Bowen Dai, Li Zhang, Shengli Li, Houlin Ning, Zhiwen Xie
{"title":"Multicarbide Evolution and High-Temperature Failure Mechanisms of Non-spherical WC-Reinforced Ni-Based Coatings","authors":"Bowen Dai, Li Zhang, Shengli Li, Houlin Ning, Zhiwen Xie","doi":"10.1007/s11666-026-02310-6","DOIUrl":"10.1007/s11666-026-02310-6","url":null,"abstract":"<div><p>The service life of hot-rolling descaling rollers is severely limited by premature failure under synergistic high-temperature friction, wear, and alternating loads. Herein, non-spherical WC particles replaced conventional spherical WC to fabricate Ni-based composite coatings via plasma arc surfacing, so as to reveal the regulation mechanism of WC dosage on multicarbide evolution and high-temperature failure mechanisms. With WC contents of 30-65 wt.%, the microstructure transformed from sparse carbide dispersion to uniform multiphase refinement and ultimately to brittle coarse carbide networks. The results confirm that WC content below 45 wt.% optimizes carbide distribution and refines microstructure. The optimized coating acquires a refined grain size of 27.1 <i>μ</i>m, high microhardness of 827 ± 3 HV<sub>1.0</sub>, and a low wear rate of (3.719 ± 0.4) × 10<sup>−6</sup> mm<sup>3</sup>/N m at 400 °C, maintaining excellent strength–ductility balance and better high-temperature performance than high-WC counterparts. Fine-grain strengthening, dense oxide films, and strong interfacial bonding jointly inhibit oxidative–adhesive wear and crack propagation. This study clarifies the linkage of non-spherical WC content, multicarbide evolution, and high-temperature performance, guiding high-performance wear-resistant coatings for hot-rolling components.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3347 - 3365"},"PeriodicalIF":3.4,"publicationDate":"2026-08-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309528","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}
Yixin Xie, Shan Gao, Bingwen Zhou, Yunfeng Liu, Bin Ya, Linggang Meng, Xingguo Zhang
{"title":"Enhancement of Corrosion Resistance, Hardness, and Fracture Toughness in WC10Co4Cr Coating by TiN-TiC Reinforcement","authors":"Yixin Xie, Shan Gao, Bingwen Zhou, Yunfeng Liu, Bin Ya, Linggang Meng, Xingguo Zhang","doi":"10.1007/s11666-026-02300-8","DOIUrl":"10.1007/s11666-026-02300-8","url":null,"abstract":"<div><p>In this study, WC-10Co-4Cr composite coatings with various TiC contents (0, 5, and 10 wt.%) and TiN additions were fabricated via high-velocity air-fuel (HVAF) spraying. The influence of TiC particle size (1 and 5 μm) on the mechanical properties and corrosion resistance of these coatings was systematically investigated. The results indicate that incorporating the TiN/TiC composite reinforcing phase reduces coating porosity more effectively than TiN alone. The coating with 5 wt.% 1 <i>μ</i>m TiC delivered the most balanced performance in 3.5 wt.% NaCl solution, reaching a microhardness of 1640 HV<sub>0.3</sub>, a fracture toughness of 6.19 MPa m<sup>1/2</sup>, and a corrosion current density of 9.60 × 10<sup>−8</sup> A cm<sup>−2</sup>. In NaOH solution, the coating containing 10 wt.% 1 <i>μ</i>m TiC performed best due to the excellent alkali corrosion resistance of TiC, showing a corrosion current density of only 1.21 × 10<sup>−7</sup> A cm<sup>−2</sup>. This work provides valuable experimental insights for designing WC-based composite coatings that offer both superior mechanical properties and high corrosion resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3289 - 3305"},"PeriodicalIF":3.4,"publicationDate":"2026-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309700","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}
Xingdong Chen, Jiaye Geng, Yanhai Cheng, Jinwen Deng
