Journal of Thermal Spray Technology最新文献

{"title":"Mechanism of Strength and Toughness Regulation of Laser Cladding Coatings Based on Interfacial Composite Textures","authors":"Haoping Wang,&nbsp;Guiquan Han,&nbsp;Cong Liu,&nbsp;Chao He,&nbsp;Tian Jiao,&nbsp;Chaofan Sun,&nbsp;Yuqi Chen","doi":"10.1007/s11666-025-02016-1","DOIUrl":"10.1007/s11666-025-02016-1","url":null,"abstract":"<div><p>Laser cladding coatings typically exhibit high strength and wear resistance but limited toughness and ductility. To address this, a composite interface texture inspired by biological tissue was developed, using laser cladding to apply Fe-based coatings onto a 1045 steel substrate. The study evaluated the mechanical properties of these coatings, focusing on how varying the depth of the micro-texture impacts performance. Findings revealed that increased micro-texture depth enhanced the bonding strength and coordinated deformation between the coating and substrate. However, it also led to greater stress concentration, increased defect quantity, and higher martensite content at the interface, causing complex shifts in impact toughness, tensile strength, and ductility. A competitive relationship was identified between the coordinated deformation induced by the micro-texture and the stress concentration at the interface. Optimal results were achieved with a micro-texture depth of 0.2 mm, which significantly improved microhardness, tensile strength, and elongation through a synergistic effect, offering the best overall mechanical properties among the tested parameters. This study provides a novel approach to resolving the trade-off between high strength and high toughness in laser cladding coatings. The insights gained are valuable for enhancing the adaptability of these coatings under challenging conditions, such as impact-sliding wear, and shed light on the mechanisms behind the simultaneous improvement in toughness and strength.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2352 - 2371"},"PeriodicalIF":3.3,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078919","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 Process Parameters on Residual Stresses of Cold Gas Sprayed IN718 Coatings on Large Repair Geometries","authors":"J.-C. Schmitt,&nbsp;F. Lang,&nbsp;J. Fiebig,&nbsp;T. Sievert,&nbsp;J. Gibmeier,&nbsp;O. Guillon,&nbsp;R. Vaßen","doi":"10.1007/s11666-025-02011-6","DOIUrl":"10.1007/s11666-025-02011-6","url":null,"abstract":"<div><p>The residual stresses induced by the various process conditions in engineering components can have a significant impact on their structural integrity and performance. It is essential to ensure reliable control of the mechanical properties of structural components during the repair process, as this directly affects their performance and longevity. Cold gas spray, a solid-state deposition technique, involves the high-velocity impact of fine powder particles onto a substrate, resulting in the formation of a dense, metallurgically bonded coating. The aim of this study is to investigate the suitability of cold gas spraying parameters for the repair of large cavities in components made of Inconel 718. Two sets of parameters, approaching the limits of the spraying facility, have been utilized and analyzed using particle diagnostics. Experimental methodologies involve the characterization of residual stress profiles using techniques such as in situ curvature measurement and the incremental hole drilling method after the cold gas spray repair. Additionally, the microstructure and topography of the as-sprayed repair coatings are demonstrated. The results demonstrate the ability of cold gas spray to successfully fill deep repair cavities and adjust the residual stress state of such repair coatings by varying the processing parameters. Lower residual compressive stresses in the layer were achieved by utilizing gas parameters, wherein the particles impact the substrate at an elevated temperature and at a comparatively reduced velocity. Both conditions exhibited coatings with consistent microstructure, good adhesion and uniform topography without major defects. This research demonstrates the potential of cold gas spray as a viable and efficient repair method for large repair geometries, offering a promising avenue for enhancing the reliability and lifespan of critical engineering structures.