Journal of Thermal Spray Technology最新文献

{"title":"Journal of Thermal Spray Technology Editor-in-Chief Named Fellow of Engineering Institute of Canada and the Canadian Academy of Engineering","authors":"","doi":"10.1007/s11666-026-02257-8","DOIUrl":"10.1007/s11666-026-02257-8","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1527 - 1527"},"PeriodicalIF":3.4,"publicationDate":"2026-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314758","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":"Study on the Wear Resistance and Failure Mechanisms of Thermal Sprayed Nanostructured TiO2 Coating by Regulating the Proportion of Partially Melted Regions","authors":"Peng Wang,&nbsp;Zekun Li,&nbsp;Wenchang Wang,&nbsp;Guozheng Ma,&nbsp;Haidou Wang","doi":"10.1007/s11666-026-02254-x","DOIUrl":"10.1007/s11666-026-02254-x","url":null,"abstract":"<div><p>Thermal-sprayed nanostructured ceramic coatings typically exhibit a bimodal structure composed of partially melted (PM) and fully melted (FM) regions, and the proportion of the PM regions significantly affects the overall performance of the coatings. In this study, nanostructured TiO₂ coating with varying proportion of the PM regions was fabricated using plasma spray by adjusting the spraying powers. The microstructure, mechanical properties and tribological behaviors, as well as failure mechanisms under extreme working condition of the coatings, were systematically investigated. The results showed that an increase in spraying powers led to a decrease in the proportion of the PM regions, which resulted in higher microhardness but lower fracture toughness of the coatings. The differences in the mechanical properties of the coatings with varying structures were primarily reflected in the PM regions. Although the weak bonding among the droplets in the PM regions made them more prone to generating wear debris, it also provided a certain degree of protection to the coatings against further wear. The wear failure mechanisms of the coatings with higher PM regions were mainly abrasive wear and fatigue wear. In contrast, the coatings with lower PM regions showed higher load-bearing capacity, but lower fracture toughness led to extensive droplet spalling, ultimately exacerbating the wear and failure of the coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2675 - 2690"},"PeriodicalIF":3.4,"publicationDate":"2026-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807619","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":"Wear and Corrosion Resistance of Laser Cladding AlXCoCr0.5MnNiTi0.5/Al-Ni Functionally Gradient Coating on AZ91HP","authors":"Yali Gao,&nbsp;Xin Li,&nbsp;Yu Liu,&nbsp;Dongdong Zhang,&nbsp;Shan Jiang,&nbsp;Xiuzhe Han","doi":"10.1007/s11666-026-02246-x","DOIUrl":"10.1007/s11666-026-02246-x","url":null,"abstract":"<div><p>To enhance the surface performance of Mg alloy, Al_XCoCr_0.5MnNiTi_0.5/Al-Ni gradient coatings were successfully prepared by laser cladding. The design of the transition coating effectively prevented the dilution of Mg. The research results showed that the Al_XCoCr_0.5MnNiTi_0.5 coatings were composed of a single BCC (Al-Ni) phase with petal-like grains. Besides, due to laser remelting, the Al-Ni remelted zone exhibited fine round grains, while the Al-Ni coating displayed needle-like grains. Compared with the substrate, the microhardness and wear volume of the HEA coatings increased by 8.17 to 8.80 times and decreased by 0.62 to 0.82 times, respectively. Among these, Al_1.50CoCr_0.5MnNiTi_0.5 had the highest microhardness and wear resistance because of solid solution strengthening, fine grain strengthening and second phase dispersion strengthening. In addition, the polarization curve indicates that the self-corrosion current decreased by 2 to 3 orders of magnitude. Nyquist plots and Bode plots also indicated that the corrosion resistance of the HEA coatings was superior to that of the substrate and the Al-Ni layer.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2656 - 2674"},"PeriodicalIF":3.4,"publicationDate":"2026-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807374","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":"Influence of Atmospheric Plasma Spray Parameters on Particle Dynamics, Adhesion, and Microstructure of Titanium Coatings Deposited on PEEK","authors":"Ali Tekin Guner,&nbsp;Cemal Meran,&nbsp;Garip Erdogan,&nbsp;Fatih Ustel,&nbsp;Murat Cihan Caliskan,&nbsp;Yagmur Guner","doi":"10.1007/s11666-026-02244-z","DOIUrl":"10.1007/s11666-026-02244-z","url":null,"abstract":"<div><p>Polyetheretherketone (PEEK) is a leading high-performance polymer for orthopedic applications due to its favorable biomechanical properties; however, its