Journal of Thermal Spray Technology最新文献

{"title":"Cold-Sprayed Bell Metal: Improving Adhesion by Substrate Laser Surface Texturing","authors":"Jan Cizek,&nbsp;Reeti Singh,&nbsp;Jan Kondas,&nbsp;Sebastian Kraft,&nbsp;Dariusz Bartocha,&nbsp;Maria Baryshnikova,&nbsp;Ondrej Kovarik","doi":"10.1007/s11666-026-02265-8","DOIUrl":"10.1007/s11666-026-02265-8","url":null,"abstract":"<div><p>Historical bells are worn and damaged by the ravages of time. The repair and restoration of these heritage masterpieces could be attempted using cold technology, provided a sufficient adhesion is reached. In this paper, the improvement of Cu20Sn bell metal repair adhesion by various substrate surface treatments was studied: grinding, polishing, cold spray grit-blasting, and laser texturing using five different patterns. The adhesion was tested by a new, simple glue-less method tailored for testing thick cold spray deposits. It was shown that while the cold spray grit-blasting provides a good adhesion of around 70 MPa, even better results of approximately 120 MPa could be obtained by the laser patterning. The detailed three-dimensional fractographic analysis allowed us to describe the failure mechanism of all specimens. For the best-performing laser texturing, this was a combination of interfacial debonding at the original substrate surface and the deposit cohesive fracture inside the pattern recessed areas.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2460 - 2470"},"PeriodicalIF":3.4,"publicationDate":"2026-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02265-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807583","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":"Hot Corrosion Characteristics of 8YSZ-RSZ Dual-Ceramic Coating with Varied Al Plating Thicknesses at 1100 °C","authors":"Liang Gao,&nbsp;Jianing Zhang,&nbsp;Shuaibo Cui,&nbsp;Yongjun Chen,&nbsp;Zhiwen Xie","doi":"10.1007/s11666-026-02264-9","DOIUrl":"10.1007/s11666-026-02264-9","url":null,"abstract":"<div><p>Optimized Al plating layers with controlled thicknesses were applied to the NiCoCrAlY-8YSZ-RSZ thermal barrier coating. The hot corrosion characteristics of the coatings were assessed in a molten sulfate mixture for a duration of 200 h at 1100 °C. Results demonstrated that the specimen without Al plating gained 19.27 ± 0.53 mg cm^–2 in weight, corroded rapidly, and eventually cracked and failed. However, the specimen with Al plating triggered the in situ production of a substantial α-Al₂O₃ phase during corrosion, restricting O₂ and SO₄^2– ions from infiltrating the coating. The structural deterioration of the coatings was found to be reliant on the Al plating thickness. The shielding effect of the 5 µm Al plating coating was compromised prematurely via the rapidly occurring interaction of <i>α</i>-Al₂O₃ with SO₄^2–, leading to its depletion. Driven by excessive thermal mismatch stress from the 15 µm Al plating, the coating experienced stress levels beyond its fracture limit, ultimately leading to extensive structural degradation. When the Al plating thickness was optimized to 10 µm, the coating displayed a desirable equilibrium between thermal stress and corrosion resistance. This was evidenced by the weight gain of 10.67 ± 0.25 mg cm^–2, approximately 50% less than without Al plating coating, and the highest structural integrity observed during sulfate-induced hot corrosion. This study presents a thickness-modulation strategy for the top Al plating layer, based on the finding that Al plating imparts structural stability to the NiCoCrAlY-8YSZ-RSZ thermal barrier coating. Hot sulfate corrosion tests conducted at 1100 °C in an oxidizing environment reveal that variations in Al plating thickness result in distinct degradation behaviors within the dual-ceramic coating. The results demonstrated that optimized Al plating promoted the in situ formation of a dense <i>α</i>-Al₂O₃ layer on the coating surface and revealed the critical role of Al plating thickness in governing coating degradation, thereby providing guidance for optimizing Al-modified thermal barrier coating systems.