Siyu Li, Chang Li, Xuan Wang, Pengfei Liu, Xing Han
{"title":"Evaluation and Analysis of Particle Oxidation of HVOF Thermal Spraying Based on GA-BP Neural Network Algorithm","authors":"Siyu Li, Chang Li, Xuan Wang, Pengfei Liu, Xing Han","doi":"10.1007/s11666-024-01906-0","DOIUrl":"10.1007/s11666-024-01906-0","url":null,"abstract":"<div><p>In the process of High velocity oxygen fuel (HVOF) spraying, micron-sprayed particles are bound to oxidize under high temperature oxygen-containing environment, particle oxidation and burning are the key factors affecting coating quality. However, how to quantitatively evaluate and control particle oxidation is the bottleneck problem faced by the industry. In this paper, a three-dimensional transient calculation model of flame flow during HVOF thermal spraying WC-12Co process was established, and the computational fluid dynamics and discrete phase surface reaction model were combined to calculate and reveal the distribution characteristics of flame flow and the oxidation degree for particles during the spraying process. The calculation showed that the oxide layer thickness of particles varies greatly with different particle sizes. The oxide layer thickness of particles with 5 μm size is about 90 Å, and the oxide layer thickness of particles with 60 μm size is only about 8 Å. By adjusting the process parameters of oxygen/fuel ratio, particle size and nitrogen mass flow rate in the model, the output samples of sprayed particle flight temperature, velocity and oxide layer thickness can be obtained. On this basis, the sample data were statistically analyzed based on Genetic Algorithm-Back Propagation (GA-BP) neural network model, and the optimal process parameters for preparing the optimized coating were determined: particle size 27 μm, oxygen/fuel ratio 3.1, nitrogen mass flow rate 0.000363 kg/s. Experiments were carried out with optimized parameters, the results show that the optimized coating has fewer defects, lower oxide content and higher hardness and wear resistance. This study provides an important theoretical basis for quantitative preparation of high quality HVOF spray coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"267 - 290"},"PeriodicalIF":3.2,"publicationDate":"2025-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455436","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}
Hipolito Domingo Carvajal Fals, Simone do Rocio Ferraz Sabino, Jeferson Trevizan Pacheco, Marcelo Taveira Veiga, Anderson Geraldo Marenda Pukasiewicz
{"title":"Improvements in Cavitation and Slurry Wear Erosion of Inconel 718 Laser Cladding Through NiNb Addition","authors":"Hipolito Domingo Carvajal Fals, Simone do Rocio Ferraz Sabino, Jeferson Trevizan Pacheco, Marcelo Taveira Veiga, Anderson Geraldo Marenda Pukasiewicz","doi":"10.1007/s11666-024-01925-x","DOIUrl":"10.1007/s11666-024-01925-x","url":null,"abstract":"<div><p>Developing new materials and alloys for coatings is increasingly crucial to reduce costs in manufacturing. Inconel, a widely used alloy, is known for its chemical inertness and resistance to high temperatures, but it lacks sufficient resistance to erosive wear. This study evaluated the wear resistance of Inconel 718 and Inconel 718 + 10% NiNb coatings produced by laser cladding, focusing on cavitation and slurry erosion. Scanning electron microscopy (SEM-EDS), x-ray diffraction, and microhardness profiling were employed to analyze the microstructure and wear. Cavitation erosion tests followed the ASTM G32 standard (2016), and slurry erosion resistance was tested according to ASTM G73-10 (2017). Mass loss and wear rates were assessed for both coatings. The laser-cladding IN718 and IN718 + 10% NiNb coatings exhibited solidification structures with fine dendrites, low dilution, no cracks, and minimal porosity. Adding 10% NiNb refined the microstructure, reducing dendrite size and improving the overall coating quality. This also resulted in a 45% increase in microhardness for the IN718 coating. A higher dispersion in microhardness was observed in the IN718 + 10% NiNb coating. The addition of 10% NiNb promoted the formation of thicker interdendritic zones in an interconnected network, with a higher concentration of the Laves phase. This enhancement increased cavitation resistance and improved slurry erosion resistance by 33% at a 60° impact angle. However, at a 30° impact angle, the improvement was less effective. This study demonstrates the potential of IN718 + 10% NiNb coatings for applications demanding enhanced cavitation and slurry erosion resistance, particularly at higher impact angles.