inherent bioinertness and low surface energy often lead to poor osseointegration. While titanium coatings are used to overcome these limitations, the existing literature lacks comprehensive data on the direct correlation between plasma parameters, in-flight particle dynamics, and the resulting coating properties on thermally sensitive PEEK. This study addresses this gap by investigating the influence of atmospheric plasma spray (APS) parameters on in-flight particle behavior and coating properties. To isolate the effects of thermal and kinetic energy, coatings were deposited by varying plasma current (425-475 A) and stand-off distance (300-350 mm) under constant plasma gas conditions, with particle temperature and velocity measured directly at the substrate plane. Statistical analysis via one-way ANOVA revealed that while increasing plasma current significantly enhanced surface roughness and thickness, it concurrently reduced tensile adhesion strength (<i>p</i> &lt; 0.05). Fractographic and microstructural analysis identified that intensified thermal flux at higher currents is associated with localized substrate outgassing and plume turbulence, leading to macroscopic defects and a transition to mixed adhesive-cohesive failure modes. The maximum adhesion strength of 14.64 ± 1.21 MPa was achieved at 425 A and 300 mm, yielding a surface roughness of Ra = 11.8 μm, which is well suited for promoting primary stability and long-term osseointegration. By establishing a quantitative process–structure–property framework, this work defines a viable operational regime that balances mechanical robustness with thermal safety, providing reproducible guidance for engineering titanium coatings on polymer-based substrates.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2389 - 2407"},"PeriodicalIF":3.4,"publicationDate":"2026-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02244-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807385","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":"Improvement in the High-Temperature Solid-Particle Gas Jet Erosion Life of TBC-Coated CMSX-4 Using a Novel Beam-Switching EBPVD Technique","authors":"Santhosh Kumar Vaiyapuri,&nbsp;Arivarasu Moganraj,&nbsp;Andrzej Nowotnik","doi":"10.1007/s11666-026-02245-y","DOIUrl":"10.1007/s11666-026-02245-y","url":null,"abstract":"<div><p>The development of thermal barrier coating (TBC) with superior thermo-mechanical properties demands different coating techniques with optimized process parameters. In this research, an efficient columnar-structured 7YSZ TBC was developed on single-crystal CMSX-4 substrate by electron-beam physical vapor deposition (EBPVD) process using novel beam-switching technique with a low electron-beam current. The performance of the developed TBCs was subjected to solid-particle erosion (SPE) test, which is one of the most aggressive and unavoidable threats to gas turbine blades, that reduces their efficiency. The SPE study of uncoated and TBC-coated CMSX-4 was conducted at an elevated temperature of 800 °C. The erodent-impingement angle was kept at 45 and 90°, by keeping all other parameters constant. The eroded samples were characterized by FESEM analysis and 3D digital microscope. All the results were critically analyzed, and it is observed that the material loss is higher in uncoated CMSX-4 than in TBC-coated CMSX-4 in both impingement angles of 45 and 90°. The developed EBPVD TBC exhibited satisfactory solid-particle erosion resistance owing to the tailored columnar-structured ceramic top coat. This satisfactory topcoat developed using the beam-switching EBPVD technique will serve the way to develop a functionally graded multi-layer TBCs top coat with two different materials in the EBPVD chamber.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2641 - 2655"},"PeriodicalIF":3.4,"publicationDate":"2026-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807387","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":"Evaluation of Thermal Conductivity and Erosion Performance of TBC–Polymer Coatings","authors":"A. Eskandari,&nbsp;M. Gupta,&nbsp;N. Markocsan","doi":"10.1007/s11666-026-02243-0","DOIUrl":"10.1007/s11666-026-02243-0","url":null,"abstract":"<div><p>Climate change mitigation requires advances in energy efficiency. Thermal barrier coatings (TBCs) are widely employed to improve thermal efficiency in gas turbines and internal combustion engines, and engineering coatings’ porosity is an important route to control the heat transfer to metallic components. In this study, porous gadolinium zirconate (Gd₂Zr₂O₇, GZO) coatings were produced using air plasma spraying (APS) with polyester as a pore-forming agent. A systematic investigation was carried out to evaluate the influence of stand-off distance, polyester particle size, and polyester content on the microstructure, porosity, thermal conductivity, and erosion resistance of the composite coatings. Results demonstrated that porosity increased with spraying distance and higher pore former content, reaching up to 50% porosity at 20 wt.