Journal of Thermal Spray Technology最新文献

{"title":"With Gratitude to Our Guest Editors and Reviewers for Their Critical Contributions in 2025","authors":"","doi":"10.1007/s11666-026-02205-6","DOIUrl":"10.1007/s11666-026-02205-6","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"951 - 954"},"PeriodicalIF":3.3,"publicationDate":"2026-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830143","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":"Numerical Modeling of Binary-Gas Plasma Jets in Multi-Arc Plasma Spraying and Validation of Temperature Profiles","authors":"K. Bobzin,&nbsp;H. Heinemann,&nbsp;M. Erck,&nbsp;K. Jasutyn,&nbsp;G. Nassar,&nbsp;F. Alberding","doi":"10.1007/s11666-026-02197-3","DOIUrl":"10.1007/s11666-026-02197-3","url":null,"abstract":"<div><p>While plasma jets in single-arc systems have been extensively researched, cascaded multi-arc configurations for binary-gas mixtures remain comparatively underexplored. In atmospheric plasma spraying (APS), the use of nitrogen or hydrogen as secondary gases is a prevalent practice to tailor jet properties. This study advances the field by analyzing the flow characteristics of binary-gas plasma jets in cascaded multi-arc systems, providing deeper insights into their influence on particle behavior. A numerical model was developed using temperature-dependent thermodynamic and transport properties, integrating upstream flow conditions from prior plasma generator simulations. To verify its predictive capability, the numerical results were compared with experimental data obtained via optical emission spectroscopic computed tomography (OES-CT). The analysis confirms the numerical model’s accuracy for thermal spraying applications. Notably, the significant temperature increase induced by hydrogen addition is clearly captured in both the OES-CT measurements and the simulation results. This research successfully bridges the process chain from plasma generation to final coating for binary-gas plasma environments.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2251 - 2266"},"PeriodicalIF":3.4,"publicationDate":"2026-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02197-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807473","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":"Effects of Spray Conditions and Heat Treatments on the Physical and Mechanical Properties of Al6061 Deposits Cold-Sprayed Using N2 Gas","authors":"Nirmal Rajpopat,&nbsp;Ahmad Nourian,&nbsp;Turner Jennings,&nbsp;Aidan Sevinsky,&nbsp;Samuel Boese,&nbsp;Sinan Müftü","doi":"10.1007/s11666-026-02189-3","DOIUrl":"10.1007/s11666-026-02189-3","url":null,"abstract":"<div><p>Understanding the influence of spray conditions and post-spray heat treatments on the performance of cold-sprayed materials using N₂ as the carrier gas is essential. This study examines the impact of various spray conditions and heat treatments on the physical and mechanical properties of cold-sprayed Al6061. Specimens prepared under two different spray conditions, varying the carrier gas temperature, were tested in both their as-sprayed and heat-treated states. Heat treatments, including standard and elevated temperature processes, were applied to enhance mechanical properties. Microstructural characterization was performed by assessing particle bonding quality, deformation behavior, and porosity fraction. Mechanical properties, including the yield and compression strengths, were assessed under both quasi-static compression and high-strain-rate testing at various strain rates. The physical properties, including thermal conductivity (TC), electrical conductivity (EC), and coefficient of thermal expansion (CTE), of specimens prepared under different conditions were evaluated and correlated with their mechanical properties. The results showed that the as-sprayed deposits exhibited inferior mechanical and physical properties compared to wrought Al6061. However, heat treatments improved interparticle bonding and significantly enhanced both the mechanical and physical properties, with values approaching those of wrought Al6061. Specifically, the high-temperature heat treatment performed near the solidus temperature of Al6061 resulted in properties that are closest to those of the wrought material. Statistical analysis of the results indicated strong correlations between the physical properties (TC, EC, CTE) and the compression strength, as well as among these physical properties themselves.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1393 - 1412"},"PeriodicalIF":3.3,"publicationDate":"2026-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02189-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830144","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 Synergistic Effects of Laser Thermal Softening and In-Situ Micro Forging on the Microstructure and Mechanical Properties of Cold Sprayed AA7075 Deposits","authors":"Yunhui Peng,&nbsp;Kang Wang,&nbsp;Xinyu Cui,&nbsp;Tianying Xiong,&nbsp;Zhipo Zhao,&nbsp;Jiqiang Wang","doi":"10.1007/s11666-026-02201-w","DOIUrl":"10.1007/s11666-026-02201-w","url":null,"abstract":"<div><p>Both laser thermal softening and in-situ micro-forging can effectively improve the microstructure and properties of cold-sprayed deposition layer. However, each process has its own limitations. In this study, laser thermal softening and in-situ micro forging were simultaneously introduced into cold spray process. The synergistic effects on the microstructure and mechanical properties of AA7075 deposits were examined. SEM, EBSD, and XRD were used to study the microstructure evolution of deposits in details. The results showed that, with 20wt.