Journal of Thermal Spray Technology最新文献

{"title":"Debonding of Porous Coating: A Late Failure Mode of Uncemented, Partially Threaded Acetabular Components—Retrieval Analysis","authors":"Łukasz Łapaj,&nbsp;Joanna Sulej-Chojnacka,&nbsp;Justyna Rozwalka,&nbsp;Abdulrahim Alaouir,&nbsp;Tomasz Markiewicz,&nbsp;Paweł Chodór,&nbsp;Jan Kiryluk,&nbsp;Adrian Mróz,&nbsp;Jan Zabrzyński","doi":"10.1007/s11666-024-01801-8","DOIUrl":"10.1007/s11666-024-01801-8","url":null,"abstract":"<div><p>Titanium plasma-sprayed (TPS) porous coatings have been used in total hip arthroplasty for decades. They are considered reliable, and very few failure cases have been described so far. This retrieval study described a series of 20 acetabular components—where total or partial debonding occurred during in vivo use and aimed to explain the underlying failure mechanisms. Implants were examined using optical and electron microscopy (SEM), metallographic sections of retrievals were prepared while pathologic samples of periprosthetic tissues were examined for presence of wear debris. Data from metallographic slides indicated that debonding was initiated at free borders of the coating and tended to progress at the interface between the TPS layer and the shell. In some cases, total debonding occurred leading material wear of both the TPS layer and acetabular shell leading to massive release of metallic debris and accelerated polyethylene wear in third body mechanism. SEM examination demonstrated that splats forming the TPS layer exhibited features suggesting a high temperature gradient between the plasma sprayed layer and the substrate material existed, leading to porosity of splats and suboptimal bonding strength. This study demonstrated that coating application parameters and certain design features (screw holes, fins) may promote long-term failure due to debonding. Surgeons should be aware of this complication as it is most likely underreported, while manufacturers should consider more rigorous pre-clinical testing as suboptimal coating bonding may result in failures during long-term clinical use.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"2137 - 2152"},"PeriodicalIF":3.2,"publicationDate":"2024-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01801-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141577232","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":"Microstructure and Tribological Behavior of Low-Temperature HVAF Ti6Al4V Coatings","authors":"P. Khamsepour,&nbsp;P. Stoyanov,&nbsp;A. Dolatabad,&nbsp;C. Moreau","doi":"10.1007/s11666-024-01800-9","DOIUrl":"10.1007/s11666-024-01800-9","url":null,"abstract":"<div><p>Ti-6Al-4 V is commonly used in gas turbine engines and is sometimes subject to wear during operation. To address this, cost-effective and environmentally friendly solutions are being explored, with a focus on solid-state additive manufacturing techniques such as cold spray (CS). CS can create a dense structure; however, the existing porosity adversely affects the mechanical properties. To reduce the need for post-heat-treatment, this paper considers inner-diameter high- velocity air-fuel (ID_HVAF) as an alternative repair method which is a relatively low-temperature HVAF process that can deposit coatings with microstructures close to those observed in CS coatings. ID_HVAF process can deposit particles at high velocities and relatively low temperatures so that a significant portion of the particles forming the coatings are deposited in the solid state. This work is based on the deposition of Ti-6Al-4 V coatings using the ID_HVAF gun. During deposition, increasing the nozzle length increases the particle velocity and substrate temperature. The particles hit a softer surface with higher kinetic energy, thus increasing the density of the samples. However, HVAF will still oxidize some Ti-6Al-4 V particles and produce vanadium oxide. To study the tribological behavior, Ti-6Al-4 V counterballs were used to simulate the dovetail interface. According to the result, the top deposited layers were densified by the application of counterbalance force. Compared to an α-β Ti-6Al-4 V bulk sample, the coatings have a smaller wear track width and a greater wear depth, resulting in less wear on the counterballs. Each of the three samples shows a combination of abrasive and adhesive wear. The low cohesion between the particles in the coatings results in smaller oxide debris with a greater amount on the wear track of the coatings. By acting as a roller between the counter ball and the coating, this debris can slightly reduce the coefficient of friction.