Journal of Thermal Spray Technology最新文献

{"title":"Physics-Informed Neural Networks for Predicting Particle Properties in Plasma Spraying","authors":"K. Bobzin,&nbsp;H. Heinemann,&nbsp;A. Dokhanchi","doi":"10.1007/s11666-025-01965-x","DOIUrl":"10.1007/s11666-025-01965-x","url":null,"abstract":"<div><p>Plasma spraying is a key industrial coating process that exhibits intricate nonlinear interactions among process parameters. This complexity makes accurate predictions of particle properties, which greatly affect process behavior, very challenging. Specifically, particle velocities and temperatures profoundly impact coating quality and process efficiency. Conventional methods often require empirical correlations and extensive parameter tuning due to their limited ability to capture the underlying physics within this intricate system. This study introduces physics-informed neural networks (PINNs) as a solution. By seamlessly integrating known physical laws and constraints directly into the model architecture, PINNs offer the potential to learn the underlying physics of the system. For comparison, artificial neural networks (ANNs) are also developed. Computational fluid dynamics simulations of a plasma generator and plasma jet model provide data to train both ANN and PINN models. The study reveals an improvement in particle velocity prediction through the proposed PINN model, demonstrating its capability to handle complex relationships. However, challenges arise in predicting particle temperature, warranting further investigation. The developed models can aid in optimizing the plasma spraying process by predicting essential particle properties and guiding necessary process adjustments to enhance coating quality.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"885 - 892"},"PeriodicalIF":3.2,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01965-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688290","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Cold Spraying of Mixed Metal Powders: A Modelling Framework for Predicting Deposition Efficiency and Coating Composition","authors":"Che Zhang,&nbsp;Tesfaye Molla,&nbsp;Christian Brandl,&nbsp;Jarrod Watts,&nbsp;Rick McCully,&nbsp;Caixian Tang,&nbsp;Graham Schaffer","doi":"10.1007/s11666-025-01967-9","DOIUrl":"10.1007/s11666-025-01967-9","url":null,"abstract":"<div><p>Cold spraying (CS) of composite coatings produced from mixed metal powders can exhibit enhanced functional properties over coatings made from pure metals. However, controlling the deposition efficiency and the resulting microstructure during CS is challenging due to interactions between different materials. In this study, we developed a modelling framework to predict the deposition efficiency (DE) of mixed metal powders and the resultant coating composition. This is achieved by predicting the critical and impact velocities as a function of particle size, which allows determination of the DEs of both matched (A/A or B/B) and mismatched (A/B or B/A) particle/substrate combinations. These DEs are then used to determine the overall DE of the composite coating and its composition by using a layer-wise deposition model. The modelling framework is validated by performing several CS experiments using Cu and Al particles together with SEM image analyses of the coating microstructures. We find that in-flight interaction of particles of different masses has a significant effect on the impact velocity and hence DE of composite coatings. By effectively predicting DE and coating composition, the proposed model serves as a valuable tool for optimizing cold spray parameters, reducing trial-and-error costs and time, and accelerating the development of novel composite coatings with enhanced properties.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1133 - 1146"},"PeriodicalIF":3.2,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01967-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919244","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":"Repair of Single-Crystal CMSX-4 Using the High Velocity Air Fuel Process","authors":"M. Létang,&nbsp;S. Björklund,&nbsp;S. Joshi,&nbsp;D. Sebold,&nbsp;O. Guillon,&nbsp;R. Vaßen","doi":"10.1007/s11666-025-01944-2","DOIUrl":"10.1007/s11666-025-01944-2","url":null,"abstract":"<div><p>Turbine blades in aircraft engines and land-based gas turbines are exposed to harsh environmental conditions that make them susceptible to degradation mechanisms, such as creep, oxidation, and fatigue damage. Therefore, research into effective repair methods is of high importance, especially for single crystal components, as they are cost-intensive to produce. The HVAF process is suitable for repair applications as it can produce dense layers with low oxygen content, which are essential for the repaired area. Additionally, the fine grain structure is advantageous for the subsequent directional recrystallization planned in future studies, aiming to transform the repair layer into a columnar or even single-crystal structure. This study focuses on applying CMSX-4 powder to single crystal substrates of similar composition using High Velocity Air Fuel Spraying (HVAF). Specifically, the effects of powder particle size, nozzle configuration, and various other process parameters, such as spray distance and carrier gas flow, on the characteristics of HVAF-deposited CMSX-4 were investigated. The microstructure was examined by scanning electron microscopy. Particle velocity and temperature measurements were performed to enhance comprehension of the process.