Journal of Thermal Spray Technology最新文献

{"title":"Special Issue Featuring Papers from the International Thermal Spray Conference (ITSC) 2024","authors":"Giovanni Bolelli, Fardad Azarmi, Sara Bagherifard, Partha Pratim Bandyopadhyay, Šárka Houdková, Heli Koivuluoto, Yuk-Chiu Lau, Hua Li, Sinan Müftü, Filofteia-Laura Toma","doi":"10.1007/s11666-025-01971-z","DOIUrl":"10.1007/s11666-025-01971-z","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"481 - 483"},"PeriodicalIF":3.2,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688502","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":"Physics-Informed Neural Networks for Predicting Particle Properties in Plasma Spraying","authors":"K. Bobzin,&nbsp;H. Heinemann,&nbsp;A. Dokhanchi","doi":"10.1007/s11666-025-01965-x","DOIUrl":"10.1007/s11666-025-01965-x","url":null,"abstract":"<div><p>Plasma spraying is a key industrial coating process that exhibits intricate nonlinear interactions among process parameters. This complexity makes accurate predictions of particle properties, which greatly affect process behavior, very challenging. Specifically, particle velocities and temperatures profoundly impact coating quality and process efficiency. Conventional methods often require empirical correlations and extensive parameter tuning due to their limited ability to capture the underlying physics within this intricate system. This study introduces physics-informed neural networks (PINNs) as a solution. By seamlessly integrating known physical laws and constraints directly into the model architecture, PINNs offer the potential to learn the underlying physics of the system. For comparison, artificial neural networks (ANNs) are also developed. Computational fluid dynamics simulations of a plasma generator and plasma jet model provide data to train both ANN and PINN models. The study reveals an improvement in particle velocity prediction through the proposed PINN model, demonstrating its capability to handle complex relationships. However, challenges arise in predicting particle temperature, warranting further investigation. The developed models can aid in optimizing the plasma spraying process by predicting essential particle properties and guiding necessary process adjustments to enhance coating quality.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"885 - 892"},"PeriodicalIF":3.2,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01965-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688290","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":"Analysis of the t′ + c Phase Content from ZrO2-16 Mol.% Y2O3-16 Mol.% Ta2O5 Mechanoactivated Powder Mixtures in Coatings Deposited by Suspension Plasma Spraying","authors":"Catalina Galeano-Camacho,&nbsp;Iván Bedoya-Trujillo,&nbsp;Sebastián Pérez,&nbsp;Hélène Ageorges,&nbsp;Juan Muñoz-Saldaña","doi":"10.1007/s11666-025-01946-0","DOIUrl":"10.1007/s11666-025-01946-0","url":null,"abstract":"<div><p>Gas turbines or power generation engines used in transportation, defense, and energy sectors use thermal barrier coatings (TBCs) to protect metallic components exposed to high-temperature conditions. This work focuses on the in situ synthesis during coating deposition by suspension plasma spraying (SPS) from powders mechanoactivated by high-energy ball milling of ZrO₂-16 mol.% YO_1.5-16 mol.% TaO_2.5 (16YTZ) for applications in TBCs. This composition is expected to present a non-transformable tetragonal phase (<i>t′</i> phase), suitable to overcome the thermodynamic limits of the mostly used conventional 6-8 wt.% yttria stabilized zirconia (YSZ). The 16YTZ powder mixtures were mechanoactivated by either planetary ball milling (240 RPM) and high-energy ball milling (1700 RPM). These mechanoactivated powders were used to obtain densified samples through sintering at 1500 °C for 2 and 20 h, as well as to deposit coatings by SPS at a stand-off distance between 60 and 80 mm using Ar/He as the plasma forming gas. The ceramics and coatings were characterized by XRD, SEM, and Raman spectroscopy. The densified ceramics showed a high <i>t′</i> phase content, i.e., &gt; 98% of the 16YTZ system, with an average tetragonality of 1.0267. Coatings deposited at a stand-off distance of 60 mm, and a deposition rate of 33 µm/min, present a porosity of less than 5%, and a tetragonality of 1.0187, which is higher than that of standard YSZ coatings. Phase quantification by Rietveld refinement revealed a multiphase condition as result of the heat transfer in the plasma plume leading to in situ synthesis of the ZrO₂ base solid solutions, formed by 89.2 wt.% of <i>t′ + c</i> phases (48.4 and 40.8 wt.% of <i>t′</i> and<i> c-</i>ZrO₂, respectively<i>)</i> 8.1% monoclinic ZrO₂, 2.4% cubic Y₂O₃ and 0.4% orthorhombic Ta₂O₅ on average. Achieving a high percentage of <i>t' + c</i> phases in the coating with a porosity of less than 5% is a significant accomplishment. This success is closely linked to the fact that tetragonality exceeds that of YSZ. These results provide a solid foundation for future experimental designs aimed at optimizing spray parameters.