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2721 - 2735"},"PeriodicalIF":3.4,"publicationDate":"2026-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807460","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 Study on Gas-Particle Acceleration Behavior in Straight Divergent and Curved Divergent Cold Spray Nozzles: Numerical Simulation and Experimental Validation","authors":"Wenpeng Wan,&nbsp;Zhe Zhan,&nbsp;Chunjie Huang,&nbsp;Zunjia Li,&nbsp;Hongxia Zhou,&nbsp;Wenya Li","doi":"10.1007/s11666-026-02263-w","DOIUrl":"10.1007/s11666-026-02263-w","url":null,"abstract":"<div><p>This study combined three-dimensional CFD numerical simulations with Lagrangian particle tracking and experimental deposition to compare straight divergent and curved divergent nozzles for cold spray under identical stagnation conditions (3 MPa, 600 °C). Importantly, the two nozzle geometries were designed to have the same expansion ratio and divergent-section length, enabling an isolated assessment of downstream profile effects. The curved divergent nozzle accelerated the gas more rapidly: Peak axial velocity reached 1003 m/s at about 114 mm downstream versus 937 m/s at the exit (220 mm downstream) for the straight divergent nozzle. The curved divergent geometry produced a faster pressure decay and earlier temperature reduction in the downstream region while also producing a stronger exit shock. Lagrangian particle tracking predicted higher impact velocities for Al, Ti, and Cu particles across 10-50 μm; mean increases (curved divergent versus straight divergent) ranged roughly from 11 to 44 m/s depending on material and diameter. Furthermore, for the investigated parameters, particles of 10-30 μm were recommended to maximize curved divergent nozzle benefits. Experimental Cu coatings validated the simulations: Curved divergent nozzle coatings were more uniform and thicker (1730 μm) than straight divergent coatings (1120 μm), corresponding to 1.5 times higher deposition efficiency. These results quantify the influence of the nozzle downstream profile on gas acceleration efficiency and demonstrate that changes in the gas field produced by different profiles consequently modify particle acceleration and deposition behavior.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2408 - 2423"},"PeriodicalIF":3.4,"publicationDate":"2026-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807455","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":"Tribological Analysis of Ni-Cr-Fe and Ni-Cr-Al Coatings on SS316 Under Elevated Temperatures","authors":"A. N. V. Siva Prasad,&nbsp;Netrananda Behera,&nbsp;Sriharsha Kumar,&nbsp;T. V. Chandramouli,&nbsp;Ranjan Yadav,&nbsp;Swaraj Suman Soans,&nbsp;M. R. Ramesh,&nbsp;Sharnappa Joladarashi","doi":"10.1007/s11666-026-02262-x","DOIUrl":"10.1007/s11666-026-02262-x","url":null,"abstract":"<div><p>Stainless steel 316 (SS316) is favored in marine and aerospace industries for its resistance to corrosion and mechanical reliability. The limited wear resistance of the material poses challenges for its application at elevated operating temperatures. To effectively address this limitation, Ni-Cr-Fe and Ni-Cr-Al coatings were expertly applied to SS316 substrates using the high-velocity oxygen fuel (HVOF) process. The examination of the coatings tribological behavior utilizing an alumina ball-on-disk configuration over a temperature range from room temperature to 800 °C, under applied loads of 10 N and 20 N. A comprehensive suite of characterization techniques includes SEM, XRD, microhardness testing, density measurements, porosity analysis, bond strength evaluation, and surface roughness assessments. Wear mechanisms were further investigated through 3D profilometry and SEM–EDS. Both coating systems showed cohesive failure at 25 N, while higher loads (70-100 N) promoted a mixed cohesive–adhesive failure mode. Ni-Cr-Fe exhibited higher hardness and bond strength than Ni-Cr-Al. The bare SS316 substrate demonstrated a continuous rise in wear rate with increasing temperature. In contrast, both coatings displayed peak wear and friction values at 300 °C, followed by a reduction at 600-800 °C due to the development of protective oxide scales (Fe₂O₃, NiO, and NiCr₂O₄). Abrasive and fatigue wear mechanisms dominated at room temperature, while oxidative and adhesive wear became prominent at 800 °C. Overall, Ni-Cr-Fe outperformed Ni-Cr-Al and the uncoated substrate regarding wear resistance and frictional stability.