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1489 - 1506"},"PeriodicalIF":3.2,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01944-2.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919246","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":"Microstructure and Wear Resistance of WC-Ni/Al Coatings by Cold Spray Using WC Particle Electroplated Ni layer","authors":"Taoding Liang,&nbsp;Chunzhi Gong,&nbsp;Changzhuang Zhou,&nbsp;Yuan Liu,&nbsp;Qiming Liu,&nbsp;Yue Wang,&nbsp;Chunjin Hang,&nbsp;Xiubo Tian","doi":"10.1007/s11666-025-01961-1","DOIUrl":"10.1007/s11666-025-01961-1","url":null,"abstract":"<div><p>In recent years, the demand for lightweight, high-strength metal materials has increased dramatically, and aluminum matrix composites have many advantages that have attracted attention. In this study, Ni layer was electroplated on the surface of tungsten carbide particles, core-shell tungsten carbide particle-reinforced aluminum matrix composite coating was prepared on the surface of ZE41 magnesium alloy by cold spraying, the microstructure, friction and wear characteristics of the two composite coatings are also discussed. The results show that the WC-Ni/Al composite coating has a dense microstructure, the gaps and pores are significantly reduced and the particle distribution is significantly improved. Compared with the WC/Al composite coating, the hardness of the WC-Ni/Al composite coating (89.64 HV) increased by 43.06%, the coefficient of friction (0.39) decreased by 9.56% and the wear amount (0.141 mm³/N·m) decreased by 23.37%. The results show the desirability of strengthening the joint interface by treating the WC with a prefabricated Ni layer, and provide a new strategy for cold spraying to prepare highly wear resistant composite coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1316 - 1328"},"PeriodicalIF":3.2,"publicationDate":"2025-02-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918967","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 Different Laser Powers on the Structure and Properties of In Situ TiC-Enhanced Ni-Based Coatings","authors":"Dongdong Zhang,&nbsp;Haozhe Li,&nbsp;Jingyu Jiang,&nbsp;Yali Gao,&nbsp;Yu Liu","doi":"10.1007/s11666-025-01963-z","DOIUrl":"10.1007/s11666-025-01963-z","url":null,"abstract":"<div><p>In situ TiC-enhanced Ni-based coating was prepared on the surface of 45 steel by laser cladding technology, the effects of different laser powers on the phase component, microstructure, microhardness and wear resistance of the coating were systematically investigated. The results show that the coating phase component contains TiC, CrB, Ni₃B, M₂₃C₆, M₇C₃ and Fe-Ni solid solutions at different laser powers. As the laser power increases, the microstructure changes from coarse columnar and dendritic crystals to finer columnar and dendritic crystals. After evaluating the microhardness of the samples with different laser powers, the highest microhardness of the composite coating was obtained at a laser power of 1600 W, which was 401.4 HV. Friction wear results revealed that the wear rate of the coating decreased with increasing laser power, and the wear rate was minimized at 1600 W, showing excellent wear resistance. This is attributed to the diffuse strengthening and grain refinement of the hard phase, which improves the hardness and wear resistance of the coating.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1208 - 1219"},"PeriodicalIF":3.2,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918962","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":"Analysis of the t′ + c Phase Content from ZrO2-16 Mol.% Y2O3-16 Mol.% Ta2O5 Mechanoactivated Powder Mixtures in Coatings Deposited by Suspension Plasma Spraying","authors":"Catalina Galeano-Camacho,&nbsp;Iván Bedoya-Trujillo,&nbsp;Sebastián Pérez,&nbsp;Hélène Ageorges,&nbsp;Juan Muñoz-Saldaña","doi":"10.1007/s11666-025-01946-0","DOIUrl":"10.1007/s11666-025-01946-0","url":null,"abstract":"<div><p>Gas turbines or power generation engines used in transportation, defense, and energy sectors use thermal barrier coatings (TBCs) to protect metallic components exposed to high-temperature conditions. This work focuses on the in situ synthesis during coating deposition by suspension plasma spraying (SPS) from powders mechanoactivated by high-energy ball milling of ZrO₂-16 mol.% YO_1.5-16 mol.