% polyester addition. Enhanced porosity led to a significant reduction, up to 80%, in thermal conductivity compared to dense GZO coatings, with larger pores showing a more pronounced effect. However, erosion tests revealed that while moderate polyester additions improved erosion resistance due to crack-arresting effects, higher porosity levels reduced mechanical integrity and accelerated material loss, particularly after polyester burn-out post-treatment. These findings highlight the balance required between optimizing thermal insulation and maintaining erosion resistance, providing new insights into the design of high-performance porous TBCs.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1733 - 1748"},"PeriodicalIF":3.4,"publicationDate":"2026-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02243-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314808","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":"Numerical Analysis of Fine Particle Dynamics in Supersonic Hybrid Aerosol Deposition","authors":"Yuki Akedo,&nbsp;Kentaro Shinoda,&nbsp;Takayasu Fujino","doi":"10.1007/s11666-026-02209-2","DOIUrl":"10.1007/s11666-026-02209-2","url":null,"abstract":"<div><p>In hybrid aerosol deposition (HAD), fine ceramic particles are sprayed by a thermal nonequilibrium plasma jet to fabricate a film under reduced pressure. The mechanism of the particle deposition is expected to be room-temperature impact consolidation (RTIC) with plasma assistance. Our previous work demonstrated that using a supersonic nozzle in HAD (called supersonic HAD) is effective in increasing particle velocity and film hardness. Furthermore, the film deposited via HAD with a stationary plasma torch and substrate had an M-shaped cross section. However, the factors that caused this film’s shape have been unclarified. In this study, therefore, a rotationally symmetric, two-dimensional (<i>r</i>–<i>z</i>) numerical analysis was performed to clarify the particle behavior in supersonic HAD. The numerical results showed that small particles, which would be deposited in HAD, impact the substrate over a wide area, whereas large particles, which can abrade the surface of the film and substrate, impact the central region of the substrate. This difference in the particle-impact region depending on particle size leads to a deposited film with an M-shaped cross section.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1912 - 1926"},"PeriodicalIF":3.4,"publicationDate":"2026-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314773","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":"Numerical Simulation and Experimental Study on Multi-particle Impact of HVAF-Sprayed WC-12Co on Rough Titanium Alloy Substrates","authors":"Haisheng Jiang,&nbsp;Chang Li,&nbsp;Xuan Wang,&nbsp;Xing Han","doi":"10.1007/s11666-026-02235-0","DOIUrl":"10.1007/s11666-026-02235-0","url":null,"abstract":"<div><p>TC18 titanium alloy is a crucial material for the manufacture of aircraft landing gear, but its corrosion resistance is insufficient in marine salt spray, inland humid heat and other environments. Active Combustion High Velocity Air Fuel (HVAF) is an efficient thermal spraying process, which can prepare dense corrosion and wear-resistant coatings on the TC18 surface, effectively solving the problem of landing gear surface protection. Based on the computational fluid dynamics (CFD) method, a model for combustion reaction and discrete phase during HVAF spraying of WC-12Co powder was established in this work. The evolution law for flame flow temperature and velocity field and the correlation between particle size and particle flight characteristics were revealed. Based on Python scripting, the spray substrate with rough surface and spray particles with random spatial position and random particle size were established. The full-period 3D multi-particle random impact model was established based on CEL (Coupled Eulerian-Lagrangian). The evolution law of temperature, strain and stress fields for particle impacting on the smooth substrate and the rough substrate was revealed. The calculation results show that compared with the smooth surface in ideal conditions, the rough surface substrate inhibits the spray particles flattening motion. The bonding area between the substrate and particles increases, the particles equivalent plastic strain decreases, the substrate equivalent plastic strain increases. The substrate stress distribution is more uniform but the average stress value increases, and the warping resistance of coating is enhanced. The deposition process is more complex. This study is of great significance to reveal the mechanism of particle deposition on rough surfaces and effectively improve coating quality. And it provides a significant theoretical reference for particle deposition modeling on rough surfaces.