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"2034 - 2051"},"PeriodicalIF":3.2,"publicationDate":"2024-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141522499","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":"Aerosol Deposition of CuFeO2 Photocathode Coatings for Hydrogen Production","authors":"Alessia Bruera,&nbsp;Andreas Elsenberg,&nbsp;Mauro Borghi,&nbsp;Giulia Dolcetti,&nbsp;Giovanni Bolelli,&nbsp;Frank Gärtner,&nbsp;Mauricio Schieda,&nbsp;Thomas Klassen,&nbsp;Luca Lusvarghi","doi":"10.1007/s11666-024-01798-0","DOIUrl":"10.1007/s11666-024-01798-0","url":null,"abstract":"<div><p>Photoelectrochemical (PEC) water splitting is a viable route for green hydrogen generation. In PEC cells, the electrodes are coated with suitable semiconductor materials, which absorb the sunlight, generating charge carriers that are used to split water molecules into H₂ and O₂. CuFeO₂ is one promising photocathode material for water splitting. However, its performance is limited by electron/hole pairs recombination within the film and at the film/substrate interface. Aerosol deposition (AD) can be employed to minimize charge recombination by spraying dense, thin films and by establishing a good back-contact interface. In this study, CuFeO₂ powders were synthesized through a conventional solid-state technique and sprayed by AD under varied parameter sets. The effect of particle size distributions, carrier gas, gas pressure and substrate temperature was investigated. The best spraying parameter set was then tuned to obtain thin coatings (&lt; 1 µm). Single-particle deformation and coatings microstructure were investigated by scanning electron microscopy. Optical properties of CuFeO₂ films were analyzed by UV–Vis spectroscopy, while photoelectrochemical performances were estimated through amperometry tests under simulated sunlight. The results of this research show that CuFeO₂ photocathodes can be successfully manufactured by AD. Their performance can be optimized by adjusting coating thickness and by annealing in air.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"1746 - 1770"},"PeriodicalIF":3.2,"publicationDate":"2024-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01798-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141522516","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":"A Critique on the Role of Object-Oriented Finite Element Analysis (OOF2) in Predicting Thermal and Mechanical Properties in Thermal Sprayed Coatings","authors":"Riddhi Joshi,&nbsp;Tanaji Paul,&nbsp;Cheng Zhang,&nbsp;Benjamin Boesl,&nbsp;Arvind Agarwal","doi":"10.1007/s11666-024-01797-1","DOIUrl":"10.1007/s11666-024-01797-1","url":null,"abstract":"<div><p>Microstructural modeling at progressive length scales can enable the prediction of thermal and mechanical properties of thermal sprayed coatings with hierarchical features. Object-oriented finite (OOF2) element modeling conducted using microstructural images, although a powerful technique, has been employed to a limited extent in thermally sprayed materials. Consequently, there is little scientific understanding of the efficiency of the OOF2 technique for estimating bulk properties. For the first time, this study provides a comprehensive analysis of these factors’ role in the OOF2 technique’s capability to predict thermal and mechanical properties in ceramic and metallic coatings manufactured by plasma spray, high-velocity oxyfuel (HVOF) spray, wire_arc spray, and cold spray. The prediction efficiency generally increases for larger grain sizes as overall microstructural features are captured even at lower magnifications. The same effect is obtained in microstructures having lower and uniformly shaped pores. The data on the porosity suggest that OOF2 predictions are most accurate when conducted on coatings manufactured using sintered feedstock because of the dense powder. In contrast, OOF2 predictions are the least accurate when hollow spherical (HOSP) feedstock having empty cores is used. These multiscale facets of microstructure, porosity, etc., thus, highlight the importance of the selection of the representative volume element for accurate analysis in OOF2, which, depending upon the process, is captured at 300× − 500× for HVOF and wire-arc spray, and 1000× − 15,000×  magnifications for plasma and cold spray. This overall assessment charts the relative importance of variables such as grain size, porosity, and feedstock as compared to that of the process and anisotropy in the prediction of properties in thermally sprayed coatings. While these conclusions are based on the limited literature of 37 articles, this study makes a bold attempt towards a guidebook for future thermal spray researchers in conducting more accurate OOF2 analysis.