{"title":"Nano-TiO2 Regulation on High-Temperature Tribological Properties of Laser-Cladded Stellite31 Coatings for Steam Turbine Valve Stems","authors":"Xingdong Chen, Jiaye Geng, Yanhai Cheng, Jinwen Deng","doi":"10.1007/s11666-026-02302-6","DOIUrl":"10.1007/s11666-026-02302-6","url":null,"abstract":"<div><p>Steam turbine valve stems are subjected to the coupled effects of high-temperature oxidation, thermal fatigue stress, and high-temperature wear during start-stop cycles and long-term service, which severely restricts their service reliability and service life. To achieve efficient surface strengthening and performance improvement of valve stems, in this study, nano-TiO<sub>2</sub>-reinforced cobalt-based alloy composite coatings were fabricated on GH901 high-temperature superalloy substrates via laser cladding, and the influence laws of the modified coatings on microstructural evolution, microhardness, and high-temperature tribological properties were systematically investigated. The results show that the introduction of nano-TiO<sub>2</sub> can effectively regulate the microstructure and mechanical properties of the coatings and significantly refine the coating grains. The maximum microhardness of the coatings is increased by 39.1% compared with the substrate, and the maximum reduction in wear rate reaches 76.48%. This is attributed to the fact that the addition of nano-TiO<sub>2</sub> promotes the formation of a continuous and dense high-temperature oxide film on the coating surface, while the second-phase particles can effectively bear the friction load and exert a synergistic strengthening effect. This study confirms that optimizing the content of nano-TiO<sub>2</sub> to regulate the coating microstructure can achieve the synergy of multiple strengthening mechanisms, significantly improve the microhardness and high-temperature wear resistance of the coatings, and can provide feasible technical support and theoretical basis for the surface strengthening modification of key high-temperature alloy components.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3049 - 3072"},"PeriodicalIF":3.4,"publicationDate":"2026-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310053","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":"Corrosion and Abrasion Resistance of Titanium, Copper and Inconel 625 Cold Spray Coatings","authors":"Christian Doblin, Paul A. White","doi":"10.1007/s11666-026-02266-7","DOIUrl":"10.1007/s11666-026-02266-7","url":null,"abstract":"<div><p>Cold spray deposition was investigated as a candidate technology for producing corrosion- and abrasion-resistant coatings for deep borehole nuclear waste disposal canisters. Commercially pure grade 2 Ti, Cu, Cu-1 wt.% alumina and Inconel 625 were deposited on AISI C1020 steel with thicknesses between 0.9 and 3.2 mm. Coating adhesion to steel was generally poor under nitrogen propellant but improved when the initial layer was deposited using helium. All coatings exhibited residual porosity. Post-spray heat treatments were applied to reduce open porosity: laser glazing for Ti and Inconel 625 and furnace heat treatment (350 °C, 1 h in air) for the Cu-based coatings. Laser treatment significantly refined the microstructure and reduced open porosity in the Ti coatings. Electrochemical testing in 0.1 M NaCl confirmed that corrosion resistance increased markedly with coating thickness and was substantially higher for Ti and Inconel 625 than for the Cu-based coatings. Furnace heat treatment enhanced corrosion resistance by approximately one order of magnitude, whereas laser glazing improved performance by roughly two orders of magnitude. Abrasion resistance (ASTM G65-00) decreased in the order: Inconel 625 > > Cu + alumina ≈ Cu > CP2-Ti. Laser glazing improved the abrasion resistance of Ti by ~ 70%, surpassing Cu + alumina, whereas heat treatments had minimal influence on the other materials. Microhardness increased significantly after cold spray due to severe plastic deformation and was partially restored toward feedstock values after heat exposure for Cu-based and Inconel 625 coatings. Laser glazing nearly doubled the hardness of Ti owing to surface TiN formation. These results emphasize the critical role of eliminating open porosity to achieve high corrosion resistance in cold-sprayed coatings, while also identifying strategies for improving abrasion resistance in coatings intended for deep borehole disposal applications.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"2909 - 2924"},"PeriodicalIF":3.4,"publicationDate":"2026-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02266-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310054","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}
