Journal of Thermal Spray Technology最新文献

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Research on the Reaction Mechanism and Solution Formulation Optimization for Plasma Electrolytic Removal of Thermal Barrier Coatings 等离子体电解去除热障涂层的反应机理及溶液配方优化研究
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-07 DOI: 10.1007/s11666-026-02187-5
Chang Song, Hong Liu, Bo Song, Zenan Sun, Ben Wang
{"title":"Research on the Reaction Mechanism and Solution Formulation Optimization for Plasma Electrolytic Removal of Thermal Barrier Coatings","authors":"Chang Song,&nbsp;Hong Liu,&nbsp;Bo Song,&nbsp;Zenan Sun,&nbsp;Ben Wang","doi":"10.1007/s11666-026-02187-5","DOIUrl":"10.1007/s11666-026-02187-5","url":null,"abstract":"<div><p>Yttria-stabilized zirconia (YSZ) has been widely adopt as a preferred thermal barrier coating(TBC) material for aircraft engine turbine blades due to the excellent performance, mature fabrication processes, and competitive cost. However, prolonged service under harsh high-temperature and high-pressure environments induces coating cracking or delamination, severely limiting engine service life and increasing costs. In this paper, a thermal barrier coating removal method was proposed based on the plasma electrolysis. With the objectives of minimizing substrate residual and preserving substrate integrity, systematic optimization of the electrolyte formulation was carried out using a single-factor variable approach. Experimental results indicate that the ammonium sulfate solution achieved a maximum removal rate of only 28.31% and left substantial residues. In contrast, an optimized composite electrolyte with 3.5% total salt concentration and an NH<sub>4</sub>F/KF mixing ratio of 1:3 attained a removal rate of 46.38%, representing a 64% improvement, while producing a surface condition suitable for subsequent recoating. Furthermore, the synergistic control of process parameters combined with the optimized formulation effectively reduced residual deposits, offering crucial technical support for the engineering application of plasma electrolytic removal in TBC repair.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1102 - 1120"},"PeriodicalIF":3.3,"publicationDate":"2026-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829238","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}
引用次数: 0
Advancing Wear Resistance of HVOF-Sprayed WC-NiCr Coatings Through Laser Remelting 激光重熔提高hvof喷涂WC-NiCr涂层的耐磨性
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-07 DOI: 10.1007/s11666-026-02190-w
Navneet K. Singh, S. V. V. N. Siva Rao, Vijay Kumar, Gidla Vinay, Harpreet Singh, Partha Pratim Bandyopadhyay
{"title":"Advancing Wear Resistance of HVOF-Sprayed WC-NiCr Coatings Through Laser Remelting","authors":"Navneet K. Singh,&nbsp;S. V. V. N. Siva Rao,&nbsp;Vijay Kumar,&nbsp;Gidla Vinay,&nbsp;Harpreet Singh,&nbsp;Partha Pratim Bandyopadhyay","doi":"10.1007/s11666-026-02190-w","DOIUrl":"10.1007/s11666-026-02190-w","url":null,"abstract":"<div><p>Thermal-sprayed coatings frequently exhibit inherent defects, including porosity, microcracks, and weak mechanical bonding, which deteriorate their overall quality. Laser remelting offers an effective means to refine the microstructure of these coatings and results in limiting these defects. In this regard, the current study investigates the effect of laser remelting (LR) at 300 W and 500 W on the microstructure, mechanical properties, and tribological performance of HVOF-sprayed WC-NiCr coatings. Laser remelting significantly refined the coating microstructure, reducing porosity and enhancing phase stability. The microhardness increased by 8% (LM1, 300 W) and 19% (LM2, 500 W) due to improved WC precipitation and the formation of secondary oxides. Tribological tests demonstrated a 27% reduction in the coefficient of friction (COF) and a 19% decrease in wear rate for LM2, attributed to the formation of protective tribolayers, including WO<sub>3</sub> and NiWO<sub>4</sub>. Additionally, surface roughness (Sa) was reduced by 39%, contributing to smoother wear tracks and lower material loss. These findings highlight laser remelting as an effective post-processing technique to enhance the wear resistance, surface integrity, and mechanical robustness of HVOF-sprayed WC-NiCr coatings. The improved tribological performance suggests that laser-remelted coatings can serve as a sustainable and high-performance alternative to cobalt-based coatings, particularly for applications in aerospace, mining, and energy sectors, where extreme wear conditions prevail.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture><span>The alternative text for this image may have been generated using AI.</span></div></div></figure></div></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1365 - 1383"},"PeriodicalIF":3.3,"publicationDate":"2026-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829148","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}
