Journal of Thermal Spray Technology最新文献_第8页

Optimization of Cr3C2-NiCr Coatings using ID-HVOF: A Statistical Approach to Key Process Parameters 基于ID-HVOF的Cr3C2-NiCr涂层优化：关键工艺参数的统计方法

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-31 DOI: 10.1007/s11666-026-02195-5

Mark Dennis Kensy, Ingor Baumann, Jonas Zajaczkowski, Leif Hagen, Wolfgang Tillmann

{"title":"Optimization of Cr3C2-NiCr Coatings using ID-HVOF: A Statistical Approach to Key Process Parameters","authors":"Mark Dennis Kensy, Ingor Baumann, Jonas Zajaczkowski, Leif Hagen, Wolfgang Tillmann","doi":"10.1007/s11666-026-02195-5","DOIUrl":"10.1007/s11666-026-02195-5","url":null,"abstract":"<div>Cr3C2-NiCr coatings are widely used to protect industrial components in harsh environments due to their exceptional wear resistance, high-temperature oxidation protection, and corrosion resistance. Such coatings are typically produced using the high-velocity oxygen fuel (HVOF) spraying process. However, internal coating applications pose challenges such as restricted surface access, limited experience with optimized process parameters and the difficulty of producing fine chromium carbides, which results in coarser particles compared to powders like WC-CoCr. This study investigates the application of a commercially available Cr3C2-NiCr powder using the ID-HVOF coating process. A Central Composite Design (CCD) within a Design of Experiments (DoE) framework was employed to analyze the effects of key process parameters—kerosene, hydrogen, oxygen, and the powder feed rate—on the coating performance. The results confirm that the validation test successfully produced a coating that matches the predicted parameters from the CCD. This study underscores the importance of statistical design in optimizing the ID-HVOF process, enabling improved mechanical properties and reliable coating quality for the internal surface protection using Cr3C2-NiCr powders.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1010 - 1023"},"PeriodicalIF":3.3,"publicationDate":"2026-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02195-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830136","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

High-Temperature Abrasive Wear and Tribological Behaviors of HVOF-Sprayed Cr3C2-NiCr Coatings: Oxidation-Dominant Mechanism hvof喷涂Cr3C2-NiCr涂层的高温磨粒磨损与摩擦学行为：氧化主导机理

IF 3.4 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-27 DOI: 10.1007/s11666-026-02207-4

Xinqing Ma, Peter Ruggiero

{"title":"High-Temperature Abrasive Wear and Tribological Behaviors of HVOF-Sprayed Cr3C2-NiCr Coatings: Oxidation-Dominant Mechanism","authors":"Xinqing Ma, Peter Ruggiero","doi":"10.1007/s11666-026-02207-4","DOIUrl":"10.1007/s11666-026-02207-4","url":null,"abstract":"<div>HVOF-formed Cr3C2-NiCr cermet coatings are extensively utilized because of their remarkable resistance to wear and erosion degradation at both room temperature and specially elevated temperatures. This research focused on comparing feedstock powders, particularly nanocrystalline feedstock, and examining the wear and tribological behaviors of their HVOF-formed coatings at elevated temperatures. The experimental investigation included characterizing the Taber wear rates of the pre-oxidized coating samples, as well as the in situ tribometer friction behaviors of the coatings at 800 °C. The primary objective was to understand how the factors such as Cr3C2 particle size, nanocrystallinity, oxidation, and test conditions influence the sliding wear behaviors of the coatings assessed under Taber abrasive wear and tribometer conditions. Through detailed analyses of the tested samples using TGA, XRD, and SEM/EDXS techniques, mechanisms dominated by oxidation and abrasion are proposed to interpret the sliding wear results. A significant finding is that the smaller-sized powder containing nano- and submicron Cr3C2 particles significantly contributed to the improvement in abrasive wear resistance and the reduction of the friction coefficient at both room and high temperatures.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 5","pages":"1591 - 1607"},"PeriodicalIF":3.4,"publicationDate":"2026-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148314717","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

