{"title":"Influence of HIPing Post-Treatment on the Cavitation Erosion in HVOF Thermally Sprayed WC-NiCrBSi Coatings","authors":"A. Algoburi, R. Ahmed, 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}
Cong Wang, Yunlong Zhu, Haidou Wang, Ming Liu, Wen Tian, Xiang Meng, Yafeng Gao, Shuying Chen, Guozheng Ma, Guo Jin
{"title":"The Multishot Damage of Supersonic Plasma Sprayed Al2O3-PF Composite Coating Deposited on Insulator","authors":"Cong Wang, Yunlong Zhu, Haidou Wang, Ming Liu, Wen Tian, Xiang Meng, Yafeng Gao, Shuying Chen, Guozheng Ma, Guo Jin","doi":"10.1007/s11666-025-01949-x","DOIUrl":"10.1007/s11666-025-01949-x","url":null,"abstract":"<div><p>Al<sub>2</sub>O<sub>3</sub>-PF composite coating is effectively generated on the surface of glass fiber reinforced resin by supersonic plasma spraying technology, which prolonged the service life of traditional insulator in the small-diameter launch devices with high-density current. The thermal properties of Al<sub>2</sub>O<sub>3</sub>-PF composite coatings had been extensively explored. Moreover, the protective effect of Al<sub>2</sub>O<sub>3</sub>-PF composite coating on the traditional glass fiber reinforced resin insulator in terms of ablative carbonization, metal contamination and insulating performance during the launching process was thoroughly investigated. The results indicate that Al<sub>2</sub>O<sub>3</sub>-PF composite coating has attractive thermal stability. After the same number of launching tests, the metal deposition on the surface of Al<sub>2</sub>O<sub>3</sub>-PF composite coating is less than that of traditional glass fiber reinforced resin insulator, as is the degree of ablative carbonization at the muzzle. These factors achieve a considerable improvement in insulation performance of the insulator during the linear drive experiment. Especially after ten launching tests, surface resistivity of the Al<sub>2</sub>O<sub>3</sub>-PF composite coating in the acceleration section is around 10<sup>6</sup> times that of the GFEP insulator. The research provides an efficient method to improve the service life and stability of traditional glass fiber reinforced resin insulator.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1463 - 1474"},"PeriodicalIF":3.2,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918956","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":"Enhancing the Elevated Temperature Tribological Performance of Ni-Based Cermet Coatings for Industrial Applications Deposited by Atmospheric Plasma Spray","authors":"Rohit Kumar Singh Gautam, Vivek Mani Tripathi, Indra Prakash Mishra, Subhash Mishra, Saood Ali, Sunil Kumar, Pushkar Jha","doi":"10.1007/s11666-025-01956-y","DOIUrl":"10.1007/s11666-025-01956-y","url":null,"abstract":"<div><p>The present work reports the development of coatings for harsh environments by improving the understanding of interactions between solid lubricants under extreme conditions, thereby aiding the design of more effective lubrication systems for high-temperature applications. The study provides valuable insights into optimizing the content of solid lubricants in coating materials for the intended purpose. The tribological characteristics of plasma-sprayed coatings, namely Ni-Al-MoS<sub>2</sub>-5 wt.% Ag (NM5), Ni-Al-MoS<sub>2</sub>-10 wt.% Ag (NM10), Ni-Al-MoS<sub>2</sub>-12.5 wt.% Ag (NM12.5), Ni-Al-MoS<sub>2</sub>-15 wt.% Ag (NM15), and Ni-Al-MoS<sub>2</sub>-12.5 wt.% Ag-7 wt.% Cr<sub>2</sub>O<sub>3</sub> (NM12.5 + 7 wt.% Cr<sub>2</sub>O<sub>3</sub>), were evaluated using a ball-on-disk tribometer. The tests were conducted from room temperature (RT) 25-800 °C against Al<sub>2</sub>O<sub>3</sub> balls. The NM12.5 + 7 wt.% Cr<sub>2</sub>O<sub>3</sub> coating demonstrated the exceptional lubricity, especially at elevated temperature (800 °C), outperforming other coatings. The NM12.5 + 7 wt.% Cr<sub>2</sub>O<sub>3</sub> initially exhibited a slightly higher coefficient of friction (COF) compared to NM12.5, particularly at temperatures up to 400 °C. Beyond 400 °C, NM12.5 + 7 wt.% Cr<sub>2</sub>O<sub>3</sub> showed a decreasing trend in COF and wear and finally attained the lowest COF (0.21) and wear rate 4.3 × 10<sup>−5</sup> mm<sup>3</sup>/Nm at 800 °C. It emphasizes the pivotal role of solid lubricants in order to form continuous compacted layers on the worn surface, and enhancing the lubrication and wear resistance at elevated temperatures. The ability of NM12.5 + 7 wt.% Cr<sub>2</sub>O<sub>3</sub> coating to achieve the lowest COF and wear at elevated temperatures highlights its effectiveness in extreme conditions.