Journal of Thermal Spray Technology最新文献

{"title":"Effect of TiC on the Microstructure and Properties of FeCoNiCrMo High-Entropy Alloy Coatings by Plasma Cladding","authors":"Weiying Gong,&nbsp;Zhidan Zhou,&nbsp;Yongzhen Zhang,&nbsp;Xin Zhang,&nbsp;Sanming Du","doi":"10.1007/s11666-024-01903-3","DOIUrl":"10.1007/s11666-024-01903-3","url":null,"abstract":"<div><p>FeCoNiCrMo-xTiC (<i>x</i> = 0, 5, 10, 15 wt.%) high-entropy alloy (HEA) coatings were prepared on 45 steel by plasma cladding and the effect of TiC content on microstructure, wear and corrosion properties were investigated. Results showed that the HEA coatings present mainly BCC and FCC structures, containing a small amount of TiC. The wear resistance of the four cladding layers is improved. When the TiC content is 5 wt.%, the wear resistance of the cladding layer is the best, and the wear rate is 1.10 × 10⁻⁴ mm³/(N m). The wear rate of the cladding layer with the added reinforcement phase is lower than that of the cladding layer without the added reinforcement phase. The wear of the cladding layer is composed of multiple wear forms, mainly abrasive wear and oxidative wear, accompanied by adhesive wear. At the same time, the 5 wt.% TiC cladding layer has a low self-corrosion current density (1.029 × 10⁻⁸ A/cm²), a relatively positive corrosion potential (− 0.478 V), and excellent corrosion resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"381 - 393"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455541","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of Microstructure and Mechanical Properties of Ni-Al Energetic Structural Materials Prepared by Cold Spraying","authors":"Tianchu Wang,&nbsp;Chuan Zhao,&nbsp;Kaiyuan Liu,&nbsp;Yansong Guo,&nbsp;Shouren Wang,&nbsp;Xiaoliang Lu,&nbsp;Pengwan Chen","doi":"10.1007/s11666-025-01931-7","DOIUrl":"10.1007/s11666-025-01931-7","url":null,"abstract":"<div><p>Ni-Al energetic structural materials (ESMs) have been a popular choice for various defense applications due to their excellent mechanical performance. However, the relationship between stagnation temperature and microstructural and mechanical properties of Ni-Al ESMs prepared by cold spraying remains unclear. In this study, three different Ni-Al ESM samples were prepared by cold spraying at stagnation temperatures of 300 °C, 350 °C, and 400 °C. The microstructural characteristics were analyzed using an x-ray diffractometer (XRD), scanning electron microscope, and transmission electron microscope, revealing the presence of stacking faults and a large number of dislocations near the grain boundaries in the Ni phase area. In addition, stress concentration was observed near the grain boundaries. Quasi–static compression tests were also conducted to analyze the mechanical properties. The results showed that the compressive strengths of the Ni-Al ESM samples were 198 MPa, 199 MPa, and 204 MPa with a stagnation temperature of 300 °C, 350 °C, and 400 °C, respectively, and the fracture strains were 0.24, 0.22 and &gt; 0.6, respectively. Based on these findings, the stagnation temperature has little effect on the compressive yield strength of the Ni-Al ESMs prepared by CS, but it significantly increases the fracture strain.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"129 - 138"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455539","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The Microstructure and Corrosion Resistance of Inconel 718 Coating by Plasma-Enhanced High-Velocity Arc Spraying","authors":"Hanbing Zhang,&nbsp;Weiwei Liu,&nbsp;Ming Liu,&nbsp;Rui Gao,&nbsp;Baodan Zhang,&nbsp;Shuying Chen,&nbsp;Guozheng Ma,&nbsp;Haidou Wang","doi":"10.1007/s11666-025-01941-5","DOIUrl":"10.1007/s11666-025-01941-5","url":null,"abstract":"<div><p>The study aimed to investigate the effect of spraying distance on the microstructure and corrosion resistance of Inconel 718 coatings applied using the plasma-enhanced high-velocity arc spraying (PEHAS) technique, especially under the influence of hydrogen plasma gas. For this purpose, the coatings were produced at four different spraying distances: 100, 150, 180, and 200 mm, and the samples obtained were referred to as SA, SB, SC, and SD, respectively. In addition, the microstructure and phase composition of the coatings were investigated, as well as the corrosion behavior of the coatings when immersed for 0-168 h in a 3.5% wt.