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2624 - 2640"},"PeriodicalIF":3.4,"publicationDate":"2026-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807454","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":"Process Optimization of Duplex Stainless Steel Fabricated by Multi-Beam Laser Directed Energy Deposition","authors":"Kaiming Wang,&nbsp;Hao Li,&nbsp;Zibo Song,&nbsp;Xiaotong Pang,&nbsp;Xixi Ji,&nbsp;Pengfei Wu,&nbsp;Jingzhong Fang,&nbsp;Zixiang Li,&nbsp;Jiang Ju,&nbsp;Jian Gu","doi":"10.1007/s11666-026-02259-6","DOIUrl":"10.1007/s11666-026-02259-6","url":null,"abstract":"<div><p>Multi-beam laser directed energy deposition (Multi-beam LDED) is an additive manufacturing process that employs multiple laser beams focused on melting and depositing metallic materials. This technology enables the fabrication or repair of duplex stainless steel (DSS) components. In this study, DSS cladding layers were fabricated via a multi-beam LDED system. Based on response surface methodology (RSM), a systematic investigation was conducted into the effects of three key process parameters—laser power, scanning speed, and wire feeding speed—on the width, <i>W</i>/<i>H</i>, and dilution rate of single-pass DSS cladding layers. Ultimately, through prediction and experimental validation, the optimal process parameters were determined as follows: total laser power (<i>P</i>_total) = 2241.6 W, scanning speed (<i>V</i>) = 7.91 mm/s, and wire feeding speed (<i>R</i>) = 1.27 cm/min. Under these optimal parameters, the single-pass DSS cladding layers exhibited a width (<i>W</i>) = 3.25 mm, a <i>W</i>/<i>H</i> = 2.3, and a dilution rate (<i>η</i>) = 36.27%. The deviations between the predicted and validated values were all below 5%. Furthermore, microstructural characterization and microhardness distribution analysis were performed. The results indicated that the cladding layers were composed entirely of austenite and ferrite phases, with no impurity phases detected. EBSD analysis revealed the presence of abundant grain dislocations within the cladding layers, which contributed to an average microhardness of 350 HV.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2310 - 2330"},"PeriodicalIF":3.4,"publicationDate":"2026-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807345","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 Vacuum Laser Remelting Post-treatment on the Microstructures and TGO Growth Kinetics of HVAF-Sprayed NiCoCrAlHfYSi and NiCoCrAlTaY Coatings","authors":"Yujun Han,&nbsp;Yandan Zhu,&nbsp;Baosen Zhang,&nbsp;Zhen Zhang","doi":"10.1007/s11666-026-02260-z","DOIUrl":"10.1007/s11666-026-02260-z","url":null,"abstract":"<div><p>This paper aims to further explore the potential performance of MCrAlY coatings with high-temperature oxidation and corrosion resistance. The NiCoCrAlHfYSi and NiCoCrAlTaY thermal spray powders were deposited by activated combustion high-velocity air fuel (AC-HVAF), and then, the deposited coatings were treated by vacuum laser remelting treatment. Additionally, the formation and propagation of microcracks were significantly suppressed at the interface between thermally grown oxides (TGO) and HVAF coatings. Additionally, the initial presence of the TGO layers of vacuum laser remelted specimens reached ranging from 0.5 to 1.0 μm. After isothermal oxidation for 200 h at 1050 °C, a pure, dense, continuous, and stable alumina layer was primarily formed onto the surface of LHVAF386 coating, while those of other types of deposited coatings usually contained some kinds of spinel oxides. The metallurgical bonding interfaces between the TGO and vacuum laser remelted coatings were adequately excellent; thus, the microcracks at these regions were not easily detected, whereas for other types of deposited coatings, the formation and propagation of microcracks usually occurred. Furthermore, for the vacuum laser remelted LHVAF386 coating, the growth rate of TGO and weight gain of the coatings was considerably lower than those of other deposited coatings, confirming the coatings might be much more stable after vaccum laser remelting treatment.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2443 - 2459"},"PeriodicalIF":3.4,"publicationDate":"2026-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807344","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":"Optimizing Micro–Nano Dual-Scale SiCp/6061Al Coatings via Plasma-Assisted Cold Spraying","authors":"Jiaying Liu,&nbsp;Chunzhi Gong,&nbsp;Chaoqun Lin,&nbsp;Zishuo Hao,&nbsp;Qiming Liu,&nbsp;Taoding Liang,&nbsp;Hirotaka Fukanuma,&nbsp;Xiubo Tian","doi":"10.1007/s11666-026-02256-9","DOIUrl":"10.1007/s11666-026-02256-9","url":null,"abstract":"<div><p>To address issues such as weak interfacial bonding, low deposit thickness, and poor ductility in the preparation of micro-nano dual-scale silicon carbide particle reinforced 6061 aluminum matrix (SiCp/6061Al) composite coatings via cold spray technology, a plasma-assisted cold spray (PCS) technique was employed. By