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"783 - 794"},"PeriodicalIF":3.2,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01946-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688389","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":"The Microstructure and Performance of Metal Based Abradable Sealing Coatings Based on Peeling Medium Particle Structure Design","authors":"Dan Guo,&nbsp;Jianming Liu,&nbsp;Tong Liu,&nbsp;Chao Wu","doi":"10.1007/s11666-025-01964-y","DOIUrl":"10.1007/s11666-025-01964-y","url":null,"abstract":"<div><p>To address the issue of inadequate abradability in existing metal-based coatings, which fall short of meeting the demands of harsh operational conditions, this article introduces the design of two novel metal-based abradable sealing coating materials. These materials are founded on the unique particle structure of the “peeling medium”. The article delves into the fundamental properties and performance under simulated working conditions of these coatings. The “peeling medium” structure refers to the powder structure design, where lubricating phases such as hBN are uniformly coated around metal particles. The experimental conditions under which the coatings were tested included a 1000-hour heat exposure test at high-temperatures. This rigorous testing regime was designed to assess the coatings’ durability and performance under long-term, high-temperature service environments. The primary results of the research revealed that both coatings maintained impressive hardness, bonding strength, and abradability after the heat exposure test. Crucially, these coatings were observed to fracture precisely at the exposed abradable components, demonstrating their ability to maintain the required abradability and excellent thermal stability. The “peeling medium” particle structure design ensures that the coatings can fracture in a controlled manner, preserving their functionality and durability in harsh environments.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"866 - 874"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688450","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":"In Situ Spray Bead Acquisition and Analysis for Coating Thickness Predictions","authors":"Uroš Hudomalj,&nbsp;Ivo Aschwanden,&nbsp;Lukas Weiss,&nbsp;Majid Nabavi,&nbsp;Konrad Wegener","doi":"10.1007/s11666-025-01953-1","DOIUrl":"10.1007/s11666-025-01953-1","url":null,"abstract":"<div><p>Coating thickness is considered to be one of the most important characteristics of thermal spray coatings. Therefore, it has long been the goal to be able to predict the coating thickness that ensues when coating an arbitrary part. A commonly applied approach is to determine the coating deposit based on a series of spray spot tests and use that for modeling the coating. Another option is to conduct spray bead tests, which better reflect the conditions during the coating. This work suggests a novel approach for in situ acquisition of the spray beads and their analysis. The acquisition is based on a 3D camera to scan the sample before and after depositing of a spray bead. The approach allows for their streamlined evaluation, enabling better understanding of spray bead formation and their modeling. The suggested analysis of spray beads includes uncertainty evaluation. This enables estimation of model prediction uncertainties which has been omitted in the previous works on the topic. The analysis shows that a relative expanded uncertainty of 10% (at 95% level of confidence) can be expected for the coating thickness prediction for the simplest scenario of coating a flat sample sprayed perpendicularly at a constant spray distance and spray speed.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"893 - 901"},"PeriodicalIF":3.2,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01953-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688482","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":"Influence of HIPing Post-Treatment on the Cavitation Erosion in HVOF Thermally Sprayed WC-NiCrBSi Coatings","authors":"A. Algoburi,&nbsp;R. Ahmed,&nbsp;V. Kumar","doi":"10.1007/s11666-025-01926-4","DOIUrl":"10.1007/s11666-025-01926-4","url":null,"abstract":"<div><p>Cavitation erosion caused by the energy released from collapsing bubbles is a major failure mode of engineering components in hydraulic and marine environments. Thermal spray coatings provide a cost-effective and environmentally friendly solution to improve the cavitation erosion resistance of components. Functionally graded WC-NiCrBSi coatings were deposited by the high-velocity oxy-fuel (HVOF) process and post-retreated using hot isostatic pressing (HIPing) to improve the interlamellar bonding at two different temperatures of 850 °C and 1200 °C. ASTM G32 cavitation erosion tests were conducted in seawater for a total test time of 24 hours. Microstructural and post-cavitation test investigations were conducted