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"1867 - 1885"},"PeriodicalIF":3.2,"publicationDate":"2024-06-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141508860","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 the Corrosion Resistance of Cold Spraying Additive Manufactured FeCoNiCrMn High Entropy Alloy: Improving Particle Bonding Quality Through Heat Treatment","authors":"Dong Wu,&nbsp;Wenya Li,&nbsp;Yaxin Xu,&nbsp;Xiawei Yang,&nbsp;Yu Su","doi":"10.1007/s11666-024-01791-7","DOIUrl":"10.1007/s11666-024-01791-7","url":null,"abstract":"<div><p>The cumulative deposition characteristic of deformed particles in the cold spray (CSAM) deposits forms unique open pore microstructure and poor bonding quality, which has great influence on the corrosion resistance. This study investigates the influence of heat treatment (HT) on the corrosion and wear behaviors of CSAM FeCoNiCrMn high entropy alloy. The results show that HT improves the bonding quality between particles, turning open micro-pores into closed, and ultimately greatly improves the corrosion resistance, which can reach the level of traditional additive manufacturing and as-cast materials. The wear resistance of the CSAM deposit after HT is improved, and the layer stripping phenomenon is weakened by the increase in interparticle bonding quality. To improve the corrosion resistance of the CSAM deposit, the first consideration is to improve the bonding quality.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"1982 - 2003"},"PeriodicalIF":3.2,"publicationDate":"2024-06-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141358576","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 of the Propane Detonation Spraying under Different Gun Structures","authors":"Hua-Kang Li,&nbsp;Du Wang,&nbsp;Yong-Jing Cui,&nbsp;Wen Lu,&nbsp;Jun-Kai Wu,&nbsp;Zhi-Min Wang,&nbsp;Feng-Ming Chu,&nbsp;Zhen-Yu Tian","doi":"10.1007/s11666-024-01793-5","DOIUrl":"10.1007/s11666-024-01793-5","url":null,"abstract":"<div><p>Detonation spraying is a technique that uses the high-temperature, high-velocity detonation waves to deposit the molten metal particles onto the target surface. The effect of the detonation spraying is influenced by the structure of the gun significantly. A series of detonation spraying gun two-dimensional (2-D) numerical models with various spray gun structures (slope lengths from 5 to 45 mm with a step of 10 mm) were established in this work, to investigate the spray performance. During the process of gas detonation, the interaction between the detonation wave and obstacles results in the generation of reflected waves, which exerts an accelerating effect on flame. Simultaneously, collisions between the flame front and obstacles introduce energy losses. Based on the above factors, the following results can be obtained: when the slope length at the nozzle diameter change point is 5 mm, the maximum flow velocity is achieved at the spray gun outlet. When the slope length at the transition point of the spray gun is 25 mm, the maximum temperature is reached at the spray gun outlet. When the slope length at the transition point of the spray gun is 45 mm, the maximum pressure is reached at the spray gun outlet. This work can contribute to the design of the detonation gun.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"2153 - 2166"},"PeriodicalIF":3.2,"publicationDate":"2024-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141377430","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":"Investigation on the Microstructure Evolution and Properties of a Novel In-Situ Fiber Phase-Reinforced Nickel Composite Coating Deposited by Wide-Band Laser","authors":"Xing Wang,&nbsp;Nannan Ren,&nbsp;Kun Zhao,&nbsp;Wei Meng,&nbsp;Hu Xie,&nbsp;Xiaohui Yin,&nbsp;Qunshuang Ma","doi":"10.1007/s11666-024-01794-4","DOIUrl":"10.1007/s11666-024-01794-4","url":null,"abstract":"<div><p>In this paper, a novel hard nickel composite coatings were fabricated by wide-band laser cladding technique. The effects of Si alloying on the composite coatings were investigated by microstructure characterization, phase identification, microhardness and wear resistance. Results showed that the in-situ precipitated phases in the laser molten pool were composed of the γ-Ni solid solution and hard phases such as Cr₂₃C₆, CrSi, Cr₅B₃. With the increase of Si element, the morphology of the precipitated phases changed significantly. When the added content of Si was 1.0 wt.%, the precipitated phase was a mainly block morphology. As the added content of Si was increased to more than 2.0 wt.%, the main precipitated phase was transformed into a long stripe morphology. With the increase of Si content, the stripe-like precipitated phase was gradually refined and finally becomes density needle-like precipitates. Element distribution analysis showed that the block precipitated phase was enriched in Cr, W and Si elements. Additionally, the enriched elements in the long strip precipitation phase were essentially the same as those in the block precipitation phase. The added Si element was highly involved in the in-situ reactions of precipitated phase. The TEM results showed that the precipitated phases contained the crystal structures of Cr₅B₃ and Cr₇C₃. The pin-on-disc wear tests revealed that the composite coating with the addition of 6 wt.