adjusting the plasma source power (16-40 kW), simultaneous heating of both the substrate and the injected particle stream was achieved. This process primarily leverages the synergistic effect of plasma induced thermal softening and helium/argon mixed gas thermal convection, effectively reducing the critical deposition velocity of the aluminum alloy particles and enhancing their plastic deformation capability. The results demonstrated that at 40 kW, the peak substrate temperature reached 252 °C, and the total coating thickness increased to 861.3 μm, corresponding to a 135% increase compared with unassisted cold spray (CS). The EDS results qualitatively showed a broader distribution of Si-containing regions in the coating cross-sections under plasma-assisted conditions. Furthermore, plasma assistance promoted particle deformation and coating densification, while the cross-sectional observations suggested fewer visible interfacial discontinuities in the examined regions. The proportion of low-angle grain boundaries decreased from 27.2% in CS to 13.6%, indicating optimized interfacial microstructure. In terms of macroscopic properties, the coating’s Vickers hardness reached 108 HV_0.5, a 20.8% improvement over CS. Rotational friction tests showed a 14.7% reduction in wear rate, a decreased friction coefficient, and a transition in the wear mechanism from composite delamination and abrasive wear to mainly mild abrasive wear, indicating significantly enhanced wear resistance. The shear strength also increased to 80.8 MPa. Consequently, the plasma-assisted cold spray technology, effectively resolves key technical challenges in fabricating aluminum alloy composite coatings via cold spray, significantly enhancing deposition thickness, microstructure, and mechanical and tribological properties.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2294 - 2309"},"PeriodicalIF":3.4,"publicationDate":"2026-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807230","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":"Thermomechanical Stress and Damage Evolution Near Film Cooling Holes in Thermal Barrier Coatings: Role of the Bond-Coat Layer","authors":"Xiaojie Han,&nbsp;Masayuki Arai","doi":"10.1007/s11666-026-02255-w","DOIUrl":"10.1007/s11666-026-02255-w","url":null,"abstract":"<div><p>Thermal barrier coatings (TBCs) produced by thermal spray processes and combined with film cooling are widely used to protect gas turbine components under severe thermomechanical environments. In such systems, fatigue cracks and interfacial damage frequently initiate near film cooling holes due to complex stress redistribution within the multilayer architecture consisting of a ceramic top coat (TC), a metallic bond coat (BC), and a substrate. Although the effects of cooling holes have been extensively investigated, the mechanical role of the bond-coat layer in stress and damage evolution under thermomechanical fatigue (TMF) remains insufficiently understood. In this study, a three-dimensional finite element framework is developed to analyze TMF-induced stress redistribution, damage accumulation, and crack initiation and propagation near film cooling holes in an air-plasma-sprayed (APS) TBC system. The model incorporates a damage-coupled inelastic constitutive formulation for the TC, temperature-dependent elastoplasticity for a CoNiCrAlY bond coat, and viscoplastic behavior for an IN738LC substrate, together with a nonlocal crack-propagation algorithm. Both in-phase and out-of-phase TMF loadings are examined over a temperature range representative of cooled TBC regions. The results demonstrate that the bond coat plays a dual mechanical role. Inelastic deformation of the bond coat relaxes stresses in the TC and modifies circumferential stress distributions around the cooling hole, while bond-coat-mediated stress redistribution promotes the accumulation of interfacial delamination strain, particularly under thermally dominated TMF conditions. Crack initiation locations rotate by approximately 90° depending on the dominant loading mode, and a characteristic stress-range threshold separates the fatigue lives under in-phase and out-of-phase conditions. These findings provide mechanistic insight into the role of bond-coat plasticity in damage evolution and durability of thermally sprayed TBC systems with cooling holes.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2691 - 2703"},"PeriodicalIF":3.4,"publicationDate":"2026-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02255-w.