on the coating surface and cross sections using scanning electron microscopy (SEM) equipped with energy-dispersive spectroscopy (EDS). Microstructural phases were investigated using x-ray diffraction (XRD). Changes in microstructure, hardness, fracture toughness, and porosity due to HIPing post-treatment are discussed. The results of this investigation show that the cavitation erosion resistance of coatings improves after HIPing post-treatment. This improvement was five times the cavitation wear resistance of as-sprayed coating at the HIPing temperature of 1200 °C, surpassing the cavitation erosion resistance of the AISI 440 C steel substrate. Microstructural changes leading to the strengthening of interlamellar and carbide-matrix boundaries, which reduce intergranular and transgranular crack propagation, are attributed to this improvement. A combination of the improvement in hardness, elastic modulus, porosity, and fracture toughness due to microstructural changes resulted in the superior cavitation erosion resistance of HIPed coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"992 - 1015"},"PeriodicalIF":3.2,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01926-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688478","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":"Analysis of Different High-Velocity Thermally Sprayed Coatings to Recover AISI H13 High-Pressure Die Casting Molds","authors":"Andre Renan Mayer,&nbsp;Willian Rafael de Oliveira,&nbsp;Eriel Biagini Sabino,&nbsp;Hipolito Domingo Carvajal Fals,&nbsp;Stefan Björklund,&nbsp;Shrikant Joshi,&nbsp;Anderson Geraldo Marenda Pukasiewicz","doi":"10.1007/s11666-025-01935-3","DOIUrl":"10.1007/s11666-025-01935-3","url":null,"abstract":"<div><p>High-pressure die casting (HPDC) is a manufacturing process used in the automotive sector to make high-precision components. Corrosion induced by molten metal and heat-checking cracks are two of main failure modes for die casting molds, changing the die's geometry and surface quality. Thermally sprayed coatings can improve the surface properties and recover the geometry of the die caused by aluminum attack. The main objective of this work is to observe the behavior of the H13, Cr₃C₂-25NiCr, and WC10Co4Cr coatings deposited by HVOF and HVAF processes in aluminum corrosion and die soldering tests. During corrosion and die soldering tests, chromium carbide in the Cr₃C₂-25NiCr coating reacts with the molten aluminum, creating a tough intermetallic interface and raising the extraction stress. After tests, it was observed that the WC 10Co 4Cr HVAF coating presented low adhesion to aluminum with no observed coating failure due to the formation of intermetallic. Die soldering tests indicated that the WC 10Co 4Cr coating protects the substrate, resulting in lower extraction stress than H13 base material and other HVOF coatings. It was observed that WC 10Co 4Cr HVAF coating showed results comparable to AlCrN PVD coating.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"939 - 955"},"PeriodicalIF":3.2,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688442","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 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":"Atmospheric Plasma Sprayed YSZ Coatings for Soilless Cultivation","authors":"Pratidhwani Biswal,&nbsp;Michél Hauer,&nbsp;Lukas Möhrke,&nbsp;Andreas Gericke,&nbsp;Stefan Rasche,&nbsp;Helga Schinkel,&nbsp;Knuth-Michael Henkel","doi":"10.1007/s11666-025-01940-6","DOIUrl":"10.1007/s11666-025-01940-6","url":null,"abstract":"<div><p>In this work, thermally sprayed coatings with sustainable spray additives are developed to allow the growth of drought-tolerant plants like moss, microclover and Chamomile. The specified spray additives are intended to imitate the powders obtained from recycled solid oxide fuel cells and dry alkaline batteries. These plants anchor to the coating with their rhizoids and shallow roots and hence can be grown without the presence of soil. The coatings are aimed to be sprayed using sustainable powders rich in growth-supporting nutrients as well as protect the substrate against biodeterioration due to vegetation. Preliminary tests of a thermally sprayed yttrium-stabilized zirconia (YSZ) ceramic coating on sheet metal confirm the growth of Chamomile plant in the absence of soil. The success of this experiment is considered as a proof of concept for the future investigations using the recycled sustainable powders. The goal of this research work is to produce sustainable thermally sprayed coatings using recyclable powders as spray additives. This research work is focused on betterment of the environment with efficient urban greening as well as efficient usage of toxic wastes.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"506 - 519"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01940-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688372","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":"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}