Journal of Thermal Spray Technology最新文献_第6页

Tribological Evaluation of Plasma-Sprayed Hydroxyapatite Coating on Wire Arc Additively Manufactured Ti6Al4V 电弧增材Ti6Al4V表面等离子喷涂羟基磷灰石涂层摩擦学性能评价

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-30 DOI: 10.1007/s11666-026-02236-z

Vikrant Singh, Anuj Bansal, Jonny Singla, Anil Kumar Singla, Vivek Kumar, Deepak Kumar Goyal, Samandeep Kaur

{"title":"Tribological Evaluation of Plasma-Sprayed Hydroxyapatite Coating on Wire Arc Additively Manufactured Ti6Al4V","authors":"Vikrant Singh, Anuj Bansal, Jonny Singla, Anil Kumar Singla, Vivek Kumar, Deepak Kumar Goyal, Samandeep Kaur","doi":"10.1007/s11666-026-02236-z","DOIUrl":"10.1007/s11666-026-02236-z","url":null,"abstract":"<div>Wear-induced deterioration in additively manufactured Ti6Al4V components restricts their long-term performance in biomedical and structural applications due to severe frictional contact and abrasive conditions. Therefore, this study aimed to enhance the surface durability and tribological reliability of wire arc additively manufactured (WAAM) Ti6Al4V substrates by depositing hydroxyapatite (HAP) coatings through plasma spraying. The optimized HAP coatings exhibited a uniform lamellar microstructure with thicknesses ranging from 134 to 169 µm and strong interfacial bonding. Tribological performance was evaluated through slurry abrasion and pin-on-disk tests against an EN31 hardened steel counterface, supported by response surface methodology (RSM)-based optimization. Slurry abrasion testing demonstrated that the HAP-coated specimens achieved an average reduction in mass loss of approximately 35-45% relative to uncoated Ti6Al4V across the investigated parameter space. Similarly, dry sliding pin-on-disk tests revealed a mass loss reduction of approximately 40-50% for the HAP-coated surfaces. Post-wear SEM analysis indicated that uncoated Ti6Al4V predominantly underwent severe plastic deformation, deep plowing, and adhesive wear. In contrast, the HAP-coated surfaces exhibited controlled microabrasion, inter-splat crack deflection, and localized brittle flaking governed by the lamellar ceramic microstructure and coating phase stability. These mechanisms restricted subsurface deformation and limited direct damage to the substrate. Statistical analysis using response surface methodology confirmed strong model predictability.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1689 - 1704"},"PeriodicalIF":3.4,"publicationDate":"2026-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314791","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}

引用次数: 0

Surface Strengthening of IF Steel by High-Velocity Cold Spray Shot Peening IF钢高速冷喷丸强化研究

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-30 DOI: 10.1007/s11666-026-02238-x

Hanqing Che, Zhijie Zhang, Yan Wang, Shaolong Li, Ling Zhang

{"title":"Surface Strengthening of IF Steel by High-Velocity Cold Spray Shot Peening","authors":"Hanqing Che, Zhijie Zhang, Yan Wang, Shaolong Li, Ling Zhang","doi":"10.1007/s11666-026-02238-x","DOIUrl":"10.1007/s11666-026-02238-x","url":null,"abstract":"<div>Cold spray, conventionally a powder consolidation process to deposit materials, shares many attributes with the shot peening process that is used to strengthen metal surfaces. It is possible to take advantage of the high particle impingement velocity achieved by the cold spray equipment and use the process as a high-velocity shot peening process to strengthen metal surfaces. Cold spray shot peening (CSSP) is an emerging surface engineering technique that integrates the high-velocity particle impact of cold spray with shot peening to enhance the mechanical properties of metallic materials. In this work, interstitial-free (IF) steel was used to explore the potential of CSSP in enhancing material surface and its mechanical properties. Results show that after different numbers of passes of CSSP, gradient microstructure was obtained, and grain refinement was achieved in the surface region. Repeated bombarding of the IF steel surface can increase its surface hardness by 53% after 125 passes of CSSP. Tensile testing results suggest that CSSP can significantly enhance yield strength. In particular, the sample after 125 passes of CSSP exhibits a yield strength approximately twice that of the as-received material while maintaining a comparable uniform elongation, thereby achieving a good combination of strength and ductility. The results of this work demonstrated that CSSP can effectively improve both surface hardness and the bulk tensile behavior of IF steel.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"2054 - 2065"},"PeriodicalIF":3.4,"publicationDate":"2026-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314787","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}

