Journal of Thermal Spray Technology最新文献

{"title":"Nozzle Geometry Evaluation for Cold Spray Applications by Using 3D-CFD Calculations","authors":"J. Gutiérrez de Frutos,&nbsp;A. List,&nbsp;S. Nielsen,&nbsp;F. Gärtner,&nbsp;T. Klassen","doi":"10.1007/s11666-025-01945-1","DOIUrl":"10.1007/s11666-025-01945-1","url":null,"abstract":"<div><p>In cold spray applications, optimum process conditions to accelerate particles may vary with different densities of the feedstock. These conditions could depend on the geometry of the spray nozzle, suggesting possible benefits of material-specific nozzle designs. The present study developed a nozzle geometry optimization concept based on three-dimensional computational fluid dynamics (3D-CFD) simulations to provide a specific nozzle design. Applying a design of experiments (DoE) approach, the proposed model seeks an optimal nozzle geometry, using aluminum Al6061 and pure copper with mean particle diameters of 40 µm as examples. Different geometry parameters were varied to reach the highest particle velocities before impact on the substrate, such as the nozzle’s divergent section length, throat cross section, and expansion ratio. The process gas was nitrogen with set stagnation pressure and temperature of 5 MPa and 500 °C, respectively. For high particle impact velocities, the simulation identified the divergent section length as the most influential parameter, followed by the throat cross section. In addition, the results show that the expansion ratio must be carefully tuned to avoid over-expansion of the gas already inside the nozzle, which is detrimental to the particle acceleration.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"570 - 586"},"PeriodicalIF":3.2,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01945-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688371","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 Microstructure and Corrosion Resistance of Inconel 718 Coating by Plasma-Enhanced High-Velocity Arc Spraying","authors":"Hanbing Zhang,&nbsp;Weiwei Liu,&nbsp;Ming Liu,&nbsp;Rui Gao,&nbsp;Baodan Zhang,&nbsp;Shuying Chen,&nbsp;Guozheng Ma,&nbsp;Haidou Wang","doi":"10.1007/s11666-025-01941-5","DOIUrl":"10.1007/s11666-025-01941-5","url":null,"abstract":"<div><p>The study aimed to investigate the effect of spraying distance on the microstructure and corrosion resistance of Inconel 718 coatings applied using the plasma-enhanced high-velocity arc spraying (PEHAS) technique, especially under the influence of hydrogen plasma gas. For this purpose, the coatings were produced at four different spraying distances: 100, 150, 180, and 200 mm, and the samples obtained were referred to as SA, SB, SC, and SD, respectively. In addition, the microstructure and phase composition of the coatings were investigated, as well as the corrosion behavior of the coatings when immersed for 0-168 h in a 3.5% wt.% NaCl solution. It was determined that the Inconel 718 coatings consisted mainly of Ni-Cr-Fe solid solutions with small amounts of oxides (NiO, Fe₂O₃, Cr₂O₃, Nb₂O₅). The oxide content within the coatings increased with greater spraying distances. Sample SC featured the lowest porosity (0.88 ± 0.08%) and the highest microhardness (505 ± 25 Hv_0.1). Electrochemical assessments, including polarization curves and electrochemical impedance spectroscopy (EIS), showed that samples SA, SB, and SC experienced an initial drop followed by a rise in corrosion potential and an initial increase followed by a decrease in corrosion current density during the immersion cycle. In contrast, the corrosion potential of sample SD consistently decreased. Over time, the formation and accumulation of corrosion products with inerts on the coatings surface helped seal the pores and prevent further corrosion. After a comprehensive analysis, it was concluded that sample SC had the most effective corrosion resistance after 168 h of immersion, evidenced by its elevated resistance to pore penetration (<i>R</i>_p), charge transfer (<i>R</i>_dl), and overall impedance modulus.