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1979 - 2001"},"PeriodicalIF":3.4,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314680","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":"Study on the Microstructure and High-Temperature Friction Properties of Ni-Co Alloy High-Speed Laser Cladding for Turbine Valve Stem","authors":"Xingdong Chen,&nbsp;Jinwen Deng,&nbsp;Yanhai Cheng,&nbsp;Jiaye Geng,&nbsp;Jiali Zhou","doi":"10.1007/s11666-026-02224-3","DOIUrl":"10.1007/s11666-026-02224-3","url":null,"abstract":"<div><p>The valve stem of a steam turbine is a core component that controls the operation of the turbine. It operates under harsh working conditions involving the coupling of high temperature, tensile–compressive stress, friction, and additional bending moment. During long-term service at temperatures above 600 °C, its nitrided surface is prone to scratches and peeling of the nitrided layer, which can lead to jamming, and even valve failure or turbine overspeed accidents. Therefore, selecting appropriate materials and surface modification technologies to improve surface morphology and high-temperature wear resistance has become a research focus in this field. In this paper, different cladding layer microstructures were prepared on the surface of C422 steel substrate using high-speed laser cladding technology, aiming to study the improvements in microhardness and friction–wear properties of the cladding layers. The results show that different process parameters have a significant impact on the microstructure and properties of the coating. Under a power of 2000W, a scanning speed of 120 mm/s is the optimal process parameter for the coating performance. Compared with conventional laser cladding coatings, the prepared coating exhibits better morphology, hardness, and wear resistance. Moreover, the enhancement of surface hardness and wear resistance of the coating mainly depends on the combined effects of solid solution strengthening, grain refinement strengthening, and dispersion hardening. Under high-temperature conditions, phase transformations in the coating are the main factor affecting high-temperature wear resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1667 - 1688"},"PeriodicalIF":3.4,"publicationDate":"2026-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314772","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 Phase Evolution of Suspension Plasma-Sprayed Ytterbium Disilicate Environmental Barrier Coatings","authors":"Madhura Bellippady,&nbsp;Nicholas Curry,&nbsp;Lisa Pin,&nbsp;Stéphane Raffy,&nbsp;Nicolaie Markocsan,&nbsp;Shrikant Joshi","doi":"10.1007/s11666-026-02229-y","DOIUrl":"10.1007/s11666-026-02229-y","url":null,"abstract":"<div><p>Suspension plasma spray offers an effective route for depositing coatings with tailored microstructures and phase compositions. In this study, YbDS and YbDS/YbMS EBCs were deposited by varying plasma chemistry specifically the hydrogen content to regulate silica volatilization during the SPS process. Coatings sprayed with zero hydrogen resulted in predominantly YbDS phases, while varying hydrogen content led to the formation of YbDS/YbMS coating with &gt; 70% amorphous content. Post-deposition heat treatment at 1300 °C for 24 h was employed to examine its improved crystallinity and phase distribution for both the coatings. As-sprayed and heat-treated microstructural analysis revealed that post-heat treatment significantly reduced porosity and promoted crack healing, especially in YbDS/YbMS coatings with approximately 45% YbMS content. Further YbDS/YbMS coatings were exposed to long-term (200 h) isothermal oxidation to evaluate microstructural changes and thermally grown oxide (TGO) formation. Finally, the wet corrosion test at 1200 °C for 500 h and erosion tests were performed on the heat-treated YbDS/YbMS coatings to assess their durability in aggressive environmental conditions.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1800 - 1821"},"PeriodicalIF":3.4,"publicationDate":"2026-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02229-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314765","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}