% NaCl solution. It was determined that the Inconel 718 coatings consisted mainly of Ni-Cr-Fe solid solutions with small amounts of oxides (NiO, Fe₂O₃, Cr₂O₃, Nb₂O₅). The oxide content within the coatings increased with greater spraying distances. Sample SC featured the lowest porosity (0.88 ± 0.08%) and the highest microhardness (505 ± 25 Hv_0.1). Electrochemical assessments, including polarization curves and electrochemical impedance spectroscopy (EIS), showed that samples SA, SB, and SC experienced an initial drop followed by a rise in corrosion potential and an initial increase followed by a decrease in corrosion current density during the immersion cycle. In contrast, the corrosion potential of sample SD consistently decreased. Over time, the formation and accumulation of corrosion products with inerts on the coatings surface helped seal the pores and prevent further corrosion. After a comprehensive analysis, it was concluded that sample SC had the most effective corrosion resistance after 168 h of immersion, evidenced by its elevated resistance to pore penetration (<i>R</i>_p), charge transfer (<i>R</i>_dl), and overall impedance modulus.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"409 - 431"},"PeriodicalIF":3.2,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455517","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Aeroacoustic Process Monitoring and Anomaly Detection in Cold Spray Additive Manufacturing","authors":"Ivan Arkhipov,&nbsp;Uğur Kokal,&nbsp;Ozan Ç. Özdemir","doi":"10.1007/s11666-025-01934-4","DOIUrl":"10.1007/s11666-025-01934-4","url":null,"abstract":"<div><p>Cold spray (CS) is an emerging additive manufacturing method used to deposit a wide range of materials by spraying solid particles at supersonic velocities using high-pressure millimeter scale de Laval nozzles. As CS technology finds applications in diverse areas, including 3D printing, the need for in situ process monitoring becomes increasingly apparent. The CS process is influenced by various process parameters, including nozzle gas inlet pressure, temperature, and powder feed rate. Accurately detecting variations in these parameters, as well as identifying process anomalies (e.g., nozzle wear, clogging), is crucial for the broader implementation of the technology. In situ detection of anomalous events and process health monitoring is paramount for identification of inconsistencies, ensuring product quality, enhancing cost efficiency, and reducing waste by early detection of faults. To this end, in this study, airborne acoustic emission was monitored during CS processes to discern acoustically detectable process parameters. Characteristics of aeroacoustic waves emitted under both free jet and deposition conditions were analyzed. Results indicate that changes in nozzle gas inlet pressure and temperature, powder feed rate, and nozzle wear status are discernible through acoustic power spectrum analysis. Time-domain analysis further facilitated the identification of anomalies associated with powder injection termination, deposit/substrate delamination, and nozzle geometry changes. Notably, the sliding window first order backward differentiation of total power and the power band in the time domain proved effective in detecting gradual anomalies, such as nozzle throat wear, whereas the second-order differentiation highlighted abrupt process changes, like delamination. This study demonstrates that airborne acoustic signals offer valuable insights pertaining to process faults in CS, establishing aeroacoustic signal monitoring as a promising component of stand-alone or multi-modal process monitoring for CS operations. Furthermore, the study offers invaluable insights for aeroacoustic signal feature engineering for the development of machine learning models for process monitoring in CS.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"97 - 119"},"PeriodicalIF":3.2,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01934-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455414","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Correction to: Characterization of ZnO-Doped Hydroxyapatite Coatings on PEEK Made by Hybrid Plasma Spraying Process for Biomedical Applications","authors":"Jun Xu,&nbsp;Andreas Pfuch,&nbsp;Thomas Seemann,&nbsp;Frank Froehlich,&nbsp;Martina Schweder,&nbsp;Thomas Lampke","doi":"10.1007/s11666-024-01920-2","DOIUrl":"10.1007/s11666-024-01920-2","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"478 - 479"},"PeriodicalIF":3.2,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of L-DED Parameters for AlMo0.5NbTa0.5TiZr Based on Response Surface Methodology","authors":"Bingbing Sun,&nbsp;Hanfeng Xu,&nbsp;Ruifeng Li,&nbsp;Xiaolin Bi,&nbsp;Bingqing Chen,&nbsp;Feng Zhang,&nbsp;Lingti Kong,&nbsp;Jinfu