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"409 - 431"},"PeriodicalIF":3.2,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455517","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":"Aeroacoustic Process Monitoring and Anomaly Detection in Cold Spray Additive Manufacturing","authors":"Ivan Arkhipov,&nbsp;Uğur Kokal,&nbsp;Ozan Ç. Özdemir","doi":"10.1007/s11666-025-01934-4","DOIUrl":"10.1007/s11666-025-01934-4","url":null,"abstract":"<div><p>Cold spray (CS) is an emerging additive manufacturing method used to deposit a wide range of materials by spraying solid particles at supersonic velocities using high-pressure millimeter scale de Laval nozzles. As CS technology finds applications in diverse areas, including 3D printing, the need for in situ process monitoring becomes increasingly apparent. The CS process is influenced by various process parameters, including nozzle gas inlet pressure, temperature, and powder feed rate. Accurately detecting variations in these parameters, as well as identifying process anomalies (e.g., nozzle wear, clogging), is crucial for the broader implementation of the technology. In situ detection of anomalous events and process health monitoring is paramount for identification of inconsistencies, ensuring product quality, enhancing cost efficiency, and reducing waste by early detection of faults. To this end, in this study, airborne acoustic emission was monitored during CS processes to discern acoustically detectable process parameters. Characteristics of aeroacoustic waves emitted under both free jet and deposition conditions were analyzed. Results indicate that changes in nozzle gas inlet pressure and temperature, powder feed rate, and nozzle wear status are discernible through acoustic power spectrum analysis. Time-domain analysis further facilitated the identification of anomalies associated with powder injection termination, deposit/substrate delamination, and nozzle geometry changes. Notably, the sliding window first order backward differentiation of total power and the power band in the time domain proved effective in detecting gradual anomalies, such as nozzle throat wear, whereas the second-order differentiation highlighted abrupt process changes, like delamination. This study demonstrates that airborne acoustic signals offer valuable insights pertaining to process faults in CS, establishing aeroacoustic signal monitoring as a promising component of stand-alone or multi-modal process monitoring for CS operations. Furthermore, the study offers invaluable insights for aeroacoustic signal feature engineering for the development of machine learning models for process monitoring in CS.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"97 - 119"},"PeriodicalIF":3.2,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01934-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455414","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":"Correction to: Characterization of ZnO-Doped Hydroxyapatite Coatings on PEEK Made by Hybrid Plasma Spraying Process for Biomedical Applications","authors":"Jun Xu,&nbsp;Andreas Pfuch,&nbsp;Thomas Seemann,&nbsp;Frank Froehlich,&nbsp;Martina Schweder,&nbsp;Thomas Lampke","doi":"10.1007/s11666-024-01920-2","DOIUrl":"10.1007/s11666-024-01920-2","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"478 - 479"},"PeriodicalIF":3.2,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455461","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 and Mechanical Properties of WC-17Co Deposited Using Laser Direct Energy Deposition (LDED) and High-Velocity Oxygen Fuel (HVOF)","authors":"Fardad Azarmi,&nbsp;Theresa Grabowski,&nbsp;Martin McDonnell","doi":"10.1007/s11666-025-01933-5","DOIUrl":"10.1007/s11666-025-01933-5","url":null,"abstract":"<div><p>Recently, laser deposition technologies have made significant advancements in their ability to manufacture high-temperature metals and ceramics. One of these technologies, known as laser direct energy deposition (LDED), has the potential to deposit a wide range of materials from polymers to refractory materials, ceramics and functionally graded materials. This study evaluates major microstructural characteristics of WC-17 Co additively manufactured by LDED technology. A LDED-manufactured WC-Co sample was examined by optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and x-ray diffraction (XRD). Electron backscatter diffraction (EBSD) experiment was also performed to validate results obtained from XRD test. This material is commonly used for deposition of protective coatings due to its high hardness and excellent wear resistance. To this end, hardness and wear resistance of the LDED-processed samples were also investigated in this study. All the tests were also repeated on high-velocity oxygen fuel (HVOF)-deposited WC-Co with the same composition for the purpose of comparison. LDED sample showed slightly higher porosity (~4%) compared to the HVOF one (~3%). Both samples experience decomposition of the carbides into compound phases as indicated by XRD results. EBSD test results also confirmed the ones obtained from XRD and detected WC, Co, W₂C, and W₃Co₃C in both samples while some more complex phases such as W₉Co₃C₄ was found in LDED sample. The LDED-deposited sample also displays unique dendritic and eutectic structures that improve the hardness and wear properties compared to the homogenous HVOF coating instead of higher porosity level. The higher wear resistance of LDED sample is also associated with its higher hardness.