引用次数: 0

Restoring Mechanical Properties of Impact-Damaged Woven Glass Fiber-Reinforced Composites by Polymer Cold Spray Repair 聚合物冷喷涂修复冲击损伤玻璃纤维增强机织复合材料的力学性能

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-30 DOI: 10.1007/s11666-026-02232-3

Ibnaj Anamika Anni, Madison S. Kaminskyj, Margaret Barrasso, Stephen McClain, Kazi Zahir Uddin, Isaac Nault, Joseph F. Stanzione III, Francis M. Haas, Behrad Koohbor

{"title":"Restoring Mechanical Properties of Impact-Damaged Woven Glass Fiber-Reinforced Composites by Polymer Cold Spray Repair","authors":"Ibnaj Anamika Anni, Madison S. Kaminskyj, Margaret Barrasso, Stephen McClain, Kazi Zahir Uddin, Isaac Nault, Joseph F. Stanzione III, Francis M. Haas, Behrad Koohbor","doi":"10.1007/s11666-026-02232-3","DOIUrl":"10.1007/s11666-026-02232-3","url":null,"abstract":"<div>This work investigates the applicability of polymer cold spray as a fast and efficient process for repairing impact damage in glass fiber-reinforced composites. Controlled projectile impacts applied by a gas gun instrument are first used to generate varying damage morphologies and depths in woven glass fiber-reinforced composites. The damaged areas are then repaired using two different thermosetting powders applied via cold spray, followed by short post-curing cycles. The thermosetting powders include a polyester-based and an epoxy-based powder reinforced with chopped glass fibers. Differences between the various repair methods are discussed in terms of their effectiveness in restoring lost properties and the apparent adhesion of the repair material to the composite substrate. Moreover, the efficacy of cold spray repair in restoring flexural strength due to impact is quantified for both feedstocks and compared to the conventional resin repair method. Results show that the thermosetting cold spray feedstock can restore up to 80% of the lost properties in cases of shallow impact damage and up to 40% for more severe, deeper damage. Regardless of damage severity and the type of feedstock, cold spray repair processes outperformed conventional resin repair in both efficacy and speed.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"2066 - 2083"},"PeriodicalIF":3.4,"publicationDate":"2026-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02232-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314714","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}

引用次数: 0

Failure Assessment and Life Prediction of Plasma-Sprayed Thermal Barrier Coatings Considering Top-Coat Cracking Behavior 考虑面层开裂行为的等离子喷涂热障涂层失效评估与寿命预测

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-23 DOI: 10.1007/s11666-026-02226-1