Announcing the Journal of Thermal Spray Technology 2025 Editor’s Choice Selections 宣布热喷涂技术杂志2025编辑选择

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-27 DOI: 10.1007/s11666-026-02206-5

引用次数: 0

Mechanical and Fracture Properties of As-Built Inconel 718 Produced by High-Speed Laser Directed Energy Deposition: Stability to Process Parameters Variation 高速激光定向能沉积制备原位Inconel 718的力学和断裂性能：对工艺参数变化的稳定性

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-26 DOI: 10.1007/s11666-026-02204-7

Ondrej Kovarik, Simone Maffia, Tobias Stittgen, Filip Wick, Vojtech Lukes, Abhinav Anand, Jan Cizek

{"title":"Mechanical and Fracture Properties of As-Built Inconel 718 Produced by High-Speed Laser Directed Energy Deposition: Stability to Process Parameters Variation","authors":"Ondrej Kovarik, Simone Maffia, Tobias Stittgen, Filip Wick, Vojtech Lukes, Abhinav Anand, Jan Cizek","doi":"10.1007/s11666-026-02204-7","DOIUrl":"10.1007/s11666-026-02204-7","url":null,"abstract":"<div>Directed energy deposition (DED) is a group of efficient additive manufacturing methods for creating complex-shaped components. Of these, the next-generation high-speed laser-based directed energy deposition (HS DED-LB) combines high-speed kinematics and a high-power infrared laser, offering unparalleled deposition speeds. Due to its novelty, the mechanical and fracture properties of the HS DED-LB deposits are virtually unknown. In this pioneer study, a series of unique testing methods was used to determine the properties and assess the influence of the inherent microstructure. As a model material, Inconel 718 was selected as an industrially relevant superalloy. To demonstrate the HS DED-LB capabilities, it was printed at a high powder feed rate of 30 g/min at different levels of laser power (up to 2400 W) and scanning speeds (up to 60 m/min). The corresponding linear energy densities ranged from 1.8 to 3.6 kJ/m, i.e., values significantly higher than those of powder bed fusion methods and lower than those of conventional DED. The method was shown to be very robust as, in this range, the tested mechanical and fracture properties differed by less than 10%. The HS DED-LB Inconel 718 exhibited a specific microstructure and texture, owing to the inherent thermal history of the melt pool. This is a favorable material state, similar to that of the traditional directionally solidified Inconel superalloys used in aerospace.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1259 - 1271"},"PeriodicalIF":3.3,"publicationDate":"2026-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02204-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830025","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

Structural and Thermal Characterization of Multilayer MCrAlY/YSZ/(YSZ + Al2O3 + TiO2) TBCs for an Internal Combustion Engine Exhaust Valve Head Application 多层MCrAlY/YSZ/(YSZ + Al2O3 + TiO2) tbc在内燃机排气阀头中的结构和热特性

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-26 DOI: 10.1007/s11666-026-02218-1