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"690 - 702"},"PeriodicalIF":3.2,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Microstructure and Wear Performance of Inconel 718 Composite Coatings Reinforced with Multi-size and Content WC-Co Fabricated by Laser Cladding","authors":"Lu Xu, Lida Zhu, Miao Yu, Jinsheng Ning, Zhichao Yang, Zongze Jiang, Peihua Xu, Shaoqing Qin, Chenglong Zhai","doi":"10.1007/s11666-024-01908-y","DOIUrl":"10.1007/s11666-024-01908-y","url":null,"abstract":"<div><p>Laser cladding provides the feasibility for fabricating various ceramic-reinforced metal–matrix composite coatings, in which the particle size and content of the reinforcing particles play a crucial role in the properties of the cladding. In this paper, to improve the hardness and wear resistance of Inconel 718 coatings, a series of composite coatings were prepared by laser cladding and the effects of WC-Co grain size and content on the macrostructure, microstructure, phase composition, and mechanical properties of Inconel 718 coatings were revealed in detail. The results showed that with the increase in WC-Co content, multiple carbides coexisted in the coating, the grain size became smaller, and the cracking susceptibility increased. The coatings containing 10-55 μm WC-Co particles have higher grain refinement and higher hardness and better plasticity, but also higher coefficient of friction (COF) values. Based on the increased hardness, the coatings containing 40-120 μm WC-Co particles showed better wear resistance, with a 70.3% reduction in wear volume compared to pure Inconel 718 with 30% WC-Co content. The wear mechanism of each coating was dominated by abrasive wear.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"337 - 353"},"PeriodicalIF":3.2,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455567","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}
Dominique Poirier, Bruno Guerreiro, Jean-Gabriel Legoux, Sylvain Bournival, Stephen Yue, Jason D. Giallonardo
{"title":"Correction to: Evolution of Cold-Sprayed Copper Deposit Mechanical Properties as Function of Substrate Geometry and Heat Treatment Parameters","authors":"Dominique Poirier, Bruno Guerreiro, Jean-Gabriel Legoux, Sylvain Bournival, Stephen Yue, Jason D. Giallonardo","doi":"10.1007/s11666-024-01917-x","DOIUrl":"10.1007/s11666-024-01917-x","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"202 - 202"},"PeriodicalIF":3.2,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455429","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":"Optimization of Microstructure and Mechanical Properties of 2219 Al Alloy Cold-Sprayed Coating by Heat Treatment","authors":"Huwei Tao, Zhilong Chang, Yong Shen, Zhuang Liu, Bingxin Jiang, Zhihang Li, Qifeng Cai, Hua Zhang","doi":"10.1007/s11666-024-01914-0","DOIUrl":"10.1007/s11666-024-01914-0","url":null,"abstract":"<div><p>This study investigates the influence of different heat treatment processes on the microstructure and mechanical properties of cold spraying coatings deposited on TIG joints of 2219 Al alloy. The results indicate that there were no significant changes in the microstructure of the joint before and after cold spraying. However, there was noticeable plastic deformation at the interface between the joint and the coating. The porosity rates of coatings subjected to room temperature, direct aging, and solution aging are 1.94%, 0.67%, and 4.57%, respectively. After direct aging, the extent of plastic deformation in the coating decreases. Following solution aging, recrystallization occurs in the coating leading to grain growth. A comparison of the microstructures of the three types of coatings revealed a gradual reduction in dislocation density and the quantity of low angle grain boundaries (LAGBs) within the coatings. Following solution aging, a significant amount of needle-like long-period transition phase θ′ precipitated. The coating hardness transitioned from a step-like distribution to a more uniform distribution, with an approximate 5HV increase in hardness within 2.5mm depth from the surface of the substrate. The tensile strength of joints with coatings improved by 5.6% and 30.9%, respectively, while the elongation increased by 15.4% and 93.3%, resulting in significantly enhanced ductility. The coating fracture mode transitions from predominantly brittle fracture to primarily ductile fracture.