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1229 - 1250"},"PeriodicalIF":3.2,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918982","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":"Effects of Heat Treatment on Plasma-Sprayed Indian Clam Seashell-Derived Hydroxyapatite (HA) Coating Applied on Ti-Alloy","authors":"Shahid Hussain, Kazi Sabiruddin","doi":"10.1007/s11666-025-01955-z","DOIUrl":"10.1007/s11666-025-01955-z","url":null,"abstract":"<div><p>Initially, spray-dried Indian clam seashell-derived hydroxyapatite (HA) powder is sprayed by atmospheric plasma spray technique on titanium alloy (Ti-6Al-4 V ELI) substrate, and further the as-sprayed HA coating is heat-treated in a muffle furnace at different temperatures of 500, 600, 700, 800, and 900 °C for a 2 h of holding time under normal atmospheric conditions, followed by furnace cooling. Heat-treated and as-sprayed coatings are characterized to examine and study the effects of heating temperature on the physical, mechanical, and tribological properties of the coatings. A suitable heating condition is tried to find through this investigation. The phases and microstructure of the as-sprayed and heat-treated coatings are analyzed by equipments XRD (x-ray diffractometer) and FESEM (field emission scanning electron microscope), respectively. Average surface roughness, microhardness, and wear behavior are estimated through the stylus profilometer (contact-type), Vickers microhardness tester, and linear reciprocating tribometer, respectively. The transformation of the secondary phase such as CaO into the primary HA phase is noticed after heat treatment. Due to increased crystallinity and crystallite size, the volumetric expansion of limitedly spread HA splats is noticed at high heating temperatures. As a result, a relatively smoother coating surface is obtained. Also, at higher heating temperatures, the coating hardness is increased due to the reduction in coating porosity and improvement in the crystallinity. However, beyond 700 °C of heating temperature, the cracks have started to form and increase in number with an increase in heating temperature. The improved tribo-mechanical properties are obtained when the heating temperature of the HA coating is kept at 800 °C.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1436 - 1451"},"PeriodicalIF":3.2,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918983","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}
Bi Zhi-jiang, Liu Kang-cheng, Cai Zhi-hai, Chen Tian-hui, Shuai Ruo-hui, Zhou Ji, Lou Li-Yan, Liu Yi, Wang Hai-Dou, Li Cheng-Xin
{"title":"Influence of Decomposition and Microstructure Evolution of cBN on the Wear Resistance of Ti-Based cBN Composite Coatings Deposited by High-Speed Laser Cladding","authors":"Bi Zhi-jiang, Liu Kang-cheng, Cai Zhi-hai, Chen Tian-hui, Shuai Ruo-hui, Zhou Ji, Lou Li-Yan, Liu Yi, Wang Hai-Dou, Li Cheng-Xin","doi":"10.1007/s11666-025-01932-6","DOIUrl":"10.1007/s11666-025-01932-6","url":null,"abstract":"<div><p>cBN particles reinforced Ti-based composite coatings were prepared by high-speed laser cladding technology in this paper. The thermal decomposition and the evolution behavior of cBN particles during the cladding process were investigated, with the generation of reinforced phases clarified. The solidification structure of the coating and its relationship with hardness, tribological property were also analyzed. The results showed that reinforced phases TiN and TiB could be in- suit synthesized due to the decomposition of cBN. And the content of the residual cBN and the newly formed TiN and TiB could be optimized through the process parameters. The microhardness of the coating can be increased from 610 ± 40HV<sub>0.3</sub> to 1217 ± 1HV<sub>0.3</sub>, with the wear loss reduced by 56%.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1177 - 1194"},"PeriodicalIF":3.2,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918927","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}
Andre Renan Mayer, Willian Rafael de Oliveira, Eriel Biagini Sabino, Hipolito Domingo Carvajal Fals, Stefan Björklund, Shrikant Joshi, Anderson Geraldo Marenda Pukasiewicz
{"title":"Analysis of Different High-Velocity Thermally Sprayed Coatings to Recover AISI H13 High-Pressure Die Casting Molds","authors":"Andre Renan Mayer, Willian Rafael de Oliveira, Eriel Biagini Sabino, Hipolito Domingo Carvajal Fals, Stefan Björklund, Shrikant Joshi, 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, Cr<sub>3</sub>C<sub>2</sub>-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 Cr<sub>3</sub>C<sub>2</sub>-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}
Ajay Kumar Behera, Sisir Mantry, Sudesna Roy, Soobhankar Pati
{"title":"Numerical Investigation of the Metal–Ceramic Coating Mechanism Through Cold Spray","authors":"Ajay Kumar Behera, Sisir Mantry, Sudesna Roy, Soobhankar Pati","doi":"10.1007/s11666-025-01939-z","DOIUrl":"10.1007/s11666-025-01939-z","url":null,"abstract":"<div><p>Cold spray technology, commonly employed for depositing ductile metal particles on metal substrates, traditionally avoids coating ceramic particles due to their lack of ductility. Recent breakthroughs have, however, demonstrated successful ceramic coating on metal substrates. However, understanding the initial bonding mechanisms between the ceramic particles and the metal substrate is crucial for optimizing coating performance. In this study, we investigated the impact behavior of single TiO<sub>2</sub> particles on AlMg3 (soft) and 304 SS (hard) substrates