Journal of Thermal Spray Technology最新文献

{"title":"Prediction of Geometry-Induced Porosity in Cold Spray Additive Manufacturing of Leading Edges","authors":"Isaac M. Nault,&nbsp;Marius Ellingsen,&nbsp;Aaron Nardi","doi":"10.1007/s11666-024-01730-6","DOIUrl":"10.1007/s11666-024-01730-6","url":null,"abstract":"<div><p>In this study, a method is demonstrated for predicting defect-laden areas within deposits produced by cold spray additive manufacturing that are caused by substrate geometry and robot tool path. Leading edge shapes were used as the test bed for this method, and porosity was selected as the metric by which defects are quantified. A porosity model was developed based on the observation that porosity is significantly influenced by particle impact velocity normal to the surface and is therefore highly correlated to particle impact angle. The model outputs deposit shape and a probability map of porosity based on initial substrate geometry and robot tool path as inputs. The model was calibrated by experimental deposits formed at varying impact angles. To validate the method, the model was applied to three airfoil leading edge geometries and was shown to qualitatively estimate the density of pores in the deposit. The study also revealed that robotics alignment is an important factor in causing defects within highly curved geometries. The mathematical construct of the model is applicable to other applications outside of leading edges and deposit properties beyond porosity, but other applications and properties are not evaluated in this study.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"839 - 857"},"PeriodicalIF":3.2,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140010021","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":"Quantitative Nondestructive Evaluation of Cold Spray Manufactured Aluminum Alloy 6061 and Copper Samples","authors":"Kishore Kumar Indu Kumar,&nbsp;Mann Baijukumar Patel,&nbsp;Samuel Boese,&nbsp;Andrew Gouldstone,&nbsp;Victor K. Champagne Jr.,&nbsp;Ozan Ç. Özdemir","doi":"10.1007/s11666-024-01738-y","DOIUrl":"10.1007/s11666-024-01738-y","url":null,"abstract":"<div><p>Cold spray (CS) is a solid-state process for depositing thick layers of material via the successive high-velocity impact of powder particles onto a solid surface, which leads to high rates of deformation, interparticle bonding, and coating build-up. Although CS is finding commercial utilization in non-load-bearing repair and coating applications, clear nondestructive characterization procedures are necessary to realize its potential in load-bearing structural applications. In this study, the viability of electrical conductivity and through thickness ultrasound wave velocity measurement methods was studied to serve as a means for nondestructive quantitative measurement for quality control in CS and potentially other additive manufacturing (AM) methods. Eddy current, ultrasound, porosity, hardness, and uniaxial tensile strength tests were conducted on CS deposited layers of aluminum alloy 6061 and copper on aluminum alloy 6061 and commercially pure copper substrates, respectively. CS gas dynamic parameters were intentionally and systematically varied to result in corresponding discrete differences in mechanical properties of deposits. Ultrasound measurements of longitudinal wave velocity and eddy current electrical conductivity measurements showed good correlation with process conditions, microstructural characterization results, and destructive mechanical tests (hardness, tensile). The results of this work show that ultrasound wave velocity and electrical conductivity correlate well with increased particle impact velocity in CS deposited aluminum and copper blocks, which evidently show an incremental decrease in porosity, increase in hardness, and increase in tensile strength. The outlined ultrasound and eddy current nondestructive testing methods present effective means for quantitative assessment of cold spray deposited structures while intact with the substrate.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 2-3","pages":"688 - 704"},"PeriodicalIF":3.2,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01738-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140009690","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 Study on Flow Field Simulation and WC-12Co Multi-layer Coating Growth in High-Velocity Oxygen-Fuel (HVOF) Thermal Spraying","authors":"Chang Li,&nbsp;Siyu Li,&nbsp;Xing Han","doi":"10.1007/s11666-024-01724-4","DOIUrl":"10.1007/s11666-024-01724-4","url":null,"abstract":"<div><p>HVOF has unique advantages as spraying metal carbides and alloys and is widely used in the aerospace, national defense industry, iron and steel metallurgy, petrochemical industry and other fields. The WC-Co coating prepared by HVOF has the characteristics of low oxide content, high bonding strength, low porosity and high temperature resistance and is the most ideal surface strengthening technology to replace surface chrome plating. In this study, a three-dimensional model of HVOF spraying was established and the flame flow characteristics in the spraying were analyzed. Combined with the discrete phase model (DPM), the influence of spraying distance, particle size and O/F ratio on temperature and velocity for particle flight were revealed. Based on the birth and death unit method, a three-dimensional thermodynamic coupling model of multi-layer coating growth was established. The stress-strain