Li","doi":"10.1007/s11666-025-01942-4","DOIUrl":"10.1007/s11666-025-01942-4","url":null,"abstract":"<div><p>To investigate the impact of process parameters on the deposition morphology of AlMo_0.5NbTa_0.5TiZr refractory high-entropy alloy during laser directional energy deposition, mathematical models were constructed for laser power, scanning rate, powder feeding rate and dilution rate, aspect ratio, and deposition area. These models were developed using the response surface method, and multi-objective optimization was conducted using the NSGA-II genetic algorithm. The results demonstrate that the optimal process parameters are laser power of 1150.08 W, scanning rate of 436.23 mm/s, and powder feeding rate of 2.81 g/min. The errors between the actual and predicted results for the dilution rate, aspect ratio, and deposition area are 6.5, 7.25, and 6.45%, respectively. These findings validate the efficacy of the multi-objective optimization of NSGA-II and the model's reliability. The findings of this study provide a theoretical framework for predicting and controlling the morphology of the deposited layer of refractory high-entropy alloy.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"366 - 380"},"PeriodicalIF":3.2,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455718","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of NiCrCoAlY Transition Layer Thickness on Structure and Properties of BNT/NiCrCoAlY Ceramic Coatings","authors":"Hefa Zhu,&nbsp;Weiling Guo,&nbsp;Longlong Zhou,&nbsp;Wei Peng,&nbsp;Haidou Wang,&nbsp;Han Dong,&nbsp;Zhiguo Xing","doi":"10.1007/s11666-025-01936-2","DOIUrl":"10.1007/s11666-025-01936-2","url":null,"abstract":"<div><p>In order to avoid the deterioration of electrical properties of Bi_0.5Na_0.5TiO₃ (BNT) ceramic coatings and metal substrate due to poor bonding performance, a NiCrCoAlY layer was introduced as a transition layer between BNT ceramic coatings and metal substrate. In this paper, BNT/NiCrCoAlY ceramic coatings were prepared by supersonic plasma spraying. The effects of NiCrCoAlY transition layer thickness on microstructure, mechanical properties, electrical properties, and domain evolution of BNT/NiCrCoAlY ceramic coatings were analyzed. The thickness of the NiCrCoAlY transition layer has a significant effect on the mechanical properties of BNT/NiCrCoAlY ceramic coatings. When the thickness of the NiCrCoAlY transition layer is 159.1 μm, the residual compressive stress on the surface of the NiCrCoAlY transition layer is the largest, which is − 185.4 MPa, and the direct bonding performance between the coating and substrate is the best. The residual compressive stress of the coating has a good positive effect on the hardness and bond strength of the coating, which significantly improves the structural integrity and mechanical properties of the coating. BNT2 ceramic coating has the largest average amplitude intensity of 46.0 pm, and the amplitude histogram ranges from − 10 to 90 pm. BNT2 ceramic coating has a relatively large value of the maximum amplitude of the butterfly loops at ± 20 V, and its localized piezoelectric response (<i>PR</i>_max) reaches 449.6 pm/V, and the ferroelectric domains exhibit an obvious switching behavior.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"444 - 459"},"PeriodicalIF":3.2,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455468","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of Scanning Rate on Microstructure and Properties of Fe-Based Amorphous Composite Coatings Prepared by Laser Cladding under Constant Heat Dissipation","authors":"Wei Zhao,&nbsp;Xiaopeng Shan,&nbsp;Wei Zha,&nbsp;Wei Lv,&nbsp;Ghulam Hussain,&nbsp;Junting Luo","doi":"10.1007/s11666-025-01929-1","DOIUrl":"10.1007/s11666-025-01929-1","url":null,"abstract":"<div><p>A water circulation system consisting of a heat dissipation plate was designed to assist laser cladding. The impact of scanning rate under constant cooling conditions on the structure and properties of Fe-based amorphous composite coatings prepared by laser cladding was investigated. The results show that with increasing scanning rate, the coating exhibits different characteristics. At 17 mm/s, the coating has the fastest cooling rate, minimal heat impact, and features predominantly amorphous phase, high hardness, and excellent wear and corrosion resistance. At 11 mm/s and 13 mm/s, local high hardness phases appear, but overall hardness is poor. At 15 mm/s, the coating has the highest hardness (630HV) due to increased amorphous content and solid solution strengthening of supersaturated <i>α</i>-Fe phase. Wear