Rashid Ali, Syed Zameer Abbas, Tauheed Shehbaz, Tareq Manzoor

{"title":"Structural and Thermal Characterization of Multilayer MCrAlY/YSZ/(YSZ + Al2O3 + TiO2) TBCs for an Internal Combustion Engine Exhaust Valve Head Application","authors":"Rashid Ali, Syed Zameer Abbas, Tauheed Shehbaz, Tareq Manzoor","doi":"10.1007/s11666-026-02218-1","DOIUrl":"10.1007/s11666-026-02218-1","url":null,"abstract":"<div>This study investigates the performance of composite thermal barrier coating (TBC) system in comparison with conventional TBC on non-heat-treated stainless steel substrates. Air plasma spray is used to deposit both conventional TBC comprising of 8 wt.% yttria-stabilized zirconia (YSZ) topcoat and NiCoCrAlY bond coat that is compared to composite TBC in which the topcoat consists of inner conventional TBC layer and composite outer layer of 8 wt.% YSZ + Al2O3 + TiO2. Feedstock for the composite topcoat was prepared at laboratory scale through sintering and ball milling. These TBCs are characterized for the phases present, microstructure and elemental distribution and phase stability in as-deposited and thermally cycled conditions. The as-deposited composite and conventional configurations have shown uniform microstructure in the layers without any crack between them. The average nanoindentation hardness of composite topcoat was ≈ 27% higher than the conventional topcoat, due to addition of alumina and titania. The measured weight gain over time as the temperature changed from 25 to 1300 °C, for conventional topcoat configuration was nearly 89% higher than composite topcoat configuration, indicating its greater thermal resistance. There is a higher elastic moduli mismatch between conventional topcoat and bond coat (30%) as compared to the composite topcoat and bond coat (13%) that resulted in higher crack density and average length of microcracks in conventional topcoat after thermal cycling. Therefore, this multilayer thermal barrier coating comprising of NiCoCrAlY and 8YSZ and a composite topcoat of 8YSZ + Al2O3 + TiO2 could provide a balance of thermal insulation and mechanical durability for high-temperature applications.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1155 - 1165"},"PeriodicalIF":3.3,"publicationDate":"2026-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830024","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

Cost-Efficient Ti-V-Sn-Sb Chlorine-Evolving Electrodes Deposited by Liquid Plasma Spraying for Antibacterial and Wastewater Treatment 高效液相等离子喷涂Ti-V-Sn-Sb析氯电极的抗菌和废水处理

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-24 DOI: 10.1007/s11666-025-02155-5

Yu Zhang, Ping Zhou, Xiaomei Liu, Yi Liu, Jing Huang, Shuangjie Wu, Hidetoshi Saitoh, Botao Zhang, Hua Li

{"title":"Cost-Efficient Ti-V-Sn-Sb Chlorine-Evolving Electrodes Deposited by Liquid Plasma Spraying for Antibacterial and Wastewater Treatment","authors":"Yu Zhang, Ping Zhou, Xiaomei Liu, Yi Liu, Jing Huang, Shuangjie Wu, Hidetoshi Saitoh, Botao Zhang, Hua Li","doi":"10.1007/s11666-025-02155-5","DOIUrl":"10.1007/s11666-025-02155-5","url":null,"abstract":"<div>Electrochemical chlorine evolution is a promising approach for antimicrobial and wastewater treatment. However, the large-scale applications of conventional electrodes are hindered by the high cost of precious metals and tedious thermal decomposition method. In this study, precious metal-free electrodes for chlorine evolution were fabricated via liquid plasma spraying technique using a Ti0.35V0.35Sn0.25Sb0.05 feedstock solution with varying total metal concentration. Scanning electron microscopy combined with EDS elemental analysis showed that the coatings exhibited a loose and porous morphology, with Ti, V, Sn and Sb elements uniformly distributed throughout. X-ray diffraction analysis identified characteristic diffraction peaks corresponding to VO2, SnO2, Sb2O5 and TiO2 in the coatings. The electrocatalytic properties of the coatings were evaluated using multiple electrochemical techniques, and the electrode prepared using the 1.0 M feedstock solution demonstrated the best performance. Antimicrobial test showed that after 30-s electrolysis, the disinfection rates of simulated tap water against E. coli and S. aureus exceeded 88.1% and 96.8%, respectively, whereas for the 0.06 M NaCl solution, both pathogens were inactivated by over 99.9% within 15 s. Additionally, methylene blue degradation reached 98.4% after 45 min of electrolysis. This study provides a new strategy for producing low-cost chlorine-evolving electrodes with potential application in antibacterial and wastewater treatment.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1056 - 1065"},"PeriodicalIF":3.3,"publicationDate":"2026-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830018","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 Behavior of TiN/ Al2O3 Composite Coatings Produced by High-Velocity Suspension Flame Spraying (HVSFS) 高速悬浮火焰喷涂TiN/ Al2O3复合涂层的微观结构和摩擦学性能