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"658 - 673"},"PeriodicalIF":3.2,"publicationDate":"2025-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01933-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688348","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":"Optimization of L-DED Parameters for AlMo0.5NbTa0.5TiZr Based on Response Surface Methodology","authors":"Bingbing Sun,&nbsp;Hanfeng Xu,&nbsp;Ruifeng Li,&nbsp;Xiaolin Bi,&nbsp;Bingqing Chen,&nbsp;Feng Zhang,&nbsp;Lingti Kong,&nbsp;Jinfu Li","doi":"10.1007/s11666-025-01942-4","DOIUrl":"10.1007/s11666-025-01942-4","url":null,"abstract":"<div><p>To investigate the impact of process parameters on the deposition morphology of AlMo_0.5NbTa_0.5TiZr refractory high-entropy alloy during laser directional energy deposition, mathematical models were constructed for laser power, scanning rate, powder feeding rate and dilution rate, aspect ratio, and deposition area. These models were developed using the response surface method, and multi-objective optimization was conducted using the NSGA-II genetic algorithm. The results demonstrate that the optimal process parameters are laser power of 1150.08 W, scanning rate of 436.23 mm/s, and powder feeding rate of 2.81 g/min. The errors between the actual and predicted results for the dilution rate, aspect ratio, and deposition area are 6.5, 7.25, and 6.45%, respectively. These findings validate the efficacy of the multi-objective optimization of NSGA-II and the model's reliability. The findings of this study provide a theoretical framework for predicting and controlling the morphology of the deposited layer of refractory high-entropy alloy.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"366 - 380"},"PeriodicalIF":3.2,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455718","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":"Revolutionizing Repair and Production: An Integrated Modular Cold Spray Additive Manufacturing System","authors":"Wenbo Li,&nbsp;Hongjian Wu,&nbsp;Fei Huang,&nbsp;Hanlin Liao,&nbsp;Sihao Deng","doi":"10.1007/s11666-025-01943-3","DOIUrl":"10.1007/s11666-025-01943-3","url":null,"abstract":"<div><p>As an emerging additive manufacturing process, cold spray additive manufacturing (CSAM) has attracted considerable attention from researchers. It allows for near-net-shape fabrication of workpieces, but its accuracy and properties often do not meet the user requirements. Additionally, the development of a generalized manufacturing strategy for workpieces with complex geometries is imminent. To address this challenge, various processes involving the entire manufacturing process cycle, from design to delivery, can be integrated. However, few researchers have conducted studies in this area. Therefore, this study developed an efficient and flexible integrated modular CSAM system for the fabrication of workpieces. The system consists of two components: software for modeling and simulation, and hardware for precise fabrication. The software component primarily facilitates the reverse engineering modeling of the workpieces, as well as forming control of the deposits, including automation of path generation and deposits shape prediction before spray. The hardware component, supported by the software’s informational groundwork, actualizes the manufacturing of the workpieces to meet expected quality. The developed system provides a generalized strategy for precision manufacturing of workpieces in CSAM.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"531 - 549"},"PeriodicalIF":3.2,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688344","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 NiCrCoAlY Transition Layer Thickness on Structure and Properties of BNT/NiCrCoAlY Ceramic Coatings","authors":"Hefa Zhu,&nbsp;Weiling Guo,&nbsp;Longlong Zhou,&nbsp;Wei Peng,&nbsp;Haidou Wang,&nbsp;Han Dong,&nbsp;Zhiguo Xing","doi":"10.1007/s11666-025-01936-2","DOIUrl":"10.1007/s11666-025-01936-2","url":null,"abstract":"<div><p>In order to avoid the deterioration of electrical properties of Bi_0.5Na_0.5TiO₃ (BNT) ceramic coatings and metal substrate due to poor bonding performance, a NiCrCoAlY layer was introduced as a transition layer between BNT ceramic coatings and metal substrate. In this paper, BNT/NiCrCoAlY ceramic coatings were prepared by supersonic plasma spraying. The effects of NiCrCoAlY transition layer thickness on microstructure, mechanical properties, electrical properties, and domain evolution of BNT/NiCrCoAlY ceramic coatings were analyzed. The thickness of the NiCrCoAlY transition layer has a significant effect on the mechanical properties of BNT/NiCrCoAlY ceramic coatings. When the thickness of the