Lubin Wang, Weize Wang, Jiangling Wan, Junhao Wang, Zhen Yao

{"title":"Failure Assessment and Life Prediction of Plasma-Sprayed Thermal Barrier Coatings Considering Top-Coat Cracking Behavior","authors":"Lubin Wang, Weize Wang, Jiangling Wan, Junhao Wang, Zhen Yao","doi":"10.1007/s11666-026-02226-1","DOIUrl":"10.1007/s11666-026-02226-1","url":null,"abstract":"<div>Crack propagation in the top coat is one of the primary failure modes of the atmospheric plasma-sprayed thermal barrier coating system (APS-TBC). However, establishing a clear relationship between it and the overall coating failure remains a challenge. This research proposes a probabilistic statistical method to quantify the risk of top-coat spallation induced by thermally grown oxide (TGO) growth and thermal mismatch. The extended finite element method (XFEM) was used to simulate residual stress and crack propagation behavior under cyclic loading, with a focus on examining the effects of peak temperature, cooling rate, and holding time, as well as the initial length, angle, and location of the crack. Subsequently, a failure criterion and life prediction model for TBCs with top-coat cracks were established based on finite element analysis (FEA) results. The failure probability and reliability were analyzed using the segmented projection method and Monte Carlo theory. Furthermore, the influence of crack distribution on coating failure was analyzed, leading to a proposed method for predicting multi-crack failure probability. Finally, experimental validation confirmed the accuracy of the simulation results, with a prediction bias of 7.5% for the single-crack model and 6.2% for the multi-crack model. The present study provides a new approach for life prediction and reliability evaluation of TBCs.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1760 - 1785"},"PeriodicalIF":3.4,"publicationDate":"2026-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314739","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}

引用次数: 0

Effect of MoB2 Reinforcement on the Microstructure and Wear Behavior of APS NiCr-MoB2 Coatings MoB2增强剂对APS NiCr-MoB2涂层组织和磨损性能的影响

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-22 DOI: 10.1007/s11666-026-02212-7

Jinyong Xu, Xudong Nie, Meng Yan, Petr Rusinov, Sergi Dosta, Chao Zhang

{"title":"Effect of MoB2 Reinforcement on the Microstructure and Wear Behavior of APS NiCr-MoB2 Coatings","authors":"Jinyong Xu, Xudong Nie, Meng Yan, Petr Rusinov, Sergi Dosta, Chao Zhang","doi":"10.1007/s11666-026-02212-7","DOIUrl":"10.1007/s11666-026-02212-7","url":null,"abstract":"<div>To evaluate the effect of boride reinforcement on the microstructure and wear resistance of nickel-based coatings, NiCr-MoB2 coatings with varying MoB2 contents were prepared by atmospheric plasma spraying. MoB2 particles are deposited without structural rearrangement, enhancing the microhardness through dispersion strengthening. The hardness of NiCr-15 wt.%MoB2 (NM15) coating reached a maximum value of 406.53 HV0.1. Phase analysis revealed that a small amount of light atoms is involved in the formation of intermetallic compounds, increasing the material’s resistance to plastic deformation. As the content of MoB2 increases, the shock effect causes the porosity of the coating to decrease and eventually stabilize at 2-3%. Friction experiments show that the adhesion of Ni-based coatings is suppressed after introducing reinforcing phases. The friction coefficient and wear rate exhibit consistent trends. NiCr-10 wt.%MoB2 (NM10) exhibits the optimum tribological performance, attaining a minimum wear rate of 3.85 × 10−6 mm3/N·m. The oxide film dynamically formed on the sliding surface prevents further damage to the internal materials of the coating. The wear mechanism of coatings is influenced by the synergistic effects of hardness and toughness, and it involves a combination of adhesive, oxidative, and abrasive wear. However, excessive addition of MoB2 accelerates brittle crack propagation and exacerbates material loss.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1623 - 1635"},"PeriodicalIF":3.4,"publicationDate":"2026-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314792","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}

引用次数: 0

Wire-Arc Directed Energy Deposition of INO X307 Cladding for Platens of Die-Casting Machines 压铸机压板用INO X307包层的线弧定向能沉积

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-21 DOI: 10.1007/s11666-026-02214-5

Tao Wang, Yang Yang, Wangping Wu, Sheng Lin, Guangyuan Wang, Xiaoyan Li, Qinqin Wang

