Journal of Thermal Spray Technology最新文献

{"title":"Optimization of Cored Wire Arc Spraying of Amorphous FeCrNiSiWNbB Coating; Hot-Corrosion and High-Temperature Erosion Evaluations","authors":"E. Bahrami,&nbsp;M. Khodaei","doi":"10.1007/s11666-025-01958-w","DOIUrl":"10.1007/s11666-025-01958-w","url":null,"abstract":"<div><p>Protective coatings are the most common solution to prevent high-temperature erosion, oxidation and especially hot corrosion of boiler tubes. One of the best protective coatings for boiler tubes is amorphous/nanocrystalline coatings, which can be deposited by different thermal spray methods especially via arc spraying as a low-cost and portable method. The aim of this study is the fabrication and characterization of Fe-based amorphous/nanocrystalline coating designed for boiler tube via the low-cost FeCrNiSiWNbB cored wire using the ferroalloy powders. This work was focused on the reducing of the porosity of coatings by optimization of the arc spraying parameters using Taguchi design of experiment, which was verified by microhardness measurements and metallography experiments. The microstructure, composition and phase constitution of the optimized coating were characterized by scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and selected area electron diffraction techniques. The erosion resistance and hot corrosion behavior of the modified coating were investigated by high-temperature erosion and hot corrosion (type II) tests, respectively. It was found that optimal FeCrNiSiWNbB coating represents a significantly higher hot corrosion resistance rate, 92, and 86% increase in comparison to carbon steel substrate and pure Fe coating, at 600 °C. Additionally, the high-temperature erosion resistance rate of optimized FeCrNiSiWNbB coating enhanced 26, and 14% at 600 °C in comparison to the pure Fe coating and plain carbon steel substrate respectively.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1368 - 1383"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919120","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":"Cold Spray Using a Phase-Change Propellant Fluid Approach: Proof of Concept and Potential Benefits","authors":"Aleksandra Nastic,&nbsp;Meisheng Xu,&nbsp;Wenzhuo Yan,&nbsp;Bruce Daniels,&nbsp;Mohan Vijay,&nbsp;Mohammed Yandouzi,&nbsp;Patrick Richer,&nbsp;Bertrand Jodoin","doi":"10.1007/s11666-025-01930-8","DOIUrl":"10.1007/s11666-025-01930-8","url":null,"abstract":"<div><p>Cold spray (CS) has captured the interest of many researchers, scientists and industries resulting in significant development of the technology in the last decade. The process is shifting from fundamental studies to industrial application developments for mass production, with great potential in fields such as energy, electronics, biomedical, aerospace and semiconductor. However, besides the recent developments, improvements and deployment of the technology, CS has been mostly limited to the use of nitrogen and/or air. One potential improvement for the technology is to operate with a phase-changing driving/propellant gas, such as steam. While it is known that steam inherently provides better gas dynamic properties than nitrogen, using it while inducing phase-change, relying on the occurrence of condensation to increase the gas and particle temperature through the release of large latent heat energy, could improve performance and efficiency of the CS technology.To demonstrate this benefit of phase-changing propellant gas and its potential to bring a substantial breakthrough in the field, the current study compares deposition characteristics, i.e., porosity, microhardness, oxygen content and adhesion, of coatings generated using steam and nitrogen across the same CS system and operating parameters. A validated non-equilibrium steam computational fluid dynamics model is developed to describe the fundamentals of condensing water droplets’ influence on flow and feedstock particle condition. A finite element model is included to conceptualize the effect of steam and nitrogen flow on copper particle interfacial deformation upon impact.