% TaO_2.5 (16YTZ) for applications in TBCs. This composition is expected to present a non-transformable tetragonal phase (<i>t′</i> phase), suitable to overcome the thermodynamic limits of the mostly used conventional 6-8 wt.% yttria stabilized zirconia (YSZ). The 16YTZ powder mixtures were mechanoactivated by either planetary ball milling (240 RPM) and high-energy ball milling (1700 RPM). These mechanoactivated powders were used to obtain densified samples through sintering at 1500 °C for 2 and 20 h, as well as to deposit coatings by SPS at a stand-off distance between 60 and 80 mm using Ar/He as the plasma forming gas. The ceramics and coatings were characterized by XRD, SEM, and Raman spectroscopy. The densified ceramics showed a high <i>t′</i> phase content, i.e., &gt; 98% of the 16YTZ system, with an average tetragonality of 1.0267. Coatings deposited at a stand-off distance of 60 mm, and a deposition rate of 33 µm/min, present a porosity of less than 5%, and a tetragonality of 1.0187, which is higher than that of standard YSZ coatings. Phase quantification by Rietveld refinement revealed a multiphase condition as result of the heat transfer in the plasma plume leading to in situ synthesis of the ZrO₂ base solid solutions, formed by 89.2 wt.% of <i>t′ + c</i> phases (48.4 and 40.8 wt.% of <i>t′</i> and<i> c-</i>ZrO₂, respectively<i>)</i> 8.1% monoclinic ZrO₂, 2.4% cubic Y₂O₃ and 0.4% orthorhombic Ta₂O₅ on average. Achieving a high percentage of <i>t' + c</i> phases in the coating with a porosity of less than 5% is a significant accomplishment. This success is closely linked to the fact that tetragonality exceeds that of YSZ. These results provide a solid foundation for future experimental designs aimed at optimizing spray parameters.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"783 - 794"},"PeriodicalIF":3.2,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01946-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688389","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the Interaction between Corrosion and Sliding Wear of Thermal Spraying WC-10Co4Cr Coating","authors":"Xu Fei,&nbsp;Zou Yunhe,&nbsp;Wang Jian,&nbsp;Tan Yong,&nbsp;Sun Jie","doi":"10.1007/s11666-025-01960-2","DOIUrl":"10.1007/s11666-025-01960-2","url":null,"abstract":"<div><p>WC coatings applied in special environments, such as marine environments, suffer from both corrosion and wear damage. During equipment operation, the coating is primarily affected by wear, while during idle periods, corrosion dominates. Therefore, understanding the interaction between corrosion resistance and wear behavior of WC coatings is critical. In this study, WC-10Co4Cr coating was prepared by high-velocity oxy-fuel (HVOF) spraying method, and the effects of wear after corrosion and corrosion after wear were investigated. The study focused on the interaction between corrosion and wear of WC-10Co4Cr coating in marine environment. The results showed that, after wear, the WC-10Co4Cr coating exhibited a more positive corrosion potential due to the oxide of Cr and the wear products. The corrosion rate of WC-10Co4Cr coating decreased after wearing. The corrosion rate of WC-10Co4Cr coating decreased by up to 94.62%. Furthermore, the friction coefficient of the WC-10Co4Cr coating was lower after corrosion due to the formation of corrosion products, which led to a reduction in wear rate by up to 80.52%. The wear morphology of the high hardness WC-10Co4Cr coating after corrosion was smoother and flatter. The experiment results indicated that corrosion and wear in WC-10Co4Cr coating showed a mutual inhibitory antagonistic effect, in which wear contributed significantly to material loss rate, playing a major role in the coating failure process.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1269 - 1280"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919143","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":"The Microstructure and Performance of Metal Based Abradable Sealing Coatings Based on Peeling Medium Particle Structure Design","authors":"Dan Guo,&nbsp;Jianming Liu,&nbsp;Tong Liu,&nbsp;Chao Wu","doi":"10.1007/s11666-025-01964-y","DOIUrl":"10.1007/s11666-025-01964-y","url":null,"abstract":"<div><p>To address the issue of inadequate abradability in existing metal-based coatings, which fall short of meeting the demands of harsh operational conditions, this article introduces the design of two novel metal-based abradable sealing coating materials. These materials are founded on the unique particle structure of the “peeling medium”. The article delves into the fundamental properties and performance under simulated working conditions of these coatings. The “peeling medium” structure refers to the powder structure design, where lubricating phases such as hBN are uniformly coated around metal particles. The experimental conditions under which the coatings were tested included a 1000-hour heat exposure test at high-temperatures. This rigorous testing regime was designed to assess the coatings’ durability and performance under long-term, high-temperature service environments. The primary results of the research revealed that both coatings maintained impressive hardness, bonding strength, and abradability after the heat exposure test. Crucially, these coatings were observed to fracture precisely at the exposed abradable components, demonstrating their ability to maintain the required abradability and excellent thermal stability. The “peeling medium” particle structure design ensures that the coatings can fracture in a controlled manner, preserving their functionality and durability in harsh environments.