NiCrCoAlY transition layer is 159.1 μm, the residual compressive stress on the surface of the NiCrCoAlY transition layer is the largest, which is − 185.4 MPa, and the direct bonding performance between the coating and substrate is the best. The residual compressive stress of the coating has a good positive effect on the hardness and bond strength of the coating, which significantly improves the structural integrity and mechanical properties of the coating. BNT2 ceramic coating has the largest average amplitude intensity of 46.0 pm, and the amplitude histogram ranges from − 10 to 90 pm. BNT2 ceramic coating has a relatively large value of the maximum amplitude of the butterfly loops at ± 20 V, and its localized piezoelectric response (<i>PR</i>_max) reaches 449.6 pm/V, and the ferroelectric domains exhibit an obvious switching behavior.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"444 - 459"},"PeriodicalIF":3.2,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455468","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 Scanning Rate on Microstructure and Properties of Fe-Based Amorphous Composite Coatings Prepared by Laser Cladding under Constant Heat Dissipation","authors":"Wei Zhao,&nbsp;Xiaopeng Shan,&nbsp;Wei Zha,&nbsp;Wei Lv,&nbsp;Ghulam Hussain,&nbsp;Junting Luo","doi":"10.1007/s11666-025-01929-1","DOIUrl":"10.1007/s11666-025-01929-1","url":null,"abstract":"<div><p>A water circulation system consisting of a heat dissipation plate was designed to assist laser cladding. The impact of scanning rate under constant cooling conditions on the structure and properties of Fe-based amorphous composite coatings prepared by laser cladding was investigated. The results show that with increasing scanning rate, the coating exhibits different characteristics. At 17 mm/s, the coating has the fastest cooling rate, minimal heat impact, and features predominantly amorphous phase, high hardness, and excellent wear and corrosion resistance. At 11 mm/s and 13 mm/s, local high hardness phases appear, but overall hardness is poor. At 15 mm/s, the coating has the highest hardness (630HV) due to increased amorphous content and solid solution strengthening of supersaturated <i>α</i>-Fe phase. Wear tests reveal low and stable wear rates for samples at 15 mm/s and 17 mm/s, correlating with their uniform hardness. Corrosion resistance tests show the best performance for the 11 mm/s samples, with excellent corrosion resistance. As scanning rate increases, the content of strengthening phases decreases, and the supersaturation of <i>α</i>-Fe phase increases, leading to decreased corrosion resistance. The 17 mm/s samples, with significantly higher amorphous phase content and lower overall content of supersaturated <i>α</i>-Fe phase, exhibit excellent corrosion resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"354 - 365"},"PeriodicalIF":3.2,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455467","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":"Plasma Spray Deposition of Na3Zr2Si2PO12 Electrolyte for High-Performance All-Solid-State Sodium-Ion Battery","authors":"Xiao-Chen Bu,&nbsp;Nan Chen,&nbsp;Xiao-Tao Luo,&nbsp;Chang-Jiu Li","doi":"10.1007/s11666-025-01928-2","DOIUrl":"10.1007/s11666-025-01928-2","url":null,"abstract":"<div><p>All-solid-state sodium-ion batteries (ASS-SIBs) have great potential for application to large-scale energy storage devices due to their safety advantages, which are avoiding flammable organics and the abundance of sodium. In this study, plasma spraying was used to deposit Na₃Zr₂Si₂PO₁₂ (NZSP) electrolyte to assemble high-performance ASS-SIBs. NZSP electrolyte layers were deposited at different spray conditions using NZSP powders in various particle sizes. The factors influencing the microstructure and compositions of NZSP layers were examined by characterizing the compositions of splat and cross-sectional microstructures of the deposits. It was found that the preferential evaporation loss of Na and P elements occurs severely to result in a large composition deviation from initial powders and spray particle size is a key factor that dominates their evaporation loss. The APS NZSP electrolytes present a dense microstructure, which is attributed to the low melting point of NZSP. The apparent porosity of the as-sprayed NZSPs was lower than 3%. The effect of annealing on the microstructure of APS NZSP was also investigated. With the increase in annealing temperature, the conductivity of the electrolyte increased and reached 1.93 × 10⁻⁴ S/cm for F-NZSP-1000 °C at 200 °C.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"495 - 505"},"PeriodicalIF":3.2,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688292","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}