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"250 - 266"},"PeriodicalIF":3.2,"publicationDate":"2025-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455462","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":"Direct Copper Metallization of Carbon Fiber-Reinforced Thermoplastic Polymers for Lightning Strike Protection Using Low-Pressure Cold Spray","authors":"Hiroki Saito, Atsushi Izumi, Yuxian Meng, Yuji Ichikawa, Kazuhiro Ogawa, Syoma Ishida, Yoshihiro Naruse, Akihiko Nishizaki","doi":"10.1007/s11666-024-01885-2","DOIUrl":"10.1007/s11666-024-01885-2","url":null,"abstract":"<div><p>Metallizing polymer composite via cold spray is an attractive process for producing lightning strike protection (LSP) in composite-based aircraft. However, direct deposition of copper, the most common conductive metal, on carbon fiber-reinforced thermoplastic polymers (CFRTP) remains challenging due to the severe polymer erosion and carbon fiber fracture induced by cold-sprayed multi-particle impact. In this work, the copper direct deposition window was explored by varying copper particle size and operating gas temperature, which are primary parameters determining particle impact energy. Following this, a lightning strike test was performed to evaluate the protective effectiveness of the deposited copper coating in reducing damage to the underlying CFRTP substrate. It was revealed that fine copper particles approximately 5 µm in diameter are effective for direct deposition due to their minimal induction of polymer erosion. Sufficient heating of the particle spray area above the glass transition temperature promoted continuous coating formation. The lightning strike tests demonstrated that the cold-sprayed copper coating effectively protects the underlying CFRTP by acting as a major electric current path and a sacrificial protective layer. These findings highlight the promising potential of cold spray as a new LSP technology for polymer composite aircraft.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"231 - 249"},"PeriodicalIF":3.2,"publicationDate":"2024-12-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01885-2.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455466","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":"Crucial Factors Influencing Mechanical and Thermal Properties of Cold-Sprayed CuCrZr Composite Coating","authors":"Min Yu, Zhihua Chang, Peiyuan Lv, Hui Chen","doi":"10.1007/s11666-024-01911-3","DOIUrl":"10.1007/s11666-024-01911-3","url":null,"abstract":"<div><p>Cold spray was employed to apply CuCrZr-based composite coatings onto CuCrZr substrates, aiming to enhance both their mechanical and thermal properties. A comparison was drawn between wear-resistant SiC and high thermal conductivity AlN reinforcements in terms of shear strength, tribological behavior, and thermal conductivity. Results show that the 30vol.% AlN/CuCrZr and 45vol.% SiC/CuCrZr coatings have similar grain structures, ceramic content and particle size distribution, but a distinct mean free path of the ceramics. The 30vol.% AlN/CuCrZr coating exhibits superior hardness and shear strength compared to the 45vol.% SiC/CuCrZr coating, attributed to the greater dispersion strengthening effect arising from the closely spaced AlN particles while the sparse distribution of SiC particles facilitates formation of the CuO lubricating film, resulting in the better wear resistance of the SiC/CuCrZr coating. Finally, the 30vol.% AlN/CuCrZr coating demonstrates superior thermal performance due to the higher thermal conductivity inherent in AlN ceramic. Therefore, the inherent thermal conductivity and distribution of the ceramic particles could be crucial factors in achieving comprehensive thermal and wear performance for the CuCrZr composite coating.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 1","pages":"219 - 230"},"PeriodicalIF":3.2,"publicationDate":"2024-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143455465","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}
David Smith, Paula Pickett, Theresa Grabowski, Joncy Thorpe, Fardad Azarmi