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-24 DOI: 10.1007/s11666-026-02208-3

Ebru Gyoktepeliler Akin, Luca Bortolotti, Edoardo Rossi, Milena Pazzi, Andreas Killinger, Luca Lusvarghi, Giovanni Bolelli

{"title":"Microstructure and Tribological Behavior of TiN/ Al2O3 Composite Coatings Produced by High-Velocity Suspension Flame Spraying (HVSFS)","authors":"Ebru Gyoktepeliler Akin, Luca Bortolotti, Edoardo Rossi, Milena Pazzi, Andreas Killinger, Luca Lusvarghi, Giovanni Bolelli","doi":"10.1007/s11666-026-02208-3","DOIUrl":"10.1007/s11666-026-02208-3","url":null,"abstract":"<div>In this study, an aqueous suspension containing fine aluminum oxide and coarser titanium nitride (TiN) powders was prepared and processed using high-velocity suspension flame spraying (HVSFS) to produce thick TiN/ Al2O3 composite coatings (>50 µm). The influence of spraying parameters, such as total gas flow and flame stoichiometry, on the microstructure, phase composition, mechanical, and tribological properties was investigated. The results demonstrate that TiN can be successfully deposited under atmospheric conditions using the HVSFS process, achieving a homogeneous distribution of TiN particles within the alumina matrix. This composite structure led to a significant increase in microhardness. Furthermore, the TiN/ Al2O3 coatings produced with λ = 0.8 exhibited improved wear resistance and a reduced coefficient of friction compared to pure Al2O3 coatings.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"549 - 562"},"PeriodicalIF":3.3,"publicationDate":"2026-03-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02208-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147607021","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

Microstructure Characteristic and Wear Resistance of Al2CrFeNiMoSix High-Entropy Alloy Coating on Cr12MoV by Laser Cladding 激光熔覆Cr12MoV表面Al2CrFeNiMoSix高熵合金涂层的组织特征及耐磨性

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-23 DOI: 10.1007/s11666-026-02185-7

Yali Gao, Shan Jiang, Yu Liu, Xin Li, Sicheng Bai, Dongdong Zhang

{"title":"Microstructure Characteristic and Wear Resistance of Al2CrFeNiMoSix High-Entropy Alloy Coating on Cr12MoV by Laser Cladding","authors":"Yali Gao, Shan Jiang, Yu Liu, Xin Li, Sicheng Bai, Dongdong Zhang","doi":"10.1007/s11666-026-02185-7","DOIUrl":"10.1007/s11666-026-02185-7","url":null,"abstract":"<div>Al2CrFeNiMoSix (x = 0, 0.25, 0.5, 0.75, 1.0) high-entropy alloy coatings were designed and fabricated on Cr12MoV by laser cladding, and the influence of Si on microstructure and wear resistance was investigated. The results show that Al2CrFeNiMoSi0 coating exhibits equiaxed crystal consisted of BCC phase. However, Al2CrFeNiMoSix (x = 0.25–1.0) coatings present Cr1.5Mo1.5Si besides of BCC phase, and the equiaxed crystal is significantly refined. Under the comprehensive effect of grain refinement strengthening and second-phase strengthening, the microhardness of Al2CrFeNiMoSix coatings is improved 152 ~ 234%, and the wear volume is reduced 59.7 ~ 78.3% compared with the substrate. Among them, Al2CrFeNiMoSi0.5 coating expresses the best wear performance. Al2CrFeNiMoSi0 coating has fatigue wear mechanism; however, Al2CrFeNiMoSi0.5 coating exhibits abrasive wear mechanism. Furthermore, the degree of oxidation wear decreases obviously with the increasing Si element.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1349 - 1364"},"PeriodicalIF":3.3,"publicationDate":"2026-03-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830149","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