Zi-Yang Chen, Xin Zhang, Yan-Neng Liang, Chang-jiu Li, Cheng-Xin Li
{"title":"Metal-Particle-Modified LSCF Current Collector Layers Fabricated by Atmospheric Plasma Spraying for High-Power Tubular Segmented-in-Series SOFCs","authors":"Zi-Yang Chen, Xin Zhang, Yan-Neng Liang, Chang-jiu Li, Cheng-Xin Li","doi":"10.1007/s11666-026-02273-8","DOIUrl":"10.1007/s11666-026-02273-8","url":null,"abstract":"<div><p>La<sub>0</sub>.<sub>6</sub>Sr<sub>0</sub>.<sub>4</sub>Co<sub>0</sub>.<sub>2</sub>Fe<sub>0</sub>.<sub>8</sub>O<sub>3−δ</sub> (LSCF) has been widely employed as a cathode and current collector material for tubular segmented-in-series solid oxide fuel cells (Tubular-SIS-SOFCs), yet plasma-sprayed LSCF current collector layers (CCLs) often suffer from insufficient gas permeability and performance degradation caused by B-site element evaporation in high-temperature plasma jets, while conventional noble-metal current collectors increase cost and compromise long-term stability. In this work, a composite strategy was developed by incorporating transition-metal particles into LSCF feedstock via atmospheric plasma spraying (APS) to construct a noble-metal-free ceramic CCL. Due to poor wettability between overheated metal droplets and LSCF splats, metallic particles solidified in a dispersed morphology within the coating. During subsequent heat treatment, in situ oxidation-induced volumetric expansion of metal particles promoted controlled crack propagation, enhancing gas diffusion pathways, while thermally driven metal-ion diffusion partially compensated B-site depletion and restored lattice conductivity. Systematic investigation revealed that the LSCF-5Fe coating fabricated at 25 kW achieved an optimal balance between gas permeability, mechanical integrity, and electrical conductivity. Among different metals, LSCF-5Cu exhibited the highest post-treatment conductivity of 100.5 S cm<sup>−1</sup>. Tubular-SIS-SOFCs employing metal-particle-modified LSCF CCLs delivered over 50% higher maximum power output compared with pure LSCF counterparts, accompanied by significantly reduced polarization resistance and stable thermal cycling performance. These results demonstrate a scalable and cost-effective strategy for replacing noble-metal current collectors and enabling high-power tubular-SIS-SOFCs.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3331 - 3346"},"PeriodicalIF":3.4,"publicationDate":"2026-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309955","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":"Fabrication of Low-Friction Cu-Based Composite Coatings Using WS2@(Cu2O/Cu) Core–Shell Powders and Their Tribofilm Formation Mechanism","authors":"Bolong Han, Yuxin Liang, Yiying Li, Yuhang Shi, Hongtao Liu, Xiaowei Li, Jianghao Qiao","doi":"10.1007/s11666-026-02298-z","DOIUrl":"10.1007/s11666-026-02298-z","url":null,"abstract":"<div><p>To address the thermal decomposition of WS<sub>2</sub> during thermal spraying and enhance the solid lubrication performance of WS<sub>2</sub>-containing coatings, this study prepared WS<sub>2</sub>@(Cu<sub>2</sub>O/Cu) core–shell powders via a facile chemical replacement method. These powders were then blended with Cu powder to fabricate Cu/WS<sub>2</sub>/Cu<sub>2</sub>O composite coatings using atmospheric plasma spraying. Quantitative XRD analysis showed that compared with the directly mixed Cu/WS<sub>2</sub> powder, the core–shell powder effectively reduced both the loss and decomposition rates of WS<sub>2</sub> during plasma spraying. At 15 wt.