{"title":"Wire-Arc Directed Energy Deposition of INO X307 Cladding for Platens of Die-Casting Machines","authors":"Tao Wang, Yang Yang, Wangping Wu, Sheng Lin, Guangyuan Wang, Xiaoyan Li, Qinqin Wang","doi":"10.1007/s11666-026-02214-5","DOIUrl":"10.1007/s11666-026-02214-5","url":null,"abstract":"<div>Die-casting machine platens suffer from severe mechanical deformation, wear, and corrosion during long-term service. In this study, an INO X307 alloy layer was deposited onto an AISI 4130 steel substrate using wire-arc directed energy deposition (WA-DED) to enhance surface performance. The cladded layer is mainly composed of γ-austenite with a small amount of residual α-ferrite. A distinct transition region forms at the interface due to elemental diffusion, exhibiting a mixed γ/α dual-phase structure with refined equiaxed grains and a compositional gradient, which contributes to strong metallurgical bonding. The cladded layer shows a significantly enhanced average microhardness of 187.2 ± 9.1 HV0.2 compared with the substrate. Tensile tests reveal high mechanical strength of the cladded layer, reaching 1019 ± 18.8 MPa in the vertical direction and 954 ± 44 MPa in the horizontal direction. In contrast, the transition region exhibits a lower ultimate tensile strength of approximately 653 MPa but much higher ductility, with elongation values of 22.7-26.2%, enabling effective stress accommodation and stable load transfer across the interface. Wear tests demonstrate a reduced wear rate of 2.33 × 10−4mm3/Nm for the cladded layer, while electrochemical measurements indicate superior corrosion resistance, characterized by a lower corrosion current density of 1.227 × 10−6 A·cm−2 and a higher charge-transfer resistance. These results confirm that the INO X307 cladded layer, together with its mechanically compliant transition region, provides an effective surface-reinforcement strategy for improving the wear resistance, corrosion behavior, and mechanical reliability of die-casting machine platens.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1858 - 1875"},"PeriodicalIF":3.4,"publicationDate":"2026-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314762","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}

引用次数: 0

Preparation of Low-Oxygen and High-Density Si-Al Alloy Targets via Plasma Spraying Technology for SiNx Films Sputtering 等离子喷涂技术制备低氧高密度硅铝合金靶材的研究

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-21 DOI: 10.1007/s11666-026-02225-2

Hongjun Yuan, Zhipeng Song, Jiahao Guo, Kewen Zhao, Wei Zhang, Junbao Guo, Longzhen Zhang, Jianfeng Li, Lu Wang, Chengyu Hu, Gequan Hu, Xiaofei Li, Peiqiang Li, Xiaochao Wu, Chengduo Wang, Benshuang Sun, Qingkui Li, Jilin He

{"title":"Preparation of Low-Oxygen and High-Density Si-Al Alloy Targets via Plasma Spraying Technology for SiNx Films Sputtering","authors":"Hongjun Yuan, Zhipeng Song, Jiahao Guo, Kewen Zhao, Wei Zhang, Junbao Guo, Longzhen Zhang, Jianfeng Li, Lu Wang, Chengyu Hu, Gequan Hu, Xiaofei Li, Peiqiang Li, Xiaochao Wu, Chengduo Wang, Benshuang Sun, Qingkui Li, Jilin He","doi":"10.1007/s11666-026-02225-2","DOIUrl":"10.1007/s11666-026-02225-2","url":null,"abstract":"Silicon-aluminum (Si-Al) alloy targets are primarily used for depositing SiNx films, which serve as indispensable functional layers in fields such as solar cells, and low-emissivity (Low-E) glass. However, Si-Al alloy targets produced via plasma spraying tend to exhibit low density, high oxygen content which leads to the formation of nodules on the target surface during the sputtering process, ultimately causing target failure and significantly compromising the quality of the SiNx films. In this study, we improved the density and melting degree of the Si-Al alloy target by optimizing the plasma spraying process. The Si-Al alloy target with a relative density of 94.0% and grain size of 0.6 μm was successfully prepared under the following plasma spraying conditions: spray distance of 120 mm, Ar gas flow rate of 50L min−1, H2 gas flow rate of 4L min−1, and spray power of 37 kW. Furthermore, to further reduce the oxygen content in the target, we proposed an in situ oxygen reduction method during plasma spraying by carbon-coating aluminum powder via high-energy ball milling. Finally, Si-Al alloy targets were prepared under identical atmospheric plasma spraying conditions. The oxygen content in the Si-Al alloy target decreased from 0.727 to 0.29 wt.% by adding 4 wt.% carbon powders to the carbon-coated aluminum powder (the content in the Si-Al mixed powder is 0.3 wt.%). Our work proposes a new process to address the oxidation-prone issue of metals during atmospheric plasma spraying, which holds significant implications for the preparation of low-oxygen metal targets.","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"2034 - 2053"},"PeriodicalIF":3.4,"publicationDate":"2026-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314788","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}