Investigation of Splat Characteristics and In-Flight Particle Oxidation in HVAF-Deposited NiCoCrAlY Coatings hvaf沉积NiCoCrAlY涂层的飞溅特性和飞行中颗粒氧化研究

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-23 DOI: 10.1007/s11666-026-02200-x

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

{"title":"Investigation of Splat Characteristics and In-Flight Particle Oxidation in HVAF-Deposited NiCoCrAlY Coatings","authors":"Aravind Kumar Thoutam, Murilo Sergio Lamana, Amirhossein Mahdavi, Andre C. Liberati, Fadhel B. Ettouil, Ritvij Chandrakar, Stéphanie Bessette, Nicolas Brodusch, Raynald Gauvin, Ali Dolatabadi, Christian Moreau","doi":"10.1007/s11666-026-02200-x","DOIUrl":"10.1007/s11666-026-02200-x","url":null,"abstract":"<div>High-Velocity Air Fuel (HVAF) thermal spray process has emerged as a promising technique for depositing oxidation-sensitive MCrAlX coatings due to its combination of relatively low flame temperatures and high particle velocities. In this study, NiCoCrAlY coatings were deposited onto stainless steel substrates using two distinct sets of HVAF parameters, to investigate the in-flight particle behavior, oxidation and splat characteristics. In-flight particle diagnostics via AccuraSpray 4.0 enabled real-time monitoring of average particle temperature and velocity at deposition. The deposited coatings exhibited a combination of partially molten and fully deformed splats. Preliminary EDS confirmed localized carbon enrichment attributed to unburnt hydrocarbons under fuel-rich conditions. β-phase grain coarsening was observed post-deposition, potentially influencing long-term oxidation resistance through modified Al diffusion behavior. High-resolution EDS and FIB-LV-SEM analyses were conducted to assess potential nanoscale oxidation and confirmed minimal oxide formation on splats, with thin surface oxides measuring approximately 15 ± 3 nm. The coatings were further examined to assess the influence of deposition parameters on microstructure evolution, coating build-up, and in-flight oxidation behavior.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1428 - 1445"},"PeriodicalIF":3.3,"publicationDate":"2026-03-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830148","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

Influence of Particle Loading in Micro-Cold Spray Direct Writing 微粒载荷对微冷喷雾直写的影响

IF 3.3 3区材料科学

Journal of Thermal Spray Technology Pub Date : 2026-03-23 DOI: 10.1007/s11666-026-02191-9

Renjie Pan, Juanfang Liu, Zuying Shen, Jun Song

{"title":"Influence of Particle Loading in Micro-Cold Spray Direct Writing","authors":"Renjie Pan, Juanfang Liu, Zuying Shen, Jun Song","doi":"10.1007/s11666-026-02191-9","DOIUrl":"10.1007/s11666-026-02191-9","url":null,"abstract":"<div>The present work characterizes the critical influence of particle mass loading on gas flow, 1-5-μm particle dynamic behavior, impact and deposition characteristics in micro-cold spray direct writing (MCSDW), which is a promising technique for microscale additive manufacturing. Through two-way coupled Eulerian–Lagrangian modeling, a critical threshold of particle loading is identified, which governs the transition from a uniform to nonuniform particle distribution. When the loading exceeds the threshold, the localized gas flow decelerates in the region of particle presence. The higher loading further reduces the particle impact velocity, widens the impact linewidth and decreases the deposition efficiency. A sensitivity analysis reveals that small particles and high inlet pressure further enhance the particle loading effects. To achieve a uniform coating with effective deposition in our cases considered, the particle loading should not be greater than the critical threshold (0.2%), the particle diameter should be ≤ 2 μm, and the inlet pressure should be (ge) 3.0 MPa. These findings advance the understanding of the mechanism of MCSDW and provide actionable strategies for precision additive manufacturing of micro features and patterns.</div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1384 - 1392"},"PeriodicalIF":3.3,"publicationDate":"2026-03-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830147","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