% WS<sub>2</sub> in raw powders, the WS<sub>2</sub> loss rate decreased from 87.1 to 71.2%, and the WS<sub>2</sub> decomposition rate dropped from 42.3 to 28.1%. Reciprocating ball-on-disk wear tests demonstrated significantly improved tribological properties of this coating. Under a 20 N load, its coefficient of friction (COF = 0.09) was 39% and the wear rate was 17% of the coating prepared with mixed Cu/WS<sub>2</sub> powders, respectively. XPS and EDS analyses revealed that a Cu<sub>2</sub>O tribofilm formed on the surface of the copper-based coating during friction. The Cu<sub>2</sub>O nanoparticles and WS<sub>2</sub> in the core–shell powder promoted the formation of a more continuous and homogeneous lubricating film—mainly composed of Cu<sub>2</sub>O and WS<sub>x</sub>O<sub>y</sub>—which accounted for the coating’s superior tribological performance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3381 - 3395"},"PeriodicalIF":3.4,"publicationDate":"2026-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309954","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":"Multi-Objective Optimization of Ultrasonic Vibration-Assisted Laser Cladding Process for Inconel 625 via Tent-SSA-BP and NSGA-II","authors":"Yangshu Liu, Yongjun Shi, Shuyao Wang, Kaijun Fan, Zhaojian Li, Quan Li, Jinshuo Zhang","doi":"10.1007/s11666-026-02296-1","DOIUrl":"10.1007/s11666-026-02296-1","url":null,"abstract":"<div><p>Ultrasonic vibration-assisted laser cladding of Inconel 625 coatings shows great application potential; however, the quality and performance of the resulting coatings are highly dependent on specific process parameters. This study aims to fabricate high-performance Inconel 625 coatings by ultrasonic vibration-assisted laser cladding, with laser power, scanning speed, powder feeding rate, and ultrasonic amplitude optimized to achieve low dilution, an appropriate aspect ratio, and high microhardness. Orthogonal experiments were conducted to analyze the effects of process parameters. On this basis, a Tent-SSA-BP prediction model was established to describe the relationship between process parameters and coating performance, and the NSGA-II algorithm was combined for multi-objective optimization, with the optimization results experimentally validated. Finally, Inconel 625 coatings were fabricated by ultrasonic vibration-assisted laser cladding using the optimized parameters and an appropriate overlap rate, and their microstructure, microhardness, and wear performance were characterized. The results show that scanning speed mainly affects dilution rate and microhardness, while laser power predominantly influences the aspect ratio. The Tent-SSA-BP model demonstrated high prediction accuracy for all three outputs. NSGA-II optimization determined the optimal parameters as a laser power of 868.29 W, scanning speed of 3.30 mm/s, powder feeding rate of 8.01 g/min, and ultrasonic amplitude of 17.83 <i>μ</i>m, with predicted dilution rate, aspect ratio, and microhardness of 43.02%, 3.04, and 210.36 HV, respectively. Compared with the coating fabricated without ultrasonic vibration, the optimized ultrasonic vibration-assisted coating exhibited refined grains, higher microhardness of 222-231 HV, a lower average friction coefficient of 0.597, and good metallurgical bonding. This study provides an effective strategy for process prediction and optimization in ultrasonic vibration-assisted laser cladding of Inconel 625 coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3030 - 3048"},"PeriodicalIF":3.4,"publicationDate":"2026-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309885","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 Evolution and Tribological Performance of Fe-Based Amorphous Coatings via Wide-Beam Laser Cladding: Role of Powder Feed Rate","authors":"Yiqi Wang, Zequn Zhang, Zeyang Zhang, Xingmei Zhang, Qun Zhang","doi":"10.1007/s11666-026-02304-4","DOIUrl":"10.1007/s11666-026-02304-4","url":null,"abstract":"<div><p>Fe-based amorphous coatings are widely used in petrochemical, mining, and power generation industries due to their excellent wear and corrosion resistance derived from the unique amorphous structure. Therefore, wide-beam laser cladding was employed to investigate the role of powder feed rate on microstructure and wear performance. The coatings exhibited amorphous–crystalline composite structure, with the amorphous phase content increasing then decreasing as the feed rate increased, peaking at about 72% at 0.8 rpm (3.2 g/min). This condition produced a gradient microstructure with a uniform interfacial layer and finely dispersed hard particles, achieving a peak hardness of 928.7 HV<sub>0.2</sub> and a specific wear rate of 6.26 × 10<sup>−7</sup> mm<sup>3</sup>/N·m by forming a protective oxide tribolayer. Lower or higher feed rates instead led to coarse crystalline growth or defects, triggering severe abrasive or brittle wear. The wear resistance arises from a synergistic strengthening–toughening mechanism: The hard amorphous matrix and dispersed crystalline phases support a stable protective tribolayer during sliding.