% Si exhibited the best wear resistance in the experimental group. The average friction coefficient was about 0.6 and the wear mass loss rate was about 2.38 × 10⁻⁵ g/m under counter-abrasive conditions. The worn surface analysis indicated that the wear mechanism of composite coatings was mainly abrasive wear. The refined needle-like precipitated phase was closely bound to the matrix and thus not easy to peel off, providing a significant improvement in the wear resistance of the laser cladding coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"1783 - 1799"},"PeriodicalIF":3.2,"publicationDate":"2024-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141386215","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 Low Plasma Spraying Power on Anode Microstructure and Performance for Metal-Supported Solid Oxide Fuel Cells","authors":"Zhigang Zhu,&nbsp;Honglong Ning,&nbsp;Chen Song,&nbsp;Kaisheng Lin,&nbsp;Taikai Liu,&nbsp;Kui Wen,&nbsp;Changguang Deng,&nbsp;Hanlin Liao,&nbsp;Min Liu","doi":"10.1007/s11666-024-01789-1","DOIUrl":"10.1007/s11666-024-01789-1","url":null,"abstract":"<div><p>Metal-supported solid oxide fuel cells have broad application prospects in distributed power generation, transportation, military, and other fields. The electrochemical performance of the cell is still a challenge in commercial applications. Regulating the anode microstructure and optimizing polarization characteristics are effective methods. In this study, atmospheric plasma spraying technology is chosen to prepare the Ni-Gd_0.2Ce_0.8O_1.9(GDC) anodes using different low plasma powers (18, 21, 24 kW), which is cost-effective and efficient. The power effect on anode microstructure and electrochemical performance is investigated. The results show that as the plasma power decreases from 24 to 18 kW, the anode’s gas permeability and three-phase reaction boundary (TPB) gradually increase. Reducing the spraying power can decrease polarization resistance and improve power density. The 18-kW anode exhibits the lowest polarization resistance and the best output performance. Open-circuit voltage and maximum power density are 1.03 V and 0.89 W cm⁻² at 750 °C, respectively. The polarization resistance and total resistance are 0.19 and 0.40 Ω cm², respectively. The experimental results prove that atmospheric plasma spraying can realize the rapid and low-cost anode preparation for high-performance MS-SOFC.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 5","pages":"1725 - 1735"},"PeriodicalIF":3.2,"publicationDate":"2024-05-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141189723","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":"Correction to: Machine Learning-Based Diagnosis of Thermal Barrier Coating Process Quality","authors":"Dongjie Sun,&nbsp;Qing He,&nbsp;Zhi Huang","doi":"10.1007/s11666-024-01796-2","DOIUrl":"10.1007/s11666-024-01796-2","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 6","pages":"2184 - 2184"},"PeriodicalIF":3.2,"publicationDate":"2024-05-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142415348","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":"Trade-Off Among Cavitation Erosion Resistance, Corrosion Resistance, and Antifouling Properties of HVOF-Sprayed WC-CoCr Coating via Adding Stainless Steel and Copper","authors":"Zhe Guo,&nbsp;Xiaomei Liu,&nbsp;Ye Tian,&nbsp;Ping Zhou,&nbsp;Miao Yu,&nbsp;Jin Liu,&nbsp;Xu Yin,&nbsp;Rui Yang,&nbsp;Hua Li","doi":"10.1007/s11666-024-01792-6","DOIUrl":"10.1007/s11666-024-01792-6","url":null,"abstract":"<div><p>This work investigated the trade-off among cavitation erosion resistance, corrosion resistance, and antifouling properties in HVOF-sprayed WC-10Co4Cr coatings. By adding 316L stainless steel (316L) and copper to WC-10Co4Cr coatings, this work aimed to enhance their antifouling ability while maintaining their cavitation erosion and corrosion resistances, presenting a comprehensive evaluation of the modified coatings, including their microstructure, hardness, fracture toughness, and resistance to cavitation erosion, corrosion, and biofouling. The results revealed that Cu addition significantly improved the antifouling property but at a cost of the compromised cavitation erosion and corrosion resistances. In contrast, 316L enhanced the cavitation erosion and corrosion resistances but did not effectively improve the antifouling property. The dual addition of Cu and 316L demonstrated a balanced performance in all three aspects. This research contributed to the development of HVOF-sprayed WC-CoCr coatings suitable for marine environments, suggesting further optimization possibilities by altering Cu and 316L contents.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"33 5","pages":"1570 - 1584"},"PeriodicalIF":3.2,"publicationDate":"2024-05-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01792-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141188112","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}