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"866 - 874"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688450","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization of Cored Wire Arc Spraying of Amorphous FeCrNiSiWNbB Coating; Hot-Corrosion and High-Temperature Erosion Evaluations","authors":"E. Bahrami,&nbsp;M. Khodaei","doi":"10.1007/s11666-025-01958-w","DOIUrl":"10.1007/s11666-025-01958-w","url":null,"abstract":"<div><p>Protective coatings are the most common solution to prevent high-temperature erosion, oxidation and especially hot corrosion of boiler tubes. One of the best protective coatings for boiler tubes is amorphous/nanocrystalline coatings, which can be deposited by different thermal spray methods especially via arc spraying as a low-cost and portable method. The aim of this study is the fabrication and characterization of Fe-based amorphous/nanocrystalline coating designed for boiler tube via the low-cost FeCrNiSiWNbB cored wire using the ferroalloy powders. This work was focused on the reducing of the porosity of coatings by optimization of the arc spraying parameters using Taguchi design of experiment, which was verified by microhardness measurements and metallography experiments. The microstructure, composition and phase constitution of the optimized coating were characterized by scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and selected area electron diffraction techniques. The erosion resistance and hot corrosion behavior of the modified coating were investigated by high-temperature erosion and hot corrosion (type II) tests, respectively. It was found that optimal FeCrNiSiWNbB coating represents a significantly higher hot corrosion resistance rate, 92, and 86% increase in comparison to carbon steel substrate and pure Fe coating, at 600 °C. Additionally, the high-temperature erosion resistance rate of optimized FeCrNiSiWNbB coating enhanced 26, and 14% at 600 °C in comparison to the pure Fe coating and plain carbon steel substrate respectively.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1368 - 1383"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919120","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":"Cold Spray Using a Phase-Change Propellant Fluid Approach: Proof of Concept and Potential Benefits","authors":"Aleksandra Nastic,&nbsp;Meisheng Xu,&nbsp;Wenzhuo Yan,&nbsp;Bruce Daniels,&nbsp;Mohan Vijay,&nbsp;Mohammed Yandouzi,&nbsp;Patrick Richer,&nbsp;Bertrand Jodoin","doi":"10.1007/s11666-025-01930-8","DOIUrl":"10.1007/s11666-025-01930-8","url":null,"abstract":"<div><p>Cold spray (CS) has captured the interest of many researchers, scientists and industries resulting in significant development of the technology in the last decade. The process is shifting from fundamental studies to industrial application developments for mass production, with great potential in fields such as energy, electronics, biomedical, aerospace and semiconductor. However, besides the recent developments, improvements and deployment of the technology, CS has been mostly limited to the use of nitrogen and/or air. One potential improvement for the technology is to operate with a phase-changing driving/propellant gas, such as steam. While it is known that steam inherently provides better gas dynamic properties than nitrogen, using it while inducing phase-change, relying on the occurrence of condensation to increase the gas and particle temperature through the release of large latent heat energy, could improve performance and efficiency of the CS technology.To demonstrate this benefit of phase-changing propellant gas and its potential to bring a substantial breakthrough in the field, the current study compares deposition characteristics, i.e., porosity, microhardness, oxygen content and adhesion, of coatings generated using steam and nitrogen across the same CS system and operating parameters. A validated non-equilibrium steam computational fluid dynamics model is developed to describe the fundamentals of condensing water droplets’ influence on flow and feedstock particle condition. A finite element model is included to conceptualize the effect of steam and nitrogen flow on copper particle interfacial deformation upon impact.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1109 - 1132"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919144","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}