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3008 - 3029"},"PeriodicalIF":3.4,"publicationDate":"2026-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309964","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 CMAS-Filled Pore Morphology on Thermomechanical Behavior of Thermal Barrier Coatings","authors":"Zhimin Yao, Wangzhuo Hu, Yining Li, Ranxing Leng","doi":"10.1007/s11666-026-02305-3","DOIUrl":"10.1007/s11666-026-02305-3","url":null,"abstract":"<div><p>Corrosion failure induced by molten CaO-MgO-Al<sub>2</sub>O<sub>3</sub>-SiO<sub>2</sub> (CMAS) infiltration critically limits thermal barrier coatings (TBCs) durability. This study develops a finite element model incorporating CMAS penetration into the ceramic layer to investigate how the morphology and size of CMAS-filled pores affect thermomechanical behavior. The results show that larger aspect ratios promote smoother heat conduction and reduce peak heat flux from 3 to 2.4 W/mm<sup>2</sup>, while stress concentration at pore tips intensifies with <i>S</i><sub>max</sub> reaching 155 MPa. Under smaller aspect ratios, the shear stress exhibits significant fluctuations, with peak values approaching 120 MPa. Enlarged circular pores induce localized heat flux concentration, whereas elliptical pores cause stronger <i>S</i><sub>max</sub> fluctuations, increasing by 35.4%. For the sinusoidal CMAS–ceramic interface, circular pores yield higher interfacial stress and greater crack susceptibility than elliptical ones. This work provides significant theoretical insights into the influence of CMAS-filled pore morphology on the thermomechanical performance of TBCs.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"3196 - 3216"},"PeriodicalIF":3.4,"publicationDate":"2026-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149309966","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":"Comparative Evaluation of Cold-Sprayed and Electroplated Copper Coatings: Enhanced Performance Characteristics and an Alternative Copper Coating Approach","authors":"Tianxiao Tian, Yaxin Xu, Cong Wang, Wenya Li, Shuo Fu, Chaochao Zhao, Shuai Geng","doi":"10.1007/s11666-026-02294-3","DOIUrl":"10.1007/s11666-026-02294-3","url":null,"abstract":"<div><p>To clarify performance differences between cold-sprayed copper coatings (CS-Cu) and electroplated copper coatings (EP-Cu), and optimize the cold spray process for efficient fabrication of high-performance Cu coatings, this study investigated the effects of spray gas temperature/pressure, spray distance, and gun traverse speed on the microstructure and properties of CS-Cu on AA6061 substrate via orthogonal experiments, and systematically compared the optimized CS-Cu with the EP-Cu. Optimization results showed that CS-Cu at specific parameters achieved optimal comprehensive performance, featuring low porosity, high hardness, and strong bonding strength. Microstructurally, CS-Cu was thicker and denser than EP-Cu, and was free of obvious interfacial. Mechanically, CS-Cu outperformed EP-Cu in elastic modulus and hardness. Wear tests revealed that CS-Cu had a lower steady-state friction coefficient and smaller wear volume (dominant abrasive wear), whereas EP-Cu exhibited inferior wear resistance and complex mechanisms due to weak interfacial bonding. CS-Cu also exhibited superior corrosion resistance, characterized by a self-corrosion current density of approximately 44% that of EP-Cu. In conclusion, optimized cold spray parameters produce dense, high-performance Cu coatings offering theoretical and experimental support for replacing electroplating in high-performance coating fabrication.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 7","pages":"2889 - 2908"},"PeriodicalIF":3.4,"publicationDate":"2026-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149310701","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}