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807341","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":"Analysis of Microstructure Evolution and Mechanical Properties of Inconel 718/TC4 Dissimilar Metal Welding by Cold Spraying","authors":"Bo Cheng,&nbsp;Hanyu Zhang,&nbsp;Yong Liu,&nbsp;Kaijie Hu,&nbsp;Renzhong Huang,&nbsp;Dianwu Zhou,&nbsp;Mingjun Zhang","doi":"10.1007/s11666-026-02252-z","DOIUrl":"10.1007/s11666-026-02252-z","url":null,"abstract":"<div><p>Titanium alloy/nickel-based alloy composite structures are widely used in lightweight designs in aerospace applications. This study introduces cold spray technology for manufacturing titanium alloy/nickel-based alloy composite structures, offering a solution that effectively prevents the formation of brittle intermetallic compounds in conventional welding of titanium alloy/nickel-based alloy. Three types of powders (Inconel 718, TC4, Ti) are used to weld Inconel 718/TC4 via the cold spray process. The results indicate that a well-bonded interface is formed using pure Ti and Inconel 718 powders, and the welded joints (CS Inconel 718) have low porosity, only 0.96 ± 0.11%. The dissimilar materials interface (CS Inconel 718/TC4 base material) demonstrates superior bonding property compared to the same material interface (CS Inconel 718/Inconel 718 base material). The dynamic recrystallization occurred in the dissimilar materials interface region, leading to an increase in <i>β</i>-phase content and the formation of nanocrystals in the intersection of interface and TC4 base metal. The microstructure of the bonding zone (CS Inconel 718) is primarily composed of γ-phase, with a minor fraction of Laves phase resulting from the metallurgical bonding between Inconel 718 particles in cold spray deposition. The mechanical properties of the joint are mainly related to the interface bonding quality and porosity. In the case of well-bonded interface, the mechanical properties of cold spray-welded joints are primarily influenced by porosity. The tensile strength of the joints improves as porosity decreases, but the microhardness shows a declining trend. Tensile tests indicate that the welded joints (CS Inconel 718) possess a room-temperature strength of 433.63 ± 30.9 MPa and retains a stable value of 390.7 ± 19.58 MPa at 600 °C, demonstrating excellent high-temperature property stability. In summary, the Inconel 718 powder is identified as the optimal filler material for cold spray welding of titanium alloy/nickel-based alloy.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2424 - 2442"},"PeriodicalIF":3.4,"publicationDate":"2026-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807219","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 Repair of 6061 Aluminum Using Nitrogen: Microstructural and Mechanical Characterization with Post-spray Heat Treatments","authors":"Ahmad Nourian,&nbsp;Aidan Sevinsky,&nbsp;Samuel Boese,&nbsp;Chad Beamer,&nbsp;Sinan Müftü","doi":"10.1007/s11666-026-02219-0","DOIUrl":"10.1007/s11666-026-02219-0","url":null,"abstract":"<div><p>This study investigates the structural repair of 6061 aluminum using cold spray deposition with nitrogen as the carrier gas, focusing on the effects of various post-spray treatments on microstructural integrity and mechanical performance. Notched aluminum plates were repaired via cold spray and subsequently subjected to conventional heat treatment and hot isostatic pressing at both standard and elevated temperatures. The efficacy of the repairs was evaluated through microstructural characterization and mechanical testing, including microhardness, tensile, three-point bending, and fatigue tests. Results showed that while the as-deposited condition showed poor interparticle bonding and weak interfacial adhesion, all post-spray treatments substantially improved the load-bearing capacity of the repaired specimens. Among these, elevated-temperature treatments resulted in superior mechanical properties due to enhanced interparticle cohesion and interfacial bonding. Fractographic analysis confirmed a transition in failure mode from interfacial delamination in standard-temperature-treated specimens to cohesive fracture within the cold spray deposits in high-temperature-treated samples.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2704 - 2720"},"PeriodicalIF":3.4,"publicationDate":"2026-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02219-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807469","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}