Journal of Thermal Spray Technology最新文献

{"title":"Physical Mechanisms in Plasma Spray Processing of Suspensions","authors":"Anis Chergui,&nbsp;Cédric Lebot,&nbsp;Vincent Rat,&nbsp;Gilles Mariaux,&nbsp;Alain Denoirjean,&nbsp;Olivier Messé,&nbsp;Benoît Changeux","doi":"10.1007/s11666-024-01905-1","DOIUrl":"10.1007/s11666-024-01905-1","url":null,"abstract":"<div><p>Suspension plasma spraying (SPS) is increasingly studied to produce finely structured coatings with columnar microstructures promising for thermal barrier coatings in aerospace application, especially. However, this process involves many parameters and complex phenomena with large spans of timescales and space scales, such as droplet breakup, liquid droplet evaporation and various physical phenomena occurring within the suspension droplet, making it difficult to master. The aim of this work is to supply a prior analysis to select the dominant physical phenomena and their sequence according to droplet properties and plasma conditions. Thus, this study provides a detailed analysis of these mechanisms, their significance and characteristic timescales, as well as the effects of plasma flow and droplet suspension properties on droplet/submicronic particle behavior. Additionally, the main governing forces acting between the different continuous and discrete phases (plasma, liquid, submicronic particles) are investigated. The results show that droplet breakup occurs much faster than other mechanisms, while the diffusion of submicron particles within droplets, mainly controlled by convection, is the longest. Furthermore, the importance of considering the lift force on droplet transport within the plasma stream is highlighted, particularly in the high-gradient region of the plasma jet.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"735 - 752"},"PeriodicalIF":3.2,"publicationDate":"2024-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688404","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 Deformation Response in Cold Sprayed SiCp/Al Composites: Strengthening, Microstructure Characterization and Thermomechanical Properties","authors":"L. Gyansah,&nbsp;Tianying Xiong,&nbsp;Raffaella Sesana","doi":"10.1007/s11666-024-01910-4","DOIUrl":"10.1007/s11666-024-01910-4","url":null,"abstract":"<div><p>SiC_p/pure Al composites with different SiC_p fractions (20, 30 and 40 wt.%) were cold sprayed followed by hot axial-compression tests at deformation temperatures of 473 K (200 °C) to 673 K (400 °C), leading to failure of specimens through routine crack propagation in their multiphase. The plastic deformation behavior of the coating with respect to the SiC_p contents and the deformation temperatures were studied at strain rate 1 s⁻¹. As-sprayed and post-failure specimens were analyzed by x-ray computed tomography (XCT), transmission electron microscopy (TEM) and scanning electron microscopy (SEM). Quasi-static thermomechanical testing results revealed that compressive strength (UCS = 228 MPa) was the highest in the deposits that were compressed at 473 K compared to those of the as-sprayed, while the as-sprayed exhibited a compressive strength of 182.8 MPa related to the increment in SiC_p fractions. Strength-plasticity synergy was promoted by dynamic recrystallization (DRX) through strengthening and refinement of the grains. The DRX degree depends relevantly on grain refinement, higher deformation temperature and the pinning effects of the interfaces promoted by the ultrafine grain structures (UFG). Reconstructed XCT data revealed different crack propagation mechanisms. A single-plane shear crack with multi-laminates fracture morphology yields relatively through the as-sprayed and as-deformed at 473 K deposits, while a multiphase plane shear cracks preeminently existed in high temperature deformed deposits resulting in multiphase-interface delaminations. Three pertinent strengthening mechanisms, videlicet, SiC_p dispersed strengthening, refined grain strengthening and dislocation strengthening existed in the gradient microstructure, and their detailed contributions to the thermomechanical properties were discussed.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"203 - 218"},"PeriodicalIF":3.2,"publicationDate":"2024-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455625","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":"Novel FeNiCrMoCBPNb High-Entropy Amorphous Coatings Prepared by Atmospheric Plasma Spraying with Excellent Corrosion and Wear Properties","authors":"Zhijun Guo,&nbsp;Yangzi Ye,&nbsp;Zhenjie Zhou,&nbsp;Qianqian Wang,&nbsp;Baosen Zhang,&nbsp;Baolong Shen","doi":"10.1007/s11666-024-01901-5","DOIUrl":"10.1007/s11666-024-01901-5","url":null,"abstract":"<div><p>Designing and fabricating Fe-based amorphous coatings with excellent wear and corrosion resistance as surface protection materials are essential to improve the service life of marine equipment. In this work, by adding 1 at.