引用次数: 0
Optimizing a Modular Cascaded Plasma Torch to Manufacture Dense Alumina Coatings with High Spray Efficiency 优化模块化级联等离子炬生产高喷涂效率致密氧化铝涂层
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-05 DOI: 10.1007/s11666-026-02179-5
Myriam Sleiman, Geoffrey Darut, Ralph Seulin, Marie Pierre Planche, Jean-Jacques Gonzalez, Pierre Freton, Francis Sambou, Armando Salito, Manfred Rösli
{"title":"Optimizing a Modular Cascaded Plasma Torch to Manufacture Dense Alumina Coatings with High Spray Efficiency","authors":"Myriam Sleiman,&nbsp;Geoffrey Darut,&nbsp;Ralph Seulin,&nbsp;Marie Pierre Planche,&nbsp;Jean-Jacques Gonzalez,&nbsp;Pierre Freton,&nbsp;Francis Sambou,&nbsp;Armando Salito,&nbsp;Manfred Rösli","doi":"10.1007/s11666-026-02179-5","DOIUrl":"10.1007/s11666-026-02179-5","url":null,"abstract":"<div><p>To minimize arc voltage fluctuations, it is imperative to restrict the arc movement. Cascaded plasma torch configurations have been developed to achieve this objective. The modular torch, employed in this study, represents one of the new designs. Featuring a specific configuration, different nozzle structures (length and inner diameter) can be used. This research aims to investigate experimentally the effects of particle characteristics (velocity and temperature) and powder mass flow rate on coating properties (microstructure, hardness, porosity, deposition efficiency). After analyzing the influence of torch geometry and operating parameters on particle characteristics, the careful selection of operating parameters, such as the geometry and the powder mass flow rate, can result in different coatings microstructures with a processing time reduced by 40 to 50% when feeding powder from 30 to 60 g/min. The findings demonstrate that increasing powder mass flow rate can (1) decrease processing time by 2 without compromising coating quality (approximately 2.5% porosity, hardness higher than 1000HV<sub>0.3</sub> at 60 g/min) compared to conventional torches (approximately 3% porosity, hardness of 1026HV<sub>0.3</sub>) and (2) enhance torch deposition efficiency (by approximately 10%).</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"591 - 600"},"PeriodicalIF":3.3,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147606881","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}
引用次数: 0
Investigation of Effects of Plasma Parameters in Axial Suspension Plasma Spray on In-Flight Suspension Treatment and Thermal Barrier Coating Microstructure 轴向悬浮等离子喷涂中等离子体参数对飞行悬浮处理和热障涂层微观结构影响的研究
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-05 DOI: 10.1007/s11666-026-02174-w
Maxime Gaudin, Simon Goutier, Geoffroy Rivaud, Aurélien Joulia, Emilie Béchade, Vincent Rat, Alan Kéromnès
{"title":"Investigation of Effects of Plasma Parameters in Axial Suspension Plasma Spray on In-Flight Suspension Treatment and Thermal Barrier Coating Microstructure","authors":"Maxime Gaudin,&nbsp;Simon Goutier,&nbsp;Geoffroy Rivaud,&nbsp;Aurélien Joulia,&nbsp;Emilie Béchade,&nbsp;Vincent Rat,&nbsp;Alan Kéromnès","doi":"10.1007/s11666-026-02174-w","DOIUrl":"10.1007/s11666-026-02174-w","url":null,"abstract":"<div><p>Suspension plasma spraying (SPS) is a thermal spray process with unique potential for producing finely structured, porous coatings for thermal barrier coating (TBC) applications. However, the complex link between plasma operating conditions and particle processing mechanisms presents significant challenges for optimizing the process and controlling the microstructure. Using an Axial III Plus torch, this study focuses on determining the effect of plasma parameters (argon, hydrogen, and nitrogen flow rates and the arc current), on the various stages of in-flight particle treatment, and how this affects the final coating architecture. The results demonstrate that the total gas flow rate primarily governs the initial fragmentation and solvent evaporation processes. In addition, the arc current and gas composition have a critical influence on the thermal and kinetic treatment of the particles, impacting the specific enthalpy and velocity of the plasma jet. The study identifies hydrogen as a particularly influential parameter due to its dual impact: it significantly enhances the plasma’s thermal conductivity while also lowering the plasma