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1109 - 1132"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919144","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":"Synergistic Effect of MoS2 and Ag on High-Temperature Tribology of Self-Lubricating Ni-Based Composite Coatings by Cold Spray Deposition","authors":"Rohit Kumar Singh Gautam,&nbsp;Vivek Mani Tripathi,&nbsp;Jitendra Kumar Gautam,&nbsp;Vineeta Adhikari,&nbsp;Subhash Mishra,&nbsp;Pushkar Jha,&nbsp;Ekta Upadhyay,&nbsp;Hemant Nautiyal,&nbsp;Rajiv Kumar","doi":"10.1007/s11666-025-01959-9","DOIUrl":"10.1007/s11666-025-01959-9","url":null,"abstract":"<div><p>As technology advances, tribo-coupling components, viz. gears, seals, bearings etc., frequently function under severe conditions, and this enhanced the demand of effective lubrication for reduced friction and wear of contacting interfaces. The optimal content of solid lubricants in the matrix is a viable alternative to acquire the desired lubrication in extended regime of temperatures. The present work investigates the tribological characteristics of cold sprayed Ni-based self-lubricating composite coatings with varying content of Ag (5, 10, 12.5 and 15 wt.%) and fixed concentration of MoS₂ (10 wt.%). The mechanical, microstructural and the tribological properties were evaluated from room temperature (RT) to 800 °C. The results revealed that the coating having 12.5 wt.% of Ag along with 10 wt.% of MoS₂ has delivered superior lubricity among all compositions in terms of lower coefficient of friction COF (0.18) and wear rate 5 × 10^-5 mm³/Nm at 800 °C. The average COF, without the use of Ag and MoS₂, has attained (0.49) at 800 °C. However, the coating containing 12.5 wt.% of Ag has attained increased COF (0.38) and wear rate 7.1 × 10^-5 mm³/Nm at 400 °C; thereafter, a declining trend was observed. The improved frictional properties were accredited to the synergistic effects of impregnated solid lubricants and novel lubricious phases (Ag₂MoO₄, Ag₂Mo₂O₇, Ag₂Mo₄O₁₃ NiO, etc.) formed on the worn surface. The observed wear mechanisms were correlated with the morphologies and tribo-chemical reaction between the contacting interfaces.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1281 - 1297"},"PeriodicalIF":3.2,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919146","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":"With Gratitude to Our Guest Editors and Reviewers for Their Critical Contributions in 2024","authors":"","doi":"10.1007/s11666-025-01962-0","DOIUrl":"10.1007/s11666-025-01962-0","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1017 - 1020"},"PeriodicalIF":3.2,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919151","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 Ni-Coated-Al2O3 Addition on Corrosion and Wear Resistance of Laser Cladded Fe-Based Composite Coatings","authors":"Weifeng Xin,&nbsp;Erguang Fu,&nbsp;Fanchang Dai,&nbsp;Xinlong Wei,&nbsp;Chao Zhang","doi":"10.1007/s11666-025-01952-2","DOIUrl":"10.1007/s11666-025-01952-2","url":null,"abstract":"<div><p>In this paper, Fe-based composite coatings reinforced by Ni-coated-Al₂O₃ particles were prepared by laser cladding to investigate the influence of Ni-coated-Al₂O₃ addition on corrosion and wear resistance. Microstructure and microhardness of Fe-based composite coatings were characterized by using x-ray diffraction, scanning electron microscope and Vickers hardness tester. Corrosion behavior was evaluated using potentiodynamic polarization tests and electrochemical impedance spectroscopy experiments. Wear behavior was conducted by a dry reciprocating sliding wear tester. Results show that Fe-based composite coatings exhibit smooth columnar microstructure and grain refinement induced by the addition of Al₂O₃ ceramic particles. The microhardness of the Fe-based composite coating is much higher than that of the substrate and increases with the increase in Ni-coated-Al₂O₃ content. The corrosion current density of Fe-based composite coatings is 5.84 × 10^-4 A·cm^-2 for pure Fe-based coating, 2.37 × 10^-4 A·cm^-2 for 1 wt.% Ni-coated-Al₂O₃ coating, 2.09 × 10^-4 A·cm^-2 for 3 wt.% Ni-coated-Al₂O₃ coating and 10.70 × 10^-4 A·cm^-2 for 5 wt.% Ni-coated-Al₂O₃ coating, respectively. Corrosion resistance can be notably enhanced by appropriate addition of Ni-coated-Al₂O₃. Also, wear resistance of Fe-based composite coating has been significantly improved by the addition of Ni-coated-Al₂O₃. The Fe-based composite coating with 3 wt.% Ni-coated-Al₂O₃ displays the highest wear resistance. The wear mechanism of Fe-based composite coatings is a mixture of abrasive wear and adhesive wear as well as oxidation wear mechanisms. The proposed Fe-based composite coatings can be applied to improve the corrosion and wear resistance of components in contact with high-speed fluids, such as hydraulic turbine blades and ship propellers.