% Nb, a novel Fe₃₄Ni₂₀Cr₂₀Mo₅B₄C₄P₁₂Nb₁ high-entropy amorphous alloy with enhanced glass-forming ability and excellent corrosion resistance was designed. The Fe₃₄Ni₂₀Cr₂₀Mo₅B₄C₄P₁₂Nb₁ composition was adopted to prepare gas-atomized powders, which were then used as feedstock to prepare coatings using atmospheric plasma spraying (APS) technology with different input power. Higher spraying power was found to lead to denser coating, but more formation of oxides and lower amorphous content. The coating-35 kW input power exhibited the best corrosion resistance in 3.5 wt.% NaCl solution and high hardness of 519 ± 21 HV. The dry sliding wear rate of the coating-35 kW at 20 N and 20 mm/s was 8.3 × 10⁻⁷ mm³/(N m), and the friction coefficient of the coating was 0.17 and kept relatively steady throughout the sliding test. This work guided designing Fe-based high-entropy amorphous coatings from both the composition aspect and the coating preparation technology.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"394 - 408"},"PeriodicalIF":3.2,"publicationDate":"2024-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455623","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":"Research on the Influence of Laser Power on the Microstructure and Performance of Fe-Based Coating","authors":"Hao-Zheng Wang,&nbsp;Xin Zhang,&nbsp;Cao Cheng-ming,&nbsp;Lu Ren,&nbsp;Jiqiang Li","doi":"10.1007/s11666-024-01904-2","DOIUrl":"10.1007/s11666-024-01904-2","url":null,"abstract":"<div><p>For the poor working environment, there would easily be sprocket tooth nest corrosion wear failure of mining sprocket, based on coaxial powder feeding method, this study prepares Fe-based alloy cladding on the surface of 42CrMo, which further improves the performance of the substrate. The effects of laser power on the dilution rate, microstructure, hardness and corrosion resistance of Fe-based alloy coating and the effect of heat treatment on the tensile properties of the cladding layer were studied. The results show that, with the increase in laser power, the grain size of the cladding layer becomes larger. When the laser power is greater than 1900 W, the cladding layer generates Fe₂B and Cr₂₃C₆; the average hardness of the coating with laser power of 1600 W is the highest, which is 586.86 HV. Electrochemical experiments show that the 1800 W coating has excellent corrosion resistance, high corrosion potential (− 0.42 V) and minimum corrosion current density (2.65 × 10⁻⁶A·cm⁻²). EDS results show that no obvious corrosion area is found on the surface of the 1800 W cladding layer. This excellent performance is attributed to the formation of a dense Cr₂O₃ passivation film on the surface of the cladding layer. The tensile test shows that the coating heat treated at 700 °C has the best tensile properties.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"316 - 336"},"PeriodicalIF":3.2,"publicationDate":"2024-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455484","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":"Fast and Nondestructive Mechanical Characterization of Thermally Sprayed and Laser Cladded Coatings: Automated Surface Acoustic Wave Spectroscopy as a New Tool for Quality Control and Research","authors":"Martin Zawischa,&nbsp;Stefan Makowski,&nbsp;Filofteia-Laura Toma","doi":"10.1007/s11666-024-01899-w","DOIUrl":"10.1007/s11666-024-01899-w","url":null,"abstract":"<div><p>Laser-induced surface acoustic wave spectroscopy (LISAWS) allows quick and nondestructive evaluation of the elastic properties such as the Young’s modulus of coatings, surfaces and surface-near bulk materials. Furthermore, the mechanical weakening due to cracks and pores can be evaluated, as they influence the propagation of surface waves as well. This makes the method a fast, accurate and versatile tool for surface characterization, and it is increasingly used in research and development, and quality control. The short measurement time of the LISAWS method allows the time-efficient distribution of the effective Young's modulus over the coated surface to be determined. For this purpose, an industrial LAwave measurement system was automated to allow for processing of a larger number of samples and fast mappings. The investigated coating materials were thermally sprayed Al₂O₃ insulation coatings and WC-reinforced 316L steel coatings on brake disks produced by laser cladding, respectively. For the Al₂O₃ coatings, the correlation between the Young's modulus and its areal distribution is shown for different process parameters, such as spray gun movement direction or spray distance, and compared with results from pull-off tests. For the WC/316L-coated brake disks, the distribution of the wave velocity over the coated surfaces or the two coated sides of different disks with varying coating qualities is used to assess the coating quality and homogeneity.