{"title":"Mechanical Properties of Cobalt Chromium Alloy Manufactured by Direct Energy Deposition Technology","authors":"David Smith, Paula Pickett, Theresa Grabowski, Joncy Thorpe, Fardad Azarmi","doi":"10.1007/s11666-024-01913-1","DOIUrl":"10.1007/s11666-024-01913-1","url":null,"abstract":"<div><p>Cobalt chromium (CoCr), a well-known biocompatible material, is additively manufactured using direct energy deposition (DED) technology in this study. This study investigates some important mechanical characteristics of the additively manufactured CoCr using two different numerical simulation methods in addition to mechanical tests and experiments. Mechanical experiments such as hardness, wear, and flexural bending test were conducted on DED-processed samples. All experiments were also conducted on conventionally processed CoCr specimens for comparison purposes. DED-processed CoCr samples exhibited a complex microstructure with a variety of features such as cellular, columnar, and equiaxed grains within their melt pools. While the DED-processed sample had a lower hardness compared to the conventionally processed one, it exhibited a higher wear resistance. The tensile strength obtained from resonance frequency testing was higher for the DED-processed CoCr sample compared to the conventionally fabricated one. The out-of-plane mechanical strength of CoCr samples was measured by conducting flexural bending test, and the conventional sample showed a higher flexural modulus than the DED sample. The bend tests were also numerically simulated using two different finite element analysis (FEA) procedures. The FEA results for the conventionally processed samples are in good agreement with the ones obtained from the experimental flexural bending test. The results of the FEA studies on the DED-processed samples were within 10-20 % of the experimental ones, showing the potential of numerical methods in estimating this property without the need of mechanical testing.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"674 - 689"},"PeriodicalIF":3.2,"publicationDate":"2024-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01913-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688512","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}
L. Gerdt, A. Hilhorst, M. Müller, M. Heidowitzsch, J. Kaspar, E. Lopez, M. Zimmermann, P. J. Jacques
{"title":"Tuning the Microstructure and Mechanical Properties of Al-Co-Cr-Fe-Ni-Ti Compositionally Complex Alloys Manufactured by Means of L-DED","authors":"L. Gerdt, A. Hilhorst, M. Müller, M. Heidowitzsch, J. Kaspar, E. Lopez, M. Zimmermann, P. J. Jacques","doi":"10.1007/s11666-024-01902-4","DOIUrl":"10.1007/s11666-024-01902-4","url":null,"abstract":"<div><p>In the current study, a combinatorial high-throughput screening approach based on CALPHAD simulations and experimental validation has been utilized to explore a Co<sub>2</sub>CrFeNi<sub>2</sub>-Al-Ti CCA-system. This technique, introduced by Kaspar et al. (High Entropy Alloys Mater. https://doi.org/10.1007/s44210-023-00023-x), allows to perform an accelerated alloy development within a wide compositional range and automated fabrication of graded components with varying chemical composition and microstructure. Extended by semi-automated analytical characterization of the produced samples, this approach enables to design novel compositionally complex alloys (CCAs) with promising properties for specific requirements. In our current work, a multiphase design of L1<sub>2</sub> γ′-strengthened Co<sub>2</sub>CrFeNi<sub>2</sub>-Al-Ti CCAs partially tolerating the disordered BCC-A2 or ordered B2 phases in the alloy microstructure has been utilized. The samples with three different chemical compositions were manufactured by means of laser directed energy deposition (L-DED). By subsequent two-step heat treatment, different phase compositions and microstructures have been realized with a main objective to achieve a high volume fraction of L1<sub>2</sub> γ′ precipitations. Mechanical properties of investigated alloys were characterized by means of tensile tests. Depending on chemical and phase composition of the alloys, the ultimate tensile strength varied in the range of 1060-1150 MPa. The formation of BCC-B2 phase led to decreased yield to tensile strength and showed a detrimental effect on ductility of investigated alloys.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"920 - 927"},"PeriodicalIF":3.2,"publicationDate":"2024-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-024-01902-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688513","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}