law of each coating unit in the growth process of WC-12Co coating was explored. The optimal particle parameters were obtained by calculating the flow field. The calculation shows that the optimal temperature and velocity of the sprayed particles are 1402 K and 535 m/s, respectively. The temperature of each coating unit gradually increases from the center to the outer ring and decreases under the action of air cooling with the spread time. The difference of temperature is obvious between the coating and the substrate, resulting in a relatively large stress value at the junction of the two and a relatively concentrated stress between adjacent elements. The maximum tensile stress in the <i>X</i>-axis direction reaches 1908 MPa and distributes in an elliptical shape at the center position of the coating unit. The shear stress in the <i>XY</i> direction is concentrated at the edge of each element for the coating, and the maximum reaches 1285 MPa.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"1135 - 1157"},"PeriodicalIF":3.2,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140009749","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":"Scratch Adhesion Testing of Thick HVOF Thermal Sprayed Coatings","authors":"Maya M. Harfouche,&nbsp;Sima A. Alidokht,&nbsp;Alejandra Islas Encalada,&nbsp;Venkata N. V. Mungala,&nbsp;Richard R. Chromik,&nbsp;Christian Moreau,&nbsp;Navid Sharifi,&nbsp;Pantcho Stoyanov,&nbsp;Mary E. Makowiec","doi":"10.1007/s11666-024-01741-3","DOIUrl":"10.1007/s11666-024-01741-3","url":null,"abstract":"<div><p>The cohesion bond strength of two different families of HVOF coatings was evaluated by cross-sectional scratch testing at multiple loads, according to the ISO working draft (ISO/WD 27307). Diamalloy 3001 coatings with and without regions of enhanced oxidation were investigated. Stellite 6 coatings with and without Cr₃C₂ carbide phases were also observed. The effects of oxidation and composition on the cohesion bond strength of these metallic and composite HVOF coatings were analyzed. Cross-sectional scratch testing revealed to be a useful qualitative tool for comparing the cohesion strength of different thick HVOF coatings, as well as identifying their failure mechanisms and observing their relationship to the coating microstructure and composition. Indeed, in both coating families tested here, the presence of ceramic compounds was linked to a decrease in the overall cohesion strength of the coating. Cracking and/or microcracking in these brittle ceramic phases was observed and is the likely mechanism behind the lower overall cohesion strength in the coatings. Splat boundary failure occurred preferentially at heavily oxidized splat boundaries in the Diamalloy 3001 coatings. Cracking within the Cr₃C₂ phase of the Stellite 6 composite coating significantly decreased the cohesive bond strength at high scratch loads.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"1158 - 1166"},"PeriodicalIF":3.2,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140009694","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":"Promoting JTST with a “Smile!” at IMAT 2023","authors":"","doi":"10.1007/s11666-024-01749-9","DOIUrl":"10.1007/s11666-024-01749-9","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"819 - 820"},"PeriodicalIF":3.2,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140422286","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 Interfacial Structure on Microstructure and Properties of Cold-Sprayed Cu-Al2O3 Composite Coating","authors":"Peiyuan Lv,&nbsp;Min Yu,&nbsp;Kai Cao,&nbsp;Hui Chen","doi":"10.1007/s11666-024-01737-z","DOIUrl":"10.1007/s11666-024-01737-z","url":null,"abstract":"<div><p>In order to clarify effect of the interfacial structure on performance of a cold-sprayed Cu-Al₂O₃ composite coating, an annealing heat treatment was carried out to provide different interfacial structures with the as-sprayed one. In this study, effect of the interfacial structure on thermal conduction, wear, and corrosion properties was explored. Results showed that extremely fine grains were formed at the deformed Cu particle edge through continuous dynamic recrystallization during cold spraying, and the subgrain structures exhibited high dislocation density, which increased the coating microhardness, thermal resistance, and local corrosion. After being annealed, the Cu-Cu splat interfaces were healed up by sintering and the subgrains were transformed into equiaxed grains by static recrystallization. The work hardening of the deformed Cu particles was also eliminated, which led to a decrease in microhardness and mechanical bonding of the Cu-Al₂O₃ particle interface, but it promoted formation of a continuous oxide lubrication film, resulting in better wear resistance. Thus, the strengthening Cu-Cu splat interfaces, the formation of Cu equiaxed grains, and the weakened Cu-Al₂O₃ interfaces caused the superior performance of the annealed composite coating.