density, thus increasing gas velocity. This duality enables fine control of the coating morphology, ranging from porous columnar structures to dense architectures with vertical cracking, by adjusting the balance between thermal and kinetic energy inputs. A plasma process map correlating specific enthalpy and plasma jet velocity with resulting microstructures is proposed, providing a framework for process selection based on target coating properties. This tool could be especially valuable for tailoring microstructures in TBC systems, where thermal conductivity and strain tolerance are critically dependent on porosity and architecture. This work highlights the importance of a detailed understanding of the thermo-kinetic treatment of particles in SPS, offering practical guidelines for process optimization and advancing the design of high-performance coatings.</p><h3>Graphical Abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"636 - 649"},"PeriodicalIF":3.3,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147606882","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}
引用次数: 0
Nondestructive Full-Surface Thickness Evaluation of Thermal Barrier Coatings Using a Robotic Multi-angle 3D Scanning and Point Cloud Analysis System 基于机器人多角度三维扫描和点云分析系统的热障涂层无损全表面厚度评价
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-05 DOI: 10.1007/s11666-026-02164-y
Tingyang Chen, Shujuan Dong, Zhenhua Cai, Haixian Liu, Chunming Deng
{"title":"Nondestructive Full-Surface Thickness Evaluation of Thermal Barrier Coatings Using a Robotic Multi-angle 3D Scanning and Point Cloud Analysis System","authors":"Tingyang Chen,&nbsp;Shujuan Dong,&nbsp;Zhenhua Cai,&nbsp;Haixian Liu,&nbsp;Chunming Deng","doi":"10.1007/s11666-026-02164-y","DOIUrl":"10.1007/s11666-026-02164-y","url":null,"abstract":"<div><p>The thickness and uniformity of thermal barrier coatings (TBCs) on turbine blades are critical parameters for ensuring their performance and service life. However, effective full-surface inspection methods and systems remain scarce. To address this, the present study developed a multi-angle automatic scanning system that integrates a laser 3D scanner, an industrial robotic arm, and a precision linear module. The system separately scanned the surface point clouds of the substrate, sprayed, and polished components to generate a comprehensive full-surface point cloud of the blade. A method combining point cloud registration algorithms with distance calculations was then proposed to determine the sprayed coating thickness, the thickness removed by polishing, and the residual coating thickness at any location on the blade surface. Comparative analysis from case experiments demonstrated that the calculated coating thickness deviates by less than 10 μm from the true thickness. Compared to traditional contact-type thickness gauges or destructive localized microscopic measurements, the proposed method offers advantages of being noncontact, nondestructive, highly accurate, and efficient, while providing detailed visualization of coating thickness uniformity over the entire blade surface.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1166 - 1184"},"PeriodicalIF":3.3,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829575","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}
引用次数: 0
Influence of Pulsed Laser Ablation Parameters on Adhesion of Cold Spray Al 6061 Coatings on Extruded Al 6061 Substrates 脉冲激光烧蚀参数对冷喷涂Al - 6061涂层在挤压Al - 6061基体上附着力的影响
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-04 DOI: 10.1007/s11666-026-02178-6
Jagannadh Sripada, Alexis Thibault, Lucas Hof, Philippe Bocher, Jean-François Béland, Phuong Vo, Éric Irissou
{"title":"Influence of Pulsed Laser Ablation Parameters on Adhesion of Cold Spray Al 6061 Coatings on Extruded Al 6061 Substrates","authors":"Jagannadh Sripada,&nbsp;Alexis Thibault,&nbsp;Lucas Hof,&nbsp;Philippe Bocher,&nbsp;Jean-François Béland,&nbsp;Phuong Vo,&nbsp;Éric Irissou","doi":"10.1007/s11666-026-02178-6","DOIUrl":"10.1007/s11666-026-02178-6","url":null,"abstract":"<div><p>The effect of pulsed laser ablation as a substrate pretreatment technique on the adhesive strength of cold-sprayed Al6061 coatings deposited onto extruded Al6061 substrates was investigated. The influence of laser ablation parameters on the surface morphology and roughness of extruded Al 6061 substrates were systematically examined. A Nd:YAG pulsed laser (1.064 µm, 12 ns, 30 Hz) was employed with fluences ranging from 1.55 to 3.53 J/cm<sup>2</sup> and surface coverages between 5.8 × and 109.6 × . Distinct morphological evolution stages were observed, progressing