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"928 - 938"},"PeriodicalIF":3.2,"publicationDate":"2024-12-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01899-w.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688508","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":"Improved Adhesion of Plasma-Sprayed Zirconia Coatings on Textured Alumina Substrates","authors":"Geoffrey Darut,&nbsp;Timothé Ferrasse,&nbsp;Sophie Costil,&nbsp;Bernard Bouteiller,&nbsp;Marie-Camille Auscher","doi":"10.1007/s11666-024-01900-6","DOIUrl":"10.1007/s11666-024-01900-6","url":null,"abstract":"<div><p>Coating adhesion by thermal spraying method requires sufficient surface roughness of the substrate. The scale of the roughness must be adapted to the spread particle thickness size to optimize their mechanical attachment after spreading and cooling, particularly in the case of plasma spraying. Grit blasting is the most common process used to create the surface asperities required for coating bonding. However, to further increase adhesion, the use of laser texturing for metallic substrates is beneficial and is already well documented in literature. In the case of ceramic substrates such as alumina, grit blasting with corundum particles is no longer effective in creating a roughness of a few micrometers. Laser texturing therefore appears to be a potential candidate for generating adhesion in coatings. In this work, adhesion mechanisms of YSZ coatings produced by atmospheric plasma spraying (APS) on a textured alumina bulk substrate were investigated. The influence of substrate surface texturing by two different lasers (pulsed and continuous) on YSZ monolayer was studied. The lasers create an adapted surface profile to generate adhesion of YSZ coatings. For the pulsed laser, the depth of the holes must reach 100 µm, while for the continuous laser, the arithmetic mean surface roughness (Sa) value must exceed 25 µm. YSZ monolayer reaches a maximum adhesion of 4.8 MPa. Al₂O₃ and Y₂O₃ materials were selected as potential bond coats to increase YSZ topcoat adhesion on textured surfaces. The use of a bond coat with the same surface profile can improve adhesion, particularly with yttria, to reach a maximum value of 13.2 MPa. Surface texturing combined with the use of a bond coat is an appropriate approach for creating adhesion of a ceramic coating to a ceramic substrate.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"703 - 713"},"PeriodicalIF":3.2,"publicationDate":"2024-12-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688510","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":"Desktop Manufacturing of Plasma-Sprayed Coating and Computational Estimation of its Mechanical Properties","authors":"Riddhi Joshi,&nbsp;Benjamin Boesl,&nbsp;Arvind Agarwal,&nbsp;Tony Thomas","doi":"10.1007/s11666-024-01851-y","DOIUrl":"10.1007/s11666-024-01851-y","url":null,"abstract":"<div><p>Traditional optimization of plasma-sprayed coatings involves resource-intensive experimental iterations of spraying parameters. This study presents a novel computational protocol for designing and manufacturing ceramic (e.g., Al₂O₃) coatings, reducing the need for extensive experiments. A computational fluid dynamics approach is adopted to simulate the morphology of Al₂O₃ powder feedstock splats. These simulated splats are then stochastically arranged to construct three-dimensional (3D) representations of plasma-sprayed Al₂O₃ coatings. The effective elastic modulus of the coating is computed using finite element analysis of the simulated microstructure. The introduced \"Desktop Manufacturing Protocol\" showcases a significant reduction in the requisite plasma spraying experiments, offering an optimized coating with desired microstructure and mechanical properties. This integrated computational approach not only streamlines the coating development process but also provides insights into the intricate relationships between spraying parameters, microstructure, and overall coating performance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 8","pages":"2686 - 2697"},"PeriodicalIF":3.2,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142844854","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 and Experimental Studies on the In-Situ Measurement of Thermal Conductivity of the Thermal Barrier Coating","authors":"Ningning Liu,&nbsp;Ruifeng Dou,&nbsp;Zhi Wen,&nbsp;Xunliang Liu","doi":"10.1007/s11666-024-01895-0","DOIUrl":"10.1007/s11666-024-01895-0","url":null,"abstract":"<div><p>The thermal conductivity of thermal barrier coating (TBC) materials can be measured using transient and steady-state methods. It is crucial to evaluate the high-temperature thermal insulation performance of TBC materials. Although several steady-state methods exist for obtaining in situ TBC thermal conductivity at high temperatures, they are limited by heating methods and heat flux measurement instruments. In this study, a transient-state method is proposed, which does not have these limitations. Numerical simulations indicate that this method accurately predicts the temperature-dependent thermal conductivity of TBC materials in situ. The experimental results align well with existing literature. This method has potential applications for monitoring TBC failures, such as sintering, cracking, and peeling.