引用次数: 0

Microstructure and Tribological Performance of Laser-Clad Fe-Based Coating: A Study on the Role of B4C Addition 激光熔覆铁基涂层的微观结构与摩擦学性能：B4C的作用研究

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-21 DOI: 10.1007/s11666-026-02215-4

Enchao Cheng, Jing Liu, Yuanxu Duan, Xuewei Li, Jian Zhang

{"title":"Microstructure and Tribological Performance of Laser-Clad Fe-Based Coating: A Study on the Role of B4C Addition","authors":"Enchao Cheng, Jing Liu, Yuanxu Duan, Xuewei Li, Jian Zhang","doi":"10.1007/s11666-026-02215-4","DOIUrl":"10.1007/s11666-026-02215-4","url":null,"abstract":"<div>Fe-based composite coatings with varying B4C contents were fabricated on Cr12 mold steel by laser cladding technology. A systematic analysis was conducted to characterize the coatings’ phase composition, microstructure, microhardness, fracture toughness, and tribological properties. The results show that an appropriate addition of B4C can refine the microstructure and facilitated the precipitation of hard phases such as Fe2B, Cr7C3 and Cr2B. However, excessive B4C led to microstructural coarsening and pronounced carbide segregation. These defects ultimately resulted in the deterioration of both mechanical strength and wear resistance. When the B4C content was 8 wt.%, the cladded layer exhibited optimal comprehensive performance, with an average microhardness of 1009.8 HV0.3, approximately 1.35 times that of the substrate, and a fracture toughness of 2.05 MPa·m1/2. Friction and wear experiments demonstrated that the Fe-based composite coatings exhibited substantially reduced wear volumes compared to the substrate when subjected to varying loads, indicating their superior resistance to abrasive damage. Notably, the composite coating with 8 wt.% B4C demonstrated superior wear resistance among all tested samples. Detailed wear mechanism investigations revealed that the degradation process resulted from a combined effect of adhesive, oxidative, and abrasive interactions. The predominant wear mode exhibited dynamic transitions dependent on both the B4C concentration and the magnitude of the applied load.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1608 - 1622"},"PeriodicalIF":3.4,"publicationDate":"2026-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314760","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}

引用次数: 0

Microstructure, Tribological Performance, and Wear Mechanisms in High Velocity Oxygen-Fuel Sprayed CoCrFeNi-Series High-Entropy Alloy Coatings 高速氧燃料喷涂cocrfeni系列高熵合金涂层的微观组织、摩擦学性能及磨损机理

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-19 DOI: 10.1007/s11666-026-02216-3