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1220 - 1228"},"PeriodicalIF":3.2,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919140","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":"An Analytical Model of the Thermal Conductivity of Thin Porous Ceramic Coatings","authors":"Lei Zhao,&nbsp;Pei-feng Hsu","doi":"10.1007/s11666-025-01954-0","DOIUrl":"10.1007/s11666-025-01954-0","url":null,"abstract":"<div><p>Thermal conductivity is a key property of thermal barrier coatings, which play a critical role in protecting components in high-temperature environments such as gas turbines and jet engines. This paper presents an analytical model for evaluating the thermal conductivity of thin, porous ceramic thermal barrier coatings. The analytical model incorporates factors such as porosity, pore orientation, and aspect ratio, which are extracted from scanning electron microscopy images. The model, which provides a comprehensive understanding of heat transfer mechanisms within coatings, was verified through comparisons with numerical simulation results from a multiphysics software tool and experimental measurements. Overall, the study provides insight into the factors affecting the thermal conductivity of porous yttrium-stabilized zirconia coatings and presents an analytical method to predict conductivity based on the coating's microstructure. Since the microstructure evolves during the service, a time-dependent thermal conductivity can be predicted if the microstructure changes over time become available. The model offers capabilities beyond those of conventional numerical models and demonstrates good agreement with experimental measurements of thermal conductivity. The information is critical for the design of thermal barrier coatings systems and thermal performance evaluation during service.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1147 - 1159"},"PeriodicalIF":3.2,"publicationDate":"2025-02-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919283","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":"In Situ Spray Bead Acquisition and Analysis for Coating Thickness Predictions","authors":"Uroš Hudomalj,&nbsp;Ivo Aschwanden,&nbsp;Lukas Weiss,&nbsp;Majid Nabavi,&nbsp;Konrad Wegener","doi":"10.1007/s11666-025-01953-1","DOIUrl":"10.1007/s11666-025-01953-1","url":null,"abstract":"<div><p>Coating thickness is considered to be one of the most important characteristics of thermal spray coatings. Therefore, it has long been the goal to be able to predict the coating thickness that ensues when coating an arbitrary part. A commonly applied approach is to determine the coating deposit based on a series of spray spot tests and use that for modeling the coating. Another option is to conduct spray bead tests, which better reflect the conditions during the coating. This work suggests a novel approach for in situ acquisition of the spray beads and their analysis. The acquisition is based on a 3D camera to scan the sample before and after depositing of a spray bead. The approach allows for their streamlined evaluation, enabling better understanding of spray bead formation and their modeling. The suggested analysis of spray beads includes uncertainty evaluation. This enables estimation of model prediction uncertainties which has been omitted in the previous works on the topic. The analysis shows that a relative expanded uncertainty of 10% (at 95% level of confidence) can be expected for the coating thickness prediction for the simplest scenario of coating a flat sample sprayed perpendicularly at a constant spray distance and spray speed.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 2-3","pages":"893 - 901"},"PeriodicalIF":3.2,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01953-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143688482","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":"The Effect of SiC Content on the Microstructure and Mechanical Properties of AlCoCrFeNiTi Laser Cladding High-Entropy Alloy Coatings","authors":"Z.-Q. Zhang,&nbsp;W. Niu,&nbsp;Y.-W. Lei,&nbsp;Y. Zheng","doi":"10.1007/s11666-024-01924-y","DOIUrl":"10.1007/s11666-024-01924-y","url":null,"abstract":"<div><p>45 steel is widely used in manufacturing industry, but the properties of 45 steel sometimes fail to meet the requirements of special applications. High-entropy AlCoCrFeNiTi coatings with different SiC contents (0, 10, 20, and 30 wt.%) were deposited on 45 steel substrates by laser cladding technology. With the increase in SiC content, the coatings consisted of BCC1 + BCC2 phases when the SiC content was 0 and 10 wt.% and TiC and Ni₄Ti₃-reinforced phase + BCC1 when the SiC content was 20 and 30 wt.%, respectively. The microhardness and wear resistance of the coating increased with increasing SiC content. When the SiC content was 30 wt.