using arbitrary Lagrangian Eulerian (ALE) with smoothed particle hydrodynamics (SPH) numerical methods. Our results revealed that upon impact, both substrates underwent significant plastic deformation due to a temperature rise exceeding 60-70% of the melting point (MP), suggesting conditions for adiabatic shear instability (ASI). However, the ceramic (TiO<sub>2</sub>) particles, limited in their deformability, fragmented and became trapped within the softened substrate due to ASI in 304 SS. At higher impact velocities on soft AlMg3, the particles exhibited reduced adherence, possibly due to excessive substrate heating (beyond MP). Interestingly, the fragmented particles formed cap-shaped splats at velocities below a threshold velocity (<i>V</i><sub>th</sub>) and ring-shaped splats above <i>V</i><sub>th</sub>. This transition is attributed to the intensity of the spring-back force, favoring a ring shape at higher impact forces. The morphology changes were evident from numerical simulations analyzing critical stress, equivalent plastic strain and temperature near the particle–substrate interface. These findings, supported by potential experimental observations, provide valuable insights into the initial stages of ceramic deposition, particularly the first layer formation, which is crucial for developing metal–ceramic coatings through cold spray.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1042 - 1064"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919147","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}
Irina Tumbusova, Stanislav Dautov, Dmitry Dzhurinskiy
{"title":"A Comparative Analysis of Microstructure and Mechanical Properties of Cr3C2-NiCr Composite Coatings Deposited by APS and HVAF Techniques","authors":"Irina Tumbusova, Stanislav Dautov, Dmitry Dzhurinskiy","doi":"10.1007/s11666-024-01915-z","DOIUrl":"10.1007/s11666-024-01915-z","url":null,"abstract":"<div><p>The Cr<sub>3</sub>C<sub>2</sub>-NiCr coating is well-known for its excellent mechanical properties and high resistance to wear/oxidation at elevated temperatures, making it a desirable material for protecting industrial steel components. The quality and properties of the as-sprayed coatings depend on various factors, with the spraying technique being a primary determinant. Atmospheric plasma spraying (APS) is a commonly used method for applying the coating at an industrial scale; meanwhile, high-velocity air fuel (HVAF) spraying is a novel approach known for superior quality and properties of as-sprayed coatings. Despite the advantages of the HVAF method, APS remains the competitive method for coating deposition due to its lower production costs, versatility in applying different materials, and requirements for powder quality and size. These advantages motivate further research and development of spraying equipment/modes for APS. The primary goal of the present work is to improve the quality and competitiveness of Cr<sub>3</sub>C<sub>2</sub>-NiCr coatings applied by the APS technique utilizing the state-of-the-art Metco TriplexPro-210 gun, in comparison with HVAF as-sprayed coatings by Kermetico C7 gun. The study involves comparing the microstructure and mechanical properties of APS and HVAF as-sprayed coatings. Microstructures were analyzed using scanning electron microscopy (SEM), energy-dispersive x-ray spectroscopy (EDS), and x-ray diffraction (XRD) methods. The XRD results were discussed based on quantitative Rietveld analysis as a guide for altering the carbide content during the spraying process. The assessment of microhardness and its distribution over the coatings were evaluated using the Weibull distribution of Vickers microhardness, while the elastic modulus and plasticity index were evaluated through a depth-dependent test using a Berkovich indenter. Additionally, the tribological properties of the as-sprayed coatings were investigated through a ball-on-disk sliding wear test, measuring the coefficient of friction and wear rate to understand their performance in relation to the coating's plasticity index.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1475 - 1488"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919166","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}
Weiying Gong, Zhidan Zhou, Yongzhen Zhang, Xin Zhang, Sanming Du
{"title":"Effect of TiC on the Microstructure and Properties of FeCoNiCrMo High-Entropy Alloy Coatings by Plasma Cladding","authors":"Weiying Gong, Zhidan Zhou, Yongzhen Zhang, Xin Zhang, 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<sup>−4</sup> mm<sup>3</sup>/(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<sup>−8</sup> A/cm<sup>2</sup>), 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}
Pratidhwani Biswal, Michél Hauer, Lukas Möhrke, Andreas Gericke, Stefan Rasche, Helga Schinkel, Knuth-Michael Henkel
{"title":"Atmospheric Plasma Sprayed YSZ Coatings for Soilless Cultivation","authors":"Pratidhwani Biswal, Michél Hauer, Lukas Möhrke, Andreas Gericke, Stefan Rasche, Helga Schinkel, 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}