from irradiated and dimpled textures at low laser exposures to cauliflower-like structures at higher exposures. This transformation was primarily governed by cumulative surface coverage resulting from overlapping laser passes, indicating that surface coverage plays a more dominant role than fluence in driving morphological changes. Surface texturing emerged at a threshold of approximately 8.4 × coverage. Cold spray deposition was subsequently performed on the laser-textured substrates and compared to coatings prepared using conventional pretreatments, including grit blasting and degreasing. Adhesion strength was assessed via two mechanical testing methods (ASTM C633 and a modified ASTM E8). Laser texturing produced substantial improvements in coating adhesion, with increases of up to 242% relative to grit-blasted substrates. A maximum bond strength of 90 MPa was achieved at a fluence of 3.53 J/cm<sup>2</sup> and 8.4 × surface coverage. These findings demonstrate that controlled laser ablation can effectively tailor surface morphology to significantly enhance the adhesion performance of cold-sprayed Al 6061 coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"830 - 846"},"PeriodicalIF":3.3,"publicationDate":"2026-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147606941","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}
引用次数: 0
Effect of Spray Distance on the Microstructure and Electrochemical Performance of LiCoO2 Cathodes Fabricated by Atmospheric Plasma Spraying 喷涂距离对常压等离子喷涂法制备LiCoO2阴极微观结构和电化学性能的影响
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-03 DOI: 10.1007/s11666-026-02182-w
C. H. Yang, C. H. Tsai, C. L. Chang
{"title":"Effect of Spray Distance on the Microstructure and Electrochemical Performance of LiCoO2 Cathodes Fabricated by Atmospheric Plasma Spraying","authors":"C. H. Yang,&nbsp;C. H. Tsai,&nbsp;C. L. Chang","doi":"10.1007/s11666-026-02182-w","DOIUrl":"10.1007/s11666-026-02182-w","url":null,"abstract":"<div><p>This study investigates the influence of stand-off distance (SOD) on the microstructure and electrochemical performance of LiCoO<sub>2</sub> (LCO) cathodes fabricated by atmospheric plasma spraying (APS). Granulated LCO powders were deposited at SODs of 6-14 cm and subsequently annealed at 600 °C. Shorter SODs enhanced particle melting, interlamellar bonding, and coating densification, while excessively short distances (≤6 cm) caused substrate overheating and delamination. The optimized condition of 8 cm produced a dense, defect-minimized 45-μm coating using 20 spray passes. After annealing, the cathode exhibited improved crystallinity and strengthened (101)/(104) texture, facilitating Li<sup>+</sup> transport and reducing internal resistance. The optimized APS-LCO film delivered a high specific capacity of 131.2 mAh g<sup>−1</sup> at 0.1 C and retained 93.7% capacity after 50 cycles. The resultant areal capacity (2.2 mAh cm<sup>−2</sup>) meets practical solid-state battery requirements and surpasses the thickness limits of vacuum-based deposition methods. These results highlight APS as a scalable, high-throughput technique for producing thick, binder-free LCO cathodes with promising structural and electrochemical characteristics.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1040 - 1055"},"PeriodicalIF":3.3,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829435","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}
引用次数: 0
Genetic Algorithm-Based Optimization of Cold-Sprayed AA2024/YSZ Composite Coating on AZ31 Magnesium Alloy 基于遗传算法的AZ31镁合金冷喷涂AA2024/YSZ复合涂层优化
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-03-03 DOI: 10.1007/s11666-026-02184-8
Ashokkumar Mohankumar, Arunkumar Thirugnanasambandam, Deepak Sampathkumar, Anbu selvam Thilaharaj
{"title":"Genetic Algorithm-Based Optimization of Cold-Sprayed AA2024/YSZ Composite Coating on AZ31 Magnesium Alloy","authors":"Ashokkumar Mohankumar,&nbsp;Arunkumar Thirugnanasambandam,&nbsp;Deepak Sampathkumar,&nbsp;Anbu selvam Thilaharaj","doi":"10.1007/s11666-026-02184-8","DOIUrl":"10.1007/s11666-026-02184-8","url":null,"abstract":"<div><p>Cold spray (CS) parameter optimization is necessary to minimize corrosion and enhance the protective properties of composite coatings on lightweight alloys. In the present work, an evolutionary genetic algorithm (GA) was used to identify the optimum combination of CS parameters and further guarantee good corrosion rate minimization and sufficient coating reliability. Yttria-stabilized zirconia (YSZ)-reinforced AA2024 aluminum alloy was cold-sprayed onto AZ31 magnesium alloy substrates. A