%, the average hardness of the cladding coating was maximum 943HV_0.3, which is about 3.7 times that of the substrate, and the coating possessed the lowest wear mass loss and friction factor. The wear mode changes from adhesive wear and oxidative wear to abrasive wear as the SiC content increased.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1195 - 1207"},"PeriodicalIF":3.2,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919235","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":"Towards Highly Dense Yb-Silicate Microstructures Deposited by Air Plasma Spray for Environmental Barrier Coating Applications II: Plasma Gas Composition, Feedstock, and Anode Orifice Comparisons","authors":"Edward J. Gildersleeve V,&nbsp;Emine Bakan,&nbsp;Robert Vaßen","doi":"10.1007/s11666-025-01937-1","DOIUrl":"10.1007/s11666-025-01937-1","url":null,"abstract":"<div><p>In all air plasma sprayed (APS) environmental barrier coating (EBC) applications, the predominant goal is to achieve maximum coating density, gas tightness, and/or hermeticity prior to subjecting it to harsh environments (i.e., high-temperature impingement of high-velocity water vapor). The microstructures of APS coatings are historically understood to be influenced by the input processing parameters. Beyond the local deposition rate (surface speed, feeding rate) explored in Part I, there are further extrinsic processing parameters such as plasma gas composition, feedstock choice, and anode orifice dimensions which can be tuned, but have not been fully explored in the context of EBCs. Screening these ancillary extrinsic inputs in a rigorous and systematic way presents challenges in determining which control variable(s) to select to gain meaningful insights. A constant particle temperature distribution (not average particle temperature) in the spray stream was held as a constraint, and the aforementioned extrinsic parameters were varied. As in Part I, a qualitative microstructural approach toward examining the presence (or absence) of advantageous vertical thin microcracks in the as-deposited coating was taken. For certain conditions, a Dense Vertically Macrocracked structure was achieved. Concurrent synthesis of these results offers further insights into process selection and parameter design can be gained.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1452 - 1462"},"PeriodicalIF":3.2,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-025-01937-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918955","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":"Exploring Slurry Abrasion Resistance of HVOF-Sprayed VC and CoNi Coatings: A Response Surface Methodology Approach","authors":"Vikrant Singh,&nbsp;Samandeep Kaur,&nbsp;Vijay Kumar,&nbsp;Anuj Bansal,&nbsp;Anil Kumar Singla","doi":"10.1007/s11666-025-01957-x","DOIUrl":"10.1007/s11666-025-01957-x","url":null,"abstract":"<div><p>Slurry abrasion (SA) evaluation is critical for assessing the wear resistance of coated surfaces under harsh operating conditions. This study investigates the performance of HVOF-sprayed vanadium carbide (VC) and VC-50CoNi coatings applied to SS316 substrates, focusing on their behavior under varying loads, slurry concentrations, and abrasive particle sizes. The mass loss during SA testing was normalized with respect to the exposed surface area (mg/cm²), providing a clear comparative analysis. Under a load of 137.2 N, particle size of 100 µm, and slurry concentration of 25,000 ppm, the VC coating exhibited the lowest mass loss of 0.158 mg/cm², while the VC-50CoNi coating demonstrated a moderate mass loss of 0.302 mg/cm². These results were compared to the uncoated SS316 substrate, which suffered the highest mass loss of 0.773 mg/cm². The novelty of this study lies in identifying the underlying mechanisms contributing to the wear behavior of these coatings. SEM analysis revealed that the superior wear resistance of VC coatings is attributed to their high hardness (1365 HV), which minimizes abrasive material removal through spalling and delamination. In contrast, the addition of Co-Ni in VC-50CoNi coatings enhances toughness, reducing crack propagation but slightly increasing mass loss due to fatigue cracking and surface roughening. The response surface methodology effectively optimized the process parameters, with statistical tests confirming the accuracy of the predictive model. These findings provide new insights into the design of wear-resistant coatings for industrial applications, emphasizing the balance between hardness and toughness achieved in composite coatings.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"34 4","pages":"1251 - 1268"},"PeriodicalIF":3.2,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143918957","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}