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"460 - 476"},"PeriodicalIF":3.2,"publicationDate":"2024-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455536","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 of HVAF and HVOF-Sprayed WC-CoCr Coatings on Aluminum Alloy","authors":"Tunji Adetayo Owoseni,&nbsp;Mohit Gupta,&nbsp;Shrikant V. Joshi,&nbsp;Mare Ingmar,&nbsp;Tommi Varis","doi":"10.1007/s11666-024-01894-1","DOIUrl":"10.1007/s11666-024-01894-1","url":null,"abstract":"<div><p>Light alloys are being increasingly investigated as alternatives to ferrous-based engineering components, based on weight considerations. However, in-service applications of such light alloy components often require a surface modification step to enhance their wear and corrosion responses for improved functionality. Thermally sprayed cermet coatings offer an enhanced resistance to wear and corrosion. This work investigates WC-CoCr coatings deposited using two different feedstocks comprising fine and coarse powder size distributions on aluminum alloy and steel substrates using high-velocity air-fuel (HVAF) and high-velocity oxy-fuel (HVOF) spray techniques. The WC-CoCr coatings were HVAF sprayed at various parameters to investigate the relationship between the processing conditions, microstructure, and performance. Microindentation, dry sliding wear, dry sand abrasion, cavitation erosion, and corrosion tests were conducted to assess the performance of the coatings. Despite the qualitative similarities in the microstructures of the coatings, the measured microindentation hardness values were observed to vary, and coatings deposited with higher particle impact velocities showed the highest microhardness between 1400 and 1600 HV0.3. For the three categories of wear investigated, the HVAF coatings showed better resistance than the HVOF coating investigated in this study. The estimated average specific wear rate (SWR) due to sliding wear of the HVOF coating was ~ 16.7 ± 4.0 × 10⁻⁸ mm³/Nm compared to that of the most resistant HVAF coating, which exhibited a SWR of ~ 1.7 ± 0.6 × 10⁻⁸ mm³/Nm. The cumulative mass loss rate due to the abrasive wear on the HVOF coating reached ~ 1.11 mg/min compared to ~ 0.76 mg/min of the most abrasion-resistant HVAF coating. All coatings showed similar corrosion resistances under the investigated conditions. The combination of wear and corrosion performance of the respective coatings could provide insight into the coating selection for intended applications.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"970 - 991"},"PeriodicalIF":3.2,"publicationDate":"2024-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01894-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688356","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":"Advancements in Deposition of High Entropy Alloys Using Cold Spray Technology","authors":"Magesh Kumaravel,&nbsp;Sara Bagherifard,&nbsp;Mario Guagliano","doi":"10.1007/s11666-024-01879-0","DOIUrl":"10.1007/s11666-024-01879-0","url":null,"abstract":"<div><p>High entropy alloys (HEAs) are the recent category of metallic alloys that exhibit superior properties, especially in extreme working environments, when compared to conventional metal alloys. Their advanced properties make them suitable candidates for various structural and functional applications as surface coating and additively manufactured components. Thus, the suitability of various deposition and fabrication techniques are being explored, taking into consideration the material’s multi-component composition. Among various manufacturing techniques, cold spray has significant merits when handling HEAs. This review is aimed at providing a detailed state of the art of cold-sprayed HEAs. The microstructure evolution after cold spray, as well as the function and performance in terms of wear resistance, mechanical strength, corrosion resistance and oxidation resistance of the deposits are discussed for all cold spray deposits of HEAs. The reported post-treatments applied to HEAs deposits and their effects on functionality are also discussed to help us lay a base for further investigations and developments in the new horizon of HEAs. Perspectives on potential future developments are discussed to provide directions for research investigations in the field of cold spraying of HEAs.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"1 - 36"},"PeriodicalIF":3.2,"publicationDate":"2024-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455538","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}