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2256 - 2266"},"PeriodicalIF":3.3,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-02011-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078944","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":"Influence of Surface Properties on Microbial Activity and Biofilm Attachment in Thermally Sprayed Cu-Bearing Coatings with Varied Cu Distributions","authors":"Hongshou Huang,&nbsp;Surinder Singh,&nbsp;Albert Juhasz,&nbsp;Andrew Siao Ming Ang,&nbsp;Nikki Stanford","doi":"10.1007/s11666-025-02013-4","DOIUrl":"10.1007/s11666-025-02013-4","url":null,"abstract":"<div><p>In this study, the influence of surface states (as-received versus polished state) on the antibacterial and anti-biofilm attachment properties of thermally sprayed Cu-bearing coatings was studied. Findings indicate that the Cu ion release rate remains the predominant factor influencing the short-period antimicrobial efficacy of these coatings in their as-received state. Additionally, the influence of surface states on the antibacterial efficacy varied with Cu distributions (Cu as a segregated phase within a composite versus Cu as a solute element within a single phase). During microbial corrosion testing with <i>Desulfovibrio vulgaris</i> over an extended exposure, Cu addition continues to exhibit a significant inhibitory effect on biofilm attachment in as-received state. In contrast to their polished counterparts, the rough surfaces of the as-received samples significantly enhanced biofilm attachment; however, this facilitating effect diminished over time. The mechanisms leading to reduced facilitation varied with Cu distribution, due to either the formation of Cu₂S in composite coatings or the preferential biofilm attachment in valley areas in coatings containing Cu as solute. Additionally, the results suggest that arc spray has greater advantages over HVOF in preparing antimicrobial corrosion coatings, as it produces more uniformly flattened splats that show inhibiting effect on biofilm attachment.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2442 - 2457"},"PeriodicalIF":3.3,"publicationDate":"2025-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-02013-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078887","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":"Finite Element Modeling and Analysis of Ceramic Particle/Substrate Interface Fracture Evolution and Particle Retention at Varying Impact Velocities in Cold Spray","authors":"Arif Alam,&nbsp;Philip A. S. Gores,&nbsp;Aisa Grace D. Custodio,&nbsp;Aleksandra Nastic,&nbsp;Jagannadh V. S. N. Sripada,&nbsp;Clodualdo Aranas Jr.,&nbsp;Gobinda C. Saha","doi":"10.1007/s11666-025-02015-2","DOIUrl":"10.1007/s11666-025-02015-2","url":null,"abstract":"<div><p>A finite element (FE) model of a 25-µm Al₂O₃ particle impacting an AISI 1018 steel surface is constructed using the Johnson–Holmquist-2 and Johnson–Cook material definition models, respectively. Particle impact velocities in the range of 200–700 m/sec, obtained using a deLaval nozzle, are considered. Energy, temperature, and strain evolutions over time for varying impact velocities are reported, along with penetration depth into target material. Penetration results are validated against experiments, showing good agreement, with observed depths between 4.8 and 8.2 µm. Penetration, contact pressure, and contact time for varying impact velocities are predicted, along with their effects on the interfacial bonding mechanism between particle and substrate. The threshold velocity for Al₂O₃ particle fragmentation is estimated at 170 m/sec. The stress behavior and the location of failure onset within the particle are predicted and described. The damage and fragmentation behavior of Al₂O₂ particles of different sizes is also analyzed. The implications of obtained results for cold spray deposition of metal matrix composite material are discussed.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2190 - 2210"},"PeriodicalIF":3.3,"publicationDate":"2025-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078898","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure and Tribological Properties of Thick (Ti, Cr, V) N Nanocomposite Coatings at a Wide Temperature Range","authors":"Yanqi Zhao,&nbsp;Yunlong Chi,&nbsp;Yuxin Wang,&nbsp;Dongyao Zhang,&nbsp;Chunli Qiu,&nbsp;Yanchun Dong,&nbsp;Yong Yang,&nbsp;Hongjian Zhao","doi":"10.1007/s11666-025-02017-0","DOIUrl":"10.1007/s11666-025-02017-0","url":null,"abstract":"<div><p>The effects of service environment temperature (25, 550, 650, 700, and 750 °C) on the friction and wear properties of (Ti, Cr, V) N composite coatings were investigated. The structure and phase of the coating before and after wear at wide temperature ranges were analyzed by scanning electron microscopy, XRD, transmission electron microscopy, and Raman spectroscopy. A wide temperature range wear test was carried out at room temperature, 550, 650, 700, and 750 °C for 20 min using a reciprocating friction and wear tester. The results show that the (Ti, Cr, V) N composite coating overcomes the shortcomings of single nitride, which is the initial oxidation temperature is low in a wide temperature range. The surface oxides produced at 25-750 °C have an important influence on the wear behavior and wear resistance. At room temperature and 550 °C, the main phase of the coating is the TiCrVN hard phase, which can reduce the wear rate of the coating at room temperature. At higher temperatures of 700 and 750 °C, dense oxide hard films of Cr₂O3, TiO₂, V₂O₅, and TiVO₄ formed on the wear scar surface play a key role during friction and wear. 650 °C is a critical temperature for wear behavior change. The mechanical properties of the coatings at 700 and 750 °C are significantly higher than those at 650 °C, and H_IT³/E^*2 is increased by 76%, which improves the wear resistance and reduces the wear rate. The coating is mainly oxidative wear at high temperatures above 700 °C. It is shown that the wear resistance and oxidation resistance of the composite coating can be improved by the mutual doping of Ti, Cr, and V elements in a wide temperature range.