High Performance Piezoceramic Coatings for Ultrasound Applications

ACX proposes an innovative new process for the manufacture of smart structures using a High Velocity Oxy-Fuel (HVOF) thermal spray process. This simple, multi-step process will be capable of depositing electroded piezoceramic coatings. The coatings will be poled while still hot, reducing poling times and voltages while increasing poling efficiency. Process times will be extremely short. The process will also eliminate the need for sintering, vastly reducing manufacturing costs. The resulting Thermally Sprayed Piezoceramic Coatings (TSPCs) will have higher bond strengths than conventional adhesives and will be conformable to any surface. By applying the coatings directly to the structure to be actuated, bond layers will be eliminated, improving the effectiveness of the actuation. TSPCs will increase the performance of smart material actuators through improved bonding and poling efficiencies, while reducing the cost of manufacturing and increasing their commercial marketability. This proposed project will provide OSD with a superior and inexpensive process for the manufacture of these structures. ACX will work with Hobart-Tafa of Concord, NH to modify their thermal spray process to accomodate PZT powders and electrode materials. At the conclusion of Phase I ACX will have demonstrated the feasibility of the process through fabrication, modeling, and detailed testing.