Material Development and Testing
capabilities
Arc-Jet Testing
Plasma has multiple arc-jet testing systems in-house utilizing our vacuum plasma spray (VPS) equipment. We can perform arc-jet testing on small coupons using a spot size of .5’’-3.3’’ per jet. We can combine up to 2 arc-jets to test larger areas/coupons. Our heat flux can be tuned from 100 W/cm2 to > 2000 w/cm2 and we can create atmospheric environments ranging from sea level to ~120,000 ft altitude. Our facilities can simulate a full trajectory and flight pattern over time, thus giving you a more detailed test result of your potential material solution under these extreme flight conditions. We have provided these types of services for material evaluations, thickness investigations, and more. Our arc-jet testing capability provides a flexible, affordable, and great way to perform risk reduction testing during R&D or product improvement initiatives.
Powder Alloying and Spheroidization (PAS)
Plasma Processes offers custom formulation and processing powders, achieving the desired chemical constituency, particle size and morphology. We welcome inquiries from bench scale through production. We use an in-house capability to perform Powder Alloying & Spheroidization (PAS). PAS transforms flaky and angular powder particles into spheres, resulting in free-flowing powder feedstock with enhanced physical characteristics such as:
- Spherical Particle Shapes
- High Density
- Improved Flow
- Low Oxygen Content
- Controlled Particle Size Distribution
- Alloying
- Custom powder formulation
Virtually any powder or powder alloy, including crystalline, spray-dried, blended, agglomerated and composite powders, can be processed. Alloys can also be created by combining powder particles in the molten state. Processed powders typically feature spherical morphology, improved flow characteristics, greater packaging densities and a reduction in trace elements as compared to feedstock. Powders can be processed in the following environments: inert, air or reactive. The benefit of a PAS system is not only to develop new material solutions or configurations, but also to create precise formulations that can then be processed using a variety of AM or Plasma processes. We have even used PAS to create material to be used within 3D printing machines. Plasma Processes manufactures high-performance, custom 3D-Powders facilitate superior flow and high packing densities and are available in research, prototype and bulk quantities. Single elements and alloys are available from essentially any element within the periodic table. We have a large and small system in-house and can perform work usually within a few weeks of contact and upon receipt of material for processing. Plasma Processes offers custom formulation and processing of customer-supplied single element and alloy powders achieving the desired chemical constituency, particle size and morphology.
Metallurgy Laboratory
Plasma has the ability to perform material testing, including microhardness, arc-jet, and more. Plasma Processes has a fully equipped metallurgical laboratory with capabilities for testing and evaluating materials. Our in-depth technical understanding of materials and their applications is one of our key strengths. Our in-house metallurgical lab is capable of performing the following tests:
Optical microscopy (Grain Size, Coating Thickness, Porosity, Phase Distribution , etc)
Scanning electron microscopy (SEM)
Energy Dispersive Spectroscopy (EDS)
Induction Coupled Plasma (ICP)
Microhardness (Vickers)
Density
Coating Bond Strength (PosiTest AT)
Powder Characterization: Flowability, Morphology, Screening
Powder and Flame Characterization: SprayWatch, Tecnar
Furnace Testing/Heat Treatment: Air up to 1500C, Ar or He up to 2500C, H2 up to 1000C, Vacuum up to 2000C
Temperature measurement: Thermocouples, Optical Pyrometers, Infrared Thermometers
Other Test Capabilities
High Heat Flux/Torch Testing (Plasma and High Velocity Oxy-Fuel)
Simulated High Altitude Plasma Arc-Jet Testing
Simulated In-Space Hot-Fire Testing of Thrusters
Metrology (Hexagon CMM, Romer Blue Light/Touch Probe, Optical Comparator, Profilometer, Keyence Vision System, Physical Measurements)
- Product 1
- Product 2
- Product 3
Super-Sonic Combustion Jet Testing (using HVOF)
Plasma has multiple in-house supersonic combustion torches (i.e. small rocket engines) utilizing our High Velocity Oxy Fuel (HVOF) equipment. Supersonic Combustion Jet testing is conducted on coupons using a spot size of <1” per jet. The jets are robotically controlled to test larger areas. The incident heat flux is measured and can be tuned from 100 W/cm2 to 1500 w/cm2 at sea level. Our facilities can simulate a trajectory over time, thus giving a more detailed test result of a potential material solution under varied conditions. Particles can be added to replicate complex combustion flows. We have provided these types of services for material evaluations, thickness investigations, bond joint testing, erosion testing, oxidation testing and more. Our Super Sonic Combustion Jet testing provides a rapid, safe, flexible, and affordable way to perform risk reduction testing during R&D or product improvement initiatives without testing in larger rocket engines.
- Product 1
- Product 2
- Product 3
- Product 1
- Product 2
- Product 3
Other Testing/Quality
- MetLab
- Optical microscopy (grain size, coating thickness, porosity, phase distribution, etc)
- Scanning electron microscopy (SEM)
- Energy Dispersive Spectroscopy (EDS)
- Induction Coupled Plasma (ICP)
- Microhardness (Vickers)
- Density
- Coating bond strength (PosiTest AT)
- Powder Characterization: flowability, morphology, screening
- Powder and Flame Characterization: SprayWatch, Tecnar
- Furnace Testing/Heat Treatment: air up to 1500C, Ar or He up to 2500C, H2 up to 1000C, vacuum up to 2000C
- Temperature measurement: thermocouples, optical pyrometers, infrared thermometers
- NDE/NDT
- Ultrasonic
- Tensile
- X-Ray
- Emissivity
- Thermal Expansion
- Thermal Cycling
- Vibration
- ASTM Specifications
- Pressure
- Proof
- High heat flux/torch testing (plasma and high velocity oxy-fuel)
Coating Processes
Plasma Spray (VPS)
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Cold Spray
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Wire-ARC Spray
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
Shrouded Plasma Spray (SPS)
- Broader and longer spray jets
- Cleaner interfaces through reverse transfer arc sputter cleaning
- Oxide-free coatings
- High coating densities (close to theoretical)
- Low residual stresses
- Increased deposition thickness capability (>25mm or 1 inch)
- High substrate/deposit preheating capability
APPLICATIONS
What it’s used for
Plasma Processes offers innovative products and services for highly demanding markets and is dedicated to providing customers with advanced materials solutions and enabling capabilities. We drive technology with engineered products and coatings for emerging technologies through the implementation of unique materials and processes.