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2414 - 2427"},"PeriodicalIF":3.3,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078885","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":"Mechanical and Tribological Properties of High Velocity Air Fuel-Sprayed IN625 and IN718 Coatings","authors":"Sudha Kumari,&nbsp;Sanjay Raj,&nbsp;Narendra Babu,&nbsp;M. Prashanth,&nbsp;Syed Junaid,&nbsp;Sumanth Govindarajan,&nbsp;Chandan Mondal,&nbsp;Nitya Nand Gosvami,&nbsp;Ayan Bhowmik","doi":"10.1007/s11666-025-02009-0","DOIUrl":"10.1007/s11666-025-02009-0","url":null,"abstract":"<div><p>This study explores the mechanical and tribological behavior of IN625 and IN718 coatings deposited on Ni-based IN718 alloy substrates using the high-velocity air fuel, HVAF technique. Microstructural analysis revealed that the IN625 coating exhibited more visible splats, weaker bonding, and a greater presence of unmelted and partially melted regions than IN718. Both IN625 and IN718 coatings retained the original constituent phases from the powder. The IN718 coating, however, demonstrated superior mechanical properties, with its hardness and adhesion strength surpassing those of IN625 by 56% and 30%, respectively. Notably, the adhesion strength was highest in a 0.5 mm thick IN718 coating, reaching 63 MPa. At room temperature, both the coatings had significant coefficient of friction (COF) values, while the wear volume loss for IN718 was reduced by 52% compared to IN625, although IN625 showed wider wear scars with more pits, deeper grooves, and peeling. IN718 formed a glaze layer, enhancing its wear resistance. These findings suggest that optimally thick IN718 HVAF coatings hold significant promise for improving performance in various repair and cladding applications.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2405 - 2413"},"PeriodicalIF":3.3,"publicationDate":"2025-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078920","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":"Mechanical Properties of Novel Arc-Sprayed Partially Amorphous Iron-Based Alloys Under Cryogenic Temperature and Hydrogen Influence","authors":"Michél Hauer,&nbsp;Lukas Möhrke,&nbsp;Pratidhwani Biswal,&nbsp;Oliver Brätz,&nbsp;Andreas Gericke,&nbsp;Benedikt Allebrodt,&nbsp;Knuth-Michael Henkel","doi":"10.1007/s11666-025-02001-8","DOIUrl":"10.1007/s11666-025-02001-8","url":null,"abstract":"<div><p>Previous own works revealed that novel partially amorphous Fe-based alloys have a combination of properties that are beneficial for the application in liquid hydrogen (LH2) tanks, such as low thermal diffusivity, little porosity, and good adhesion. The influence of cryogenic temperatures or hydrogen on coating tensile strength, on the other hand, has not been investigated yet for this material. However, this is crucial for the long-term durability of the coatings under hydrogen and other alternative fuels. Thus, in this work, tubular coating tensile (TCT) tests were performed at room temperature, cryogenic temperatures and after hydrogen charging. For this, a methodology for hydrogen charging was developed to identify a possible regime being sufficient for inducing a measurable amount of hydrogen. Subsequently, the fracture surfaces were evaluated analytically, optically and profilometrically. Under cryogenic conditions, a significant increase in tensile strength and finer structures of the fracture surfaces were observed. The TCT tests with ex-situ hydrogen charging revealed a small reduction in tensile strength and ductility compared to specimens tested at room temperature, proven by the coarse structure of the fracture surface.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2081 - 2093"},"PeriodicalIF":3.3,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-02001-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078869","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-Sprayed Ti-Carbon Nanofibers: Study of Conductive and Electrochemical Properties","authors":"Edwin Torres Díaz,&nbsp;Alessio Silvello,&nbsp;Edwin Rúa Ramirez,&nbsp;Rodolpho Fernando Vaz,&nbsp;Irene García Cano","doi":"10.1007/s11666-025-02007-2","DOIUrl":"10.1007/s11666-025-02007-2","url":null,"abstract":"<div><p>The cold gas spray (CS) technique has emerged as a promising coating deposition method in the last decades for many materials, including Ti and most recently metal matrix composites, such as graphene-reinforced Ti. In this study, CS Ti coatings reinforced with two types of carbon nanofibers (GFs), HCNFs and MWCNTs, were evaluated regarding their electrochemical, electrical, and thermal properties before and after heat treatments (HT) at 700 and 1000 °C. The results indicated that incorporating GFs did not alter the CS Ti coatings deposition efficiency, porosity, or hardness in as-sprayed condition. HT reduced the CS Ti and Ti-GFs coatings resistivity by 21 and 23%, respectively, as well as improved their thermal conductivity by 25 and 32%, respectively. CS Ti-GFs coatings demonstrated an impressive reduction in corrosion rate of up to 80% compared to unreinforced Ti. These findings highlight the potential of CS Ti-GFs composite coatings applied through CS for industrial applications requiring high corrosion resistance. However, improvements by incorporating GFs in Ti powder in thermal and electrical properties were limited, indicating the need to optimize matrix–reinforcement interaction and CS process parameters to maximize their performance in these areas. </p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2227 - 2239"},"PeriodicalIF":3.3,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-02007-2.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078870","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":"Monitoring Failure Sequence in Cold-Sprayed Al6061 Deposits Using Acoustic Emission","authors":"Zi Wen Tham,&nbsp;Santhakumar Sampath,&nbsp;Yi Fan Chen,&nbsp;Augustine Kok Heng Cheong,&nbsp;Li Tian Chew,&nbsp;Debbie Hwee Leng Seng,&nbsp;Pei Wang,&nbsp;Shijie Wang,&nbsp;Zheng Zhang,&nbsp;Lei Zhang","doi":"10.1007/s11666-025-02008-1","DOIUrl":"10.1007/s11666-025-02008-1","url":null,"abstract":"<div><p>Cold spray (CS) is a recent addition to the thermal spray family with extensive research conducted on the effects of different process parameters during CS deposition various metallic powders. While mechanical and fatigue strengths of cold-sprayed deposits have been evaluated through static and dynamic testing, identifying the sequence of failure mechanisms—whether cracks within the coating occur before delamination at the coating–substrate interface—remains visually challenging but crucial for pinpointing weak points within the deposit. To address this, acoustic emission (AE) testing was employed in this study to reliably determine the failure sequence through in situ monitoring. Using a four-point bending setup, a 2.5-mm-thick Al6061 coating on an Al6061-T6 substrate was analyzed in real time with AE data and video correlation. The findings revealed that cracks associated with higher AE frequencies (≥ 100 kHz) appeared first, accompanied subsequently by delamination, which was correlated with lower-frequency AE events (&lt; 100 kHz). This AE methodology shows promise for integration with other static tests, such as open-hole tension as well as fatigue testing to determine similar failure sequences. By providing a clear understanding of failure mechanisms, this approach advances the structural evaluation of cold-sprayed deposits and their potential applications.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2267 - 2279"},"PeriodicalIF":3.3,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078923","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":"In Situ Synthesis of FeAl Intermetallic Coatings by Wire Electrical Explosion-Spraying","authors":"Hui Zhou,&nbsp;Shunjiang Son,&nbsp;Xudong Wang,&nbsp;Chaojian He,&nbsp;Weipeng Chen,&nbsp;Jinyuan Ma,&nbsp;Yupeng Wei,&nbsp;Wei Zhang,&nbsp;Liang Zhu","doi":"10.1007/s11666-025-02000-9","DOIUrl":"10.1007/s11666-025-02000-9","url":null,"abstract":"<div><p>FeAl intermetallic compounds have several advantages over other Fe-based alloys. Surface engineering was used to prepare intermetallic FeAl coatings to exploit the properties of these components. However, this method requires complex processing, and controlling the phase composition of the coating makes it difficult to prepare Fe-Al coatings using conventional surface engineering. In this study, a novel constrained wire electrical explosion spraying device was used to prepare FeAl coatings. A FeAl intermetallic coating was successfully synthesized by electrical explosion spraying of twisted 316L/Al wires. The charging voltage affected the phase compositions, microstructures, and deposition efficiencies of the coatings. Considering the phase composition, deposition efficiency, and microstructure of the coating, a charging voltage of 8.8 kV was determined to be suitable based on the overheating factor of the twisted wires, which influenced the amount of liquefied and gasified metal. Intermetallic FeAl compounds were formed as the clusters of liquefied and gasified 316L and Al were cooled. In addition to the overheating factor, the wire expansion velocity was influenced by the charging voltage. The combined effects of the overheating factor and expansion velocity determine the temperature and velocity of the explosive products, ultimately affecting the degree of product flattening and coating microstructure.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 6","pages":"2119 - 2128"},"PeriodicalIF":3.3,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145078938","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}