tests reveal low and stable wear rates for samples at 15 mm/s and 17 mm/s, correlating with their uniform hardness. Corrosion resistance tests show the best performance for the 11 mm/s samples, with excellent corrosion resistance. As scanning rate increases, the content of strengthening phases decreases, and the supersaturation of <i>α</i>-Fe phase increases, leading to decreased corrosion resistance. The 17 mm/s samples, with significantly higher amorphous phase content and lower overall content of supersaturated <i>α</i>-Fe phase, exhibit excellent corrosion resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"354 - 365"},"PeriodicalIF":3.2,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455467","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Heating Behavior of Cold Spray Particles in Laser","authors":"Wanqing Wang,&nbsp;Xinyu Ye,&nbsp;Chengjie Ge,&nbsp;Shuo Yin,&nbsp;Wenya Li,&nbsp;Xinkun Suo","doi":"10.1007/s11666-025-01938-0","DOIUrl":"10.1007/s11666-025-01938-0","url":null,"abstract":"<div><p>Laser-assisted cold spraying (LACS) is garnering significant interest as an innovative surface treatment technology that integrates cold spray technology with laser. However, the primary role of laser on in-flight particles remains underexplored. This study aims to elucidate the impact of laser on in-flight particles through meticulously designed experiments and comprehensive multi-physical field simulations, in which the in-flight iron and nickel particles were heated by the laser parallel to the substrates and deposited on the substrates, while the substrates were not heated by the laser. The cross-sectional microstructures, porosity, oxygen content and microhardness of the coatings were characterized to assess the effect of the laser on the in-flight particles. The heating behavior of the in-flight particles under varying velocity and laser power was evaluated using multi-physical field simulations. The results indicated that the microstructures and properties of the coatings, including porosity, flattening ratios, oxygen content and microhardness, were not significantly influenced by the laser irradiation. The simulations further revealed that the laser irradiation had negligible effect on the temperature variation of the in-flight particles, attributed to the short duration time of laser exposure. The investigation enhances our understanding of the mechanism of LACS.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"88 - 96"},"PeriodicalIF":3.2,"publicationDate":"2025-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455464","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Cold Spray Additive Manufacturing of SmCo-Al Permanent Magnets","authors":"Jaël Giguère,&nbsp;Jean-Michel Lamarre,&nbsp;Fabrice Bernier,&nbsp;Alexandre Nascimento,&nbsp;Christian Lacroix,&nbsp;David Ménard,&nbsp;Frédéric Sirois","doi":"10.1007/s11666-024-01923-z","DOIUrl":"10.1007/s11666-024-01923-z","url":null,"abstract":"<div><p>A key factor to ensure a sustainable future for the air transport industry is electrification. Exploring new designs for permanent magnet electric motors could increase their potential. Unfortunately, complex shaped magnets cannot be produced easily using current fabrication methods. Cold spray additive manufacturing could eventually help to alleviate this problem by allowing the fabrication of magnets with complex geometries consolidated on electric motor parts. Furthermore, another aspect to increase the electric motors’ efficiency is the possibility to operate at higher RPM and with higher electrical currents, consequently generating more heat. Currently, most magnets are prepared with NdFeB, which is less tolerant to high-temperature exposure. This work reports on the cold spray additive manufacturing of samarium-cobalt (SmCo), a material of growing interest since it preserves most of its magnetic properties up to 350 °C. The permanent magnets were fabricated using a SmCo-Al composite powder mix in a standardized simple geometry to evaluate the impact of the fabrication parameters. The impact of the powder mix composition and the gas temperature on the magnetic properties is investigated. The results demonstrate that the use of cold spray would be effective for fabricating SmCo composite permanent magnets directly on the electric motor parts.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"120 - 128"},"PeriodicalIF":3.2,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01923-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455696","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}