing point of interest. Radiation sources, such as the Sun or a Moon's albedo is represented as a collection of points, each of which is assigned a flux value to represent a section of the radiation source. Planetary bodies, such as a Martian moon, is represented as a collection of triangular facets which are distributed in spherical height fields for optimization. These design aspects and the overall model architecture will be presented. Specific uses to be presented includes a study of the lighting condition on Phobos for a possible future surface mission, and computing the incident flux on a spacecraft's solar panels and radiators from direct and reflected solar radiation subject to self-shadowing or shadowing by third bodies.

de Carufel, Guy↗
NASA NTRS1989

Color constancy and the natural image

Color vision is useful only if it is possible to identify an object's color across many viewing contexts. Here, consideration is given to recent results on how to estimate the surface reflectance function of an object from image data, despite (1) uncertainty in the spectral power distribution of the ambient lighting, and (2) uncertainty about what other surfaces will be in the field of view.

Wandall, Brian A.↗
NASA NTRS2003

Variability in Ocean Color Associated with Phytoplankton and Terrigenous Matter: Time Series Measurements and Algorithm Development at the FRONT Site on the New England Continental Shelf

Fronts in the coastal ocean describe areas of strong horizontal gradients in both physical and biological properties associated with tidal mixing and freshwater estuarine output (e.g. Simpson, 1981 and O Donnell, 1993). Related gradients in optically important constituents mean that fronts can be observed from space as changes in ocean color as well as sea surface temperature (e.g., Dupouy et al., 1986). This research program is designed to determine which processes and optically important constituents must be considered to explain ocean color variations associated with coastal fronts on the New England continental shelf, in particular the National Ocean Partnership Program (NOPP) Front Resolving Observational Network with Telemetry (FRONT) site. This site is located at the mouth of Long Island sound and was selected after the analysis of 12 years of AVHRR data showed the region to be an area of strong frontal activity (Ullman and Cornillon, 1999). FRONT consists of a network of modem nodes that link bottom mounted Acoustic Doppler Current Profilers (ADCPs) and profiling arrays. At the center of the network is the Autonomous Vertically Profiling Plankton Observatory (AVPPO) (Thwaites et al. 1998). The AVPPO consists of buoyant sampling vehicle and a trawl-resistant bottom-mounted enclosure, which holds a winch, the vehicle (when not sampling), batteries, and controller. Three sampling systems are present on the vehicle, a video plankton recorder, a CTD with accessory sensors, and a suite of bio-optical sensors including Satlantic OCI-200 and OCR-200 spectral radiometers and a WetLabs ac-9 dual path absorption and attenuation meter. At preprogrammed times the vehicle is released, floats to the surface, and is then winched back into the enclosure with power and data connection maintained through the winch cable. Communication to shore is possible through a bottom cable and nearby surface telemetry buoy, equipped with a mobile modem, giving the capability for near-real time data transmission and interactive sampling control.

Morrison, John R.↗
DOE OSTI2016

Inflation in the closed FLRW model and the CMB

Recent cosmic microwave background (CMB) observations put strong constraints on the spatial curvature via estimation of the parameter Ω{sub k} assuming an almost scale invariant primordial power spectrum. We study the evolution of the background geometry and gauge-invariant scalar perturbations in an inflationary closed FLRW model and calculate the primordial power spectrum. We find that the inflationary dynamics is modified due to the presence of spatial curvature, leading to corrections to the nearly scale invariant power spectrum at the end of inflation. When evolved to the surface of last scattering, the resulting temperature anisotropy spectrum ( C {sup TT}{sub ℓ}) shows deficit of power at low multipoles (ℓ < 20). By comparing our results with the recent Planck data we discuss the role of spatial curvature in accounting for CMB anomalies and in the estimation of the parameter Ω{sub k}. Since the curvature effects are limited to low multipoles, the Planck estimation of cosmological parameters remains robust under inclusion of positive spatial curvature.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Materials and Additive Manufacturing for Energy Efficiency in Wind Turbine and Aircraft Industries

The purpose of this project was to develop surface treatments which will inhibit the formation of ice on turbine blades and propellers. ORNL worked with Piedmont Propulsion Systems, LLC and First Aviation Services Inc. to demonstrate a new surface treatment for two primary markets, aviation and wind turbines, as well as secondary markets such as power lines, bridges, boats, roofs and antennas among others. Exploring alternative surface treatments for wind turbines will provide anti-icing properties and erosion/abrasion prevention properties similar to those for aviation applications. A series of superhydrophobic coating materials was synthesized and successfully applied on anti-ice tape materials that could be used in a wide range of wind turbine and aviation applications to prevent ice accumulation. The coatings developed in this project were based on superhydrophobic particles of different geometries and sizes that were homogeneously dispersed in polymeric binders. The superhydrophobic features of the coatings are volumetric and their abrasion resistance was evaluated. Future research will involve the demonstration of anti-icing properties of the surface treatment developed in this project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Experiments, Statistical Analysis, and Modeling to Evaluate the Porosity Influence in SPS Coatings

Suspension plasma spray (SPS) is far more complicated than conventional plasma spray and requires a deep knowledge about the influence of process parameters and their correlations. In this study, YSZ coatings were manufactured by SPS with six different process parameters such as plasma power, suspension mass load, original powder size, substrate surface topology, spray distance, and spray step. Then, the porosity of as-prepared coatings was investigated by image method and X-ray transmission technique. A multivariate analysis on the collected experimental data was carried out by employing mathematical statistics methods. The results showed that: 1) Coating porosity has a negative correlation with plasma power and suspension mass load and a positive correlation with the original powder size, spray distance, spray step, and substrate roughness; 2) Spraying distance is the main factor affecting to coating porosity, followed by suspension mass load and substrate surface roughness, respectively. A linear model for porosity prediction was developed and was verified by experiments. Furthermore, the mechanism by which process parameters influence coating porosity is additionally discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Multivariate Analysis of the Influence of Process Parameters on Suspension Plasma-Sprayed Coatings

Suspension plasma spray (SPS) is far more complicated than conventional plasma spray and requires a deep knowledge about the influence of process parameters and their correlations. In this study, YSZ coatings were manufactured by SPS with six different process parameters such as plasma power, suspension mass load, original powder size, substrate surface topology, spray distance, and spray step. Afterwards, the porosity of as-prepared coatings was investigated by image method and X-ray transmission technique. A multivariate analysis on the collected experimental data was carried out by employing mathematical statistics methods. The results showed that: 1) Coating porosity has a negative correlation with plasma power and suspension mass load and a positive correlation with the original powder size, spray distance, spray step, and substrate roughness; 2) Spraying distance is the main factor affecting to coating porosity, followed by suspension mass load and substrate surface roughness, respectively. A linear model for porosity prediction was developed and was verified by experiments. The mechanism by which process parameters influence coating porosity is also discussed.

Zhao, Yongli↗