three-factor, five-level central composite design (CCD) with response surface methodology (RSM) was used to develop a quadratic regression model between corrosion rate and working gas temperature (WGT), nozzle spray distance (NSD), and feedstock flow rate (FFR). Analysis of variance (ANOVA) validated the high statistical significance of the model (<i>F</i> = 193.50, <i>p</i> &lt; 0.0001), high determination coefficients (<i>R</i><sup>2</sup> = 0.9792, adjusted <i>R</i><sup>2</sup> = 0.9643, predicted <i>R</i><sup>2</sup> = 0.9596), and a low coefficient of variation (7.55%). Regression diagnostics were used to test the adequacy of the model, resulting in bounded residuals within ± 4.15 and errors normally distributed. The desirability function showed a composite desirability value of 0.9625, where all three components were desired by 1.0, validating the robustness of the optimization window. Sensitivity analysis derived the parameter influence ordering as WGT &gt; NSD &gt; &gt; FFR, where WGT had the highest control. GA optimization set the optimum global at WGT = 504.44 °C, NSD = 17.17 mm, and FFR = 22.16 g/min, and the corrosion rate was 1.0267 mm/year. Microstructural analysis of the best coating exhibited a compact morphology, avoiding electrolyte permeability and providing enhanced corrosion protection. The results prove the verified GA–RSM approach to design CS process parameters that offer improved corrosion protection of lightweight Mg alloys.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"980 - 1009"},"PeriodicalIF":3.3,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829350","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}
引用次数: 0
Research on the TBCs Anomalous Failure Mechanisms Driven by Interface Roughness via Morphology-Dependent Stress 基于形貌相关应力的界面粗糙度驱动TBCs异常破坏机制研究
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-02-27 DOI: 10.1007/s11666-026-02176-8
Yudong Yao, Yanting Ai, Jing Tian, Peng Guan, Tiannan Bao, Xiao Hu, Huiyuan Wang
{"title":"Research on the TBCs Anomalous Failure Mechanisms Driven by Interface Roughness via Morphology-Dependent Stress","authors":"Yudong Yao,&nbsp;Yanting Ai,&nbsp;Jing Tian,&nbsp;Peng Guan,&nbsp;Tiannan Bao,&nbsp;Xiao Hu,&nbsp;Huiyuan Wang","doi":"10.1007/s11666-026-02176-8","DOIUrl":"10.1007/s11666-026-02176-8","url":null,"abstract":"<div><p>The increase in the interfacial roughness of the thermal barrier coatings (TBCs) leads to the concentration of interfacial stresses, but the experimental life also increases. The intuitive explanation of this anomalous failure mechanism has been a problem that has plagued scholars for many years. In this study, a method for solving the interfacial morphology-dependent stress of TBCs is developed, and the anomalous failure mechanism is elucidated intuitively. In addition, the multiscale of TBCs with microstructures is established based on experimental parameters by applying the submodel method, and the effects of interface roughness on conventional stresses and morphology-dependent stress are analyzed. The results show that both the maximum principal stress and the equivalent stress increase with the increase in the interface roughness. As the roughness increases, the compressive stress perpendicular to the interface weakens and the minimum value of shear stress along the interface does not differ much. At the TBC interface near the valleys, cracks initiate under the minimum value of shear stress along the interface, and then, cracks expand under compressive stress perpendicular to the interface until the TBCs are disrupted. The strong correlation between compressive stress and damage at different roughnesses, as well as the fact that the damage location of the actual TBCs is consistent with the description of the failure mechanism, which justify the failure mechanism proposed in this study. These conclusions can provide a theoretical basis for the mesoscopic interface design of long service life TBCs.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1121 - 1139"},"PeriodicalIF":3.3,"publicationDate":"2026-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829986","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}
引用次数: 0
Catalytic Properties of Atmospheric Plasma-Sprayed Coatings for Alkaline Water Electrolysis Hydrogen Production Systems 常压等离子喷涂涂料对碱性水电解制氢系统的催化性能
IF 3.3 3区 材料科学
Journal of Thermal Spray Technology Pub Date : 2026-02-26 DOI: 10.1007/s11666-026-02177-7
Zhenglong Sun, Xi Tan, Jianhong Gao, Qinggui Li, Shuoyu Wang, Zhengkang Wu, Guijun Ding, Xiaohong Hu, Zhiyong Zhong
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