Depositing plasma sprayed NiCoCrAlY coating on additively manufactured Inconel 718 surfaces: Is grit blasting always necessary?

IF 2.7 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Letters Pub Date : 2025-02-15 DOI:10.1016/j.matlet.2025.138238

Niroj Maharjan , Michael Boschen , Sam Meure , Andrew Ang

引用次数: 0

Abstract

Additive manufacturing (AM) often produces non-uniform surfaces with defects such as oxides, cracks and unmelted particles; yet their effect on coating deposition is not well investigated. This study demonstrates that plasma sprayed NiCoCrAlY coating can be directly deposited on AM Inconel 718 surfaces without any grit blasting. Coating adhesion strengths exceeding 60 MPa are achieved, and AM-induced roughness exhibits little influence on the overall coating integrity. However, heat treatment introduces ∼3–5 µm thick surface oxide layer that significantly reduces adhesion strength by hindering metallurgical bonding between the splats and the substrate. The findings highlight the feasibility for direct deposition of plasma sprayed coating on AM parts while emphasizing the need to control oxidation during post-processing.

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来源期刊

Materials Letters 工程技术-材料科学：综合

CiteScore

5.60

自引率

3.30%

发文量

1948

审稿时长

50 days

期刊介绍： Materials Letters has an open access mirror journal Materials Letters: X, sharing the same aims and scope, editorial team, submission system and rigorous peer review. Materials Letters is dedicated to publishing novel, cutting edge reports of broad interest to the materials community. The journal provides a forum for materials scientists and engineers, physicists, and chemists to rapidly communicate on the most important topics in the field of materials. Contributions include, but are not limited to, a variety of topics such as: • Materials - Metals and alloys, amorphous solids, ceramics, composites, polymers, semiconductors • Applications - Structural, opto-electronic, magnetic, medical, MEMS, sensors, smart • Characterization - Analytical, microscopy, scanning probes, nanoscopic, optical, electrical, magnetic, acoustic, spectroscopic, diffraction • Novel Materials - Micro and nanostructures (nanowires, nanotubes, nanoparticles), nanocomposites, thin films, superlattices, quantum dots. • Processing - Crystal growth, thin film processing, sol-gel processing, mechanical processing, assembly, nanocrystalline processing. • Properties - Mechanical, magnetic, optical, electrical, ferroelectric, thermal, interfacial, transport, thermodynamic • Synthesis - Quenching, solid state, solidification, solution synthesis, vapor deposition, high pressure, explosive