Xiaoqian Li, Congcong Wang, Aimin Liang

{"title":"Microstructure, Tribological Performance, and Wear Mechanisms in High Velocity Oxygen-Fuel Sprayed CoCrFeNi-Series High-Entropy Alloy Coatings","authors":"Xiaoqian Li, Congcong Wang, Aimin Liang","doi":"10.1007/s11666-026-02216-3","DOIUrl":"10.1007/s11666-026-02216-3","url":null,"abstract":"<div>Although numerous studies have explored the tribological performance of CoCrFeNi-series high-entropy alloy (HEA) and its coatings, how tribo-oxidation governs the wear behavior across different coating compositions, particularly when processed by high-velocity oxygen-fuel (HVOF) spraying, has not been systematically established. In this study, the microstructure and tribological behavior of CoCrFeNi, AlCoCrFeNi, and MnCoCrFeNi HEA coatings prepared via HVOF spraying were comparatively investigated. The findings reveal that the tribological performance of these HEA coatings is primarily influenced by the characteristics of the tribo-oxide films and related interactions with the coating matrix, rather than by hardness alone under the present testing conditions. Notably, the MnCoCrFeNi coating exhibits superior wear resistance sliding against both GCr15 steel and Al2O3 counterparts, despite its lower hardness (424.5 HV) than AlCoCrFeNi coating. Superior performance is attributed to the formation of adherent and uniform MnCr2O4 spinel oxide films with moderate hardness and relatively higher crack initiation resistance. In this case, synergistic tribo-oxidation, mild abrasive wear, and controlled plastic deformation collectively suppress material loss. Furthermore, the spatial distribution of oxygen within the wear tracks is identified as a useful descriptor of the tribo-oxide film properties and the actual wear conditions. These findings provide insight for designing advanced anti-wear metallic coatings with tailored tribo-oxide films.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1574 - 1590"},"PeriodicalIF":3.4,"publicationDate":"2026-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314789","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}

引用次数: 0

In-Flight Oxidation Behavior and Splat Morphology of NiCoCrAlY Coatings Deposited by Low-Temperature HVAF 低温HVAF沉积NiCoCrAlY涂层的飞行氧化行为和片状形貌

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-04-18 DOI: 10.1007/s11666-026-02213-6

Murilo Sergio Lamana, Aravind Kumar Thoutam, Amirhossein Mahdavi, Andre C. Liberati, Fadhel B. Ettouil, Ritvij Chandrakar, Stephanie Bessette, Nicolas Brodusch, Raynald Gauvin, Ali Dolatabadi, Christian Moreau

{"title":"In-Flight Oxidation Behavior and Splat Morphology of NiCoCrAlY Coatings Deposited by Low-Temperature HVAF","authors":"Murilo Sergio Lamana, Aravind Kumar Thoutam, Amirhossein Mahdavi, Andre C. Liberati, Fadhel B. Ettouil, Ritvij Chandrakar, Stephanie Bessette, Nicolas Brodusch, Raynald Gauvin, Ali Dolatabadi, Christian Moreau","doi":"10.1007/s11666-026-02213-6","DOIUrl":"10.1007/s11666-026-02213-6","url":null,"abstract":"<div>While the use of thermal barrier coatings (TBCs) protects turbine blades in oxidizing environments, the potential of low-temperature high-velocity air-fuel (HVAF) spraying to reduce in-flight oxidation during bond coat deposition remains largely unexplored. This study investigates the effect of low-temperature HVAF process parameters on the microstructure of NiCoCrAlY splats and coating formation on steel substrates. The resulting splats deposited by the use of an internal diameter HVAF torch exhibited craters and surface features indicative of partially melted and plastically deformed particles. Particle velocity measurements revealed a strong correlation between stand-off distance and both splat morphology and particle deposition density. Energy-dispersive spectroscopy (EDS) analyses detected no significant in-flight oxidation. In order to assess the possible nanoscale oxide formation, advanced characterization techniques, including focused ion beam (FIB) cross-sectioning and low-voltage scanning electron microscopy (LV-SEM), were employed. The optimized process parameters were chosen to fabricate the bulk coating, and the quality and microstructure of the final coating were studied. Among the tested conditions, a 50 mm stand-off distance yielded the highest deposition efficiency and lowest porosity, likely due to reduced particle flight time and bow shock effects. These results underscore the critical role of spray parameters in controlling splat behavior and oxide formation, offering new insights into optimizing low-temperature HVAF for advanced bond coat applications in aerospace.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1705 - 1717"},"PeriodicalIF":3.4,"publicationDate":"2026-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314738","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}

引用次数: 0