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"912 - 930"},"PeriodicalIF":3.2,"publicationDate":"2024-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140009689","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":"Announcing the Journal of Thermal Spray Technology 2023 Editor’s Choice Selections","authors":"","doi":"10.1007/s11666-024-01739-x","DOIUrl":"10.1007/s11666-024-01739-x","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 1","pages":"1 - 2"},"PeriodicalIF":3.2,"publicationDate":"2024-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140429980","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":"Microstructure and Properties of AlCoCrFeNi2.1 Eutectic High-Entropy Alloy Coatings Fabricated by Extreme High-Speed and Conventional Laser Cladding","authors":"Jia Wang,&nbsp;Yang Li,&nbsp;Bingwen Lu,&nbsp;Jin Liu,&nbsp;Na Tan,&nbsp;Yujie Zhou,&nbsp;Yujun Cai,&nbsp;Zichuan Lu","doi":"10.1007/s11666-024-01734-2","DOIUrl":"10.1007/s11666-024-01734-2","url":null,"abstract":"<div><p>AlCoCrFeNi_2.1 eutectic high-entropy alloys (HEAs) are a new kind of alloy with high entropy and eutectic properties. Their advantages in terms of strength and shape matching can be fully exploited using extreme high-speed laser cladding (EHLA). In this paper, AlCoCrFeNi_2.1 eutectic HEA coatings were prepared by conventional laser cladding (CLA) and EHLA. The microstructures and phase compositions of the two coatings were analyzed by scanning electron microscopy, x-ray diffraction, and electron backscatter diffraction. The microhardness and wear resistance values of the coatings were tested using a microhardness tester and a friction and wear tester, respectively. The results showed that the surface qualities of both the CLA and EHLA coatings were good and had no cracks or defects. Compared with those of the CLA coating, the EHLA coating had finer grains and a more uniform distribution. Both coatings contained face-centered cubic (FCC) and body-centered cubic (BCC) phases, but the BCC phase of the EHLA coating was less precipitated than the CLA coating. The higher microhardness and better wear resistance of the EHLA coatings occurred in the presence of Hall–Petch strengthening.</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":"33 4","pages":"992 - 1005"},"PeriodicalIF":3.2,"publicationDate":"2024-02-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139951881","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":"Microstructure and Thermal Property Evolution of Plasma-Sprayed Lu2SiO5 EBCs Under High Temperature Environments","authors":"Xin Zhong,&nbsp;Ruihui Liang,&nbsp;Pingping Liu,&nbsp;Du Hong,&nbsp;Lujie Wang,&nbsp;Yaran Niu,&nbsp;Xuebin Zheng","doi":"10.1007/s11666-024-01735-1","DOIUrl":"10.1007/s11666-024-01735-1","url":null,"abstract":"<div><p>Lutetium monosilicate (Lu₂SiO₅) has been considered as environmental barrier coatings (EBCs) materials for SiC_<i>f</i>/SiC. Microstructural evolution and thermal properties changes of the Lu₂SiO₅ coating would occur in high temperature environment. In this study, Lu₂SiO₅ coating was fabricated by vacuum plasma spray technique. The microstructure, thermal stability, thermal conductivity, as well as thermal expansion behavior of the coating before and after thermal aging at 1350 °C were investigated. The tri-layer EBCs of Lu₂SiO₅/Yb₂Si₂O₇/Si were designed and prepared onto SiC_<i>f</i>/SiC substrates, and its thermal shocking behaviors were also explored. Results showed that the as-sprayed coating was mainly composed of Lu₂SiO₅, Lu₂O₃ and amorphous phases, and significant microstructural evolution, such as grain growth and defects reduction, was observed after thermal aging. The coating exhibited linear expansion, and the CTE of the coating before and after heat treatment were similar, while the thermal conductivity increased after thermal aging. Thermal shock results showed that the coating remained intact after 100 cycles, and penetrating microcracks in the Lu₂SiO₅ top layer were mostly stopped at the Lu₂SiO₅-Yb₂Si₂O₇ interface, indicating that the tri-layer EBCs on the SiC_<i>f</i>/SiC substrate had good thermal shock resistance. The thermal shock behaviors were explained based on microstructure combined with thermal stresses analysis.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 4","pages":"1220 - 1230"},"PeriodicalIF":3.2,"publicationDate":"2024-02-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139951701","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":"Microstructural Feature Extraction by a Convolutional Neural Network for Cold Spray of Aluminum Alloys","authors":"Siyu Tu,&nbsp;Phuong Vo","doi":"10.1007/s11666-024-01736-0","DOIUrl":"10.1007/s11666-024-01736-0","url":null,"abstract":"<div><p>The use of process–microstructure–property relationships for cold spray can significantly reduce application development cost and time compared to legacy trial and error strategies. However, due to the heterogeneous microstructure of a cold spray deposit, with (prior) particle boundaries outlining consolidated splats (deformed particles) in the as-spray condition, the use of automated analysis methods is challenging. In this work, we demonstrate the utility of quantitative data developed from a convolutional neural network (CNN) for feature extraction of cold spray microstructures. Specifically, the power of CNN is harnessed to automatically segment the deformed particles, which is hardly accessible at scale with traditional image processing techniques. Deposits produced with various processing conditions are evaluated with metallography. Parameters related to particle morphology such as flattening ratio are also quantified and correlated to strength.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 2-3","pages":"540 - 550"},"PeriodicalIF":3.2,"publicationDate":"2024-02-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01736-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139919919","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}