% alumina particles in the raw material powder, the optimal laser power for cold spray was approximately 1.8 kW. At this point, the porosity of the deposits dropped to 0.1%, while the powder deposition efficiency slightly decreased (from 27.3% to 23.9%). The ultimate tensile strength (UTS) reached 292 ± 15 MPa, and the elongation (EL) increased to 8.4 ± 1.1%. Compared to the deposits produced via in-situ micro-forging assisted cold spray solely, the UTS and the EL increased by approximately 59.5% and 58.5%, respectively. As the laser power increased, the initially increased and then decreased, and the local misorientation within the deposited layers significantly reduced. In addition, T6 heat treatment further eliminated defects in the deposited layer and enhanced its mechanical properties. The heat-treated 1.8 kW deposits exhibited the highest UTS (446 ± 14 MPa), while the EL slightly decreased to 7.1% ± 0.6%. The evidences verify that the synergistic effects of laser thermal softening and in-situ micro forging are feasible for improving the performance of cold sprayed AA7075 deposits.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1512 - 1525"},"PeriodicalIF":3.3,"publicationDate":"2026-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147830200","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":"Numerical Investigation of Flame Characteristics and Particle Behavior in HVOF Thermal Spraying Using a Non-premixed Combustion Model","authors":"Zhaomiao Liu,&nbsp;Jiale Fan,&nbsp;Yan Pang,&nbsp;Xiang Wang","doi":"10.1007/s11666-026-02199-1","DOIUrl":"10.1007/s11666-026-02199-1","url":null,"abstract":"<div><p>High-Velocity Oxygen Fuel (HVOF) thermal spraying is widely used to produce high-performance coatings, and numerical modeling provides a practical approach for analyzing flame and particle interactions and process optimization. In this study, a comprehensive numerical model of a JP-5000 HVOF system was developed based on non-premixed combustion. The combustion characteristics of hydrogen, methane, and propane were systematically compared. The influence of the mean mixture fraction was examined to identify an appropriate operating range, including fuel-rich conditions characterized by a lower oxidizer-to-fuel ratio. The effects of particle injection position on particle behavior were also investigated. The coupled influence of spray distance and powder feed rate was evaluated by combining numerical predictions with experimental porosity measurements of WC-12Co coatings. The results indicate that hydrogen produces higher flame temperatures and gas velocities than hydrocarbon fuels. The mean mixture fraction exhibits a nonlinear influence on particle thermokinetic behavior. Axial particle injection enhances particle heating and acceleration compared with radial injection. Spray distance and powder feed rate interact to affect coating porosity.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1413 - 1427"},"PeriodicalIF":3.3,"publicationDate":"2026-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829809","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":"Microstructural, Micromechanical, and Corrosion Properties of ID-HVOF and Cold Spray Inconel 625 Coatings","authors":"Sarah Blunk,&nbsp;Maya M. Harfouche,&nbsp;Vikram Singh,&nbsp;Christopher Yi,&nbsp;Wendong Fang,&nbsp;Srikanta Prasad,&nbsp;Dawei Yuan,&nbsp;Maniya Aghasibeig,&nbsp;Janine Mauzeroll,&nbsp;Richard R. Chromik","doi":"10.1007/s11666-026-02186-6","DOIUrl":"10.1007/s11666-026-02186-6","url":null,"abstract":"<div><p>Novel internal diameter HVOF (ID-HVOF) systems enable the targeted deposition of uniform coatings on challenging geometries, including the internal surfaces of components. By introducing an inert gas to the combustion fuels, these systems achieve warm spray ability, enabling solid and semisolid-state deposition of metal particles with minimized oxidation. As such, ID-HVOF systems show great promise as a complementary technique to cold spray deposition for restoration and repair applications in hard-to-reach areas of components. In this study, a hydrogen-fueled ID-HVOF spray system with nitrogen gas addition was used for the deposition of Inconel 625 (IN625) protective coatings. The effect of standoff distance (SOD), and spray configuration, on deposition properties was investigated. The process–microstructure–performance relationships were investigated, with emphasis on wear behavior and corrosion, and compared to benchmark cold-sprayed IN625 coatings. Wear tests were conducted at room temperature and at 300 °C using a ball-on-flat reciprocating sliding test, with Al₂O₃ spheres as counterparts under a normal load of 5 N. A detailed analysis of the worn surfaces and the counterparts was performed and associated with the friction response and wear mechanisms. Accelerated electrochemical corrosion testing was performed at room temperature in 0.61 M (3.5 wt.%) NaCl solution, and the resulting corrosion behavior was correlated with deposition parameters. Both ID-HVOF and CS coatings exhibited similarly low porosity levels, indicating dense microstructures. The ID-HVOF coatings showed microhardness values between 340 and 410 HV, higher than the bulk IN625 (~ 310 HV) and comparable mechanical performance across all configurations. The CS coating reached ~ 560 HV, attributed to severe plastic deformation and work hardening during solid-state deposition. At 300 °C, the ID-HVOF coatings displayed lower wear rates and more stable friction compared with CS and bulk IN625. Electrochemical tests in 3.5 wt.% NaCl revealed lower corrosion current densities and more stable corrosion potentials for ID-HVOF coatings, confirming their excellent corrosion resistance. These findings demonstrate that optimized ID-HVOF parameters can produce coatings with mechanical and functional properties comparable to CS, offering a viable approach for restoring internal components.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"774 - 790"},"PeriodicalIF":3.3,"publicationDate":"2026-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147607250","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":"Special Issue Featuring Papers from the International Thermal Spray Conference (ITSC) 2025","authors":"","doi":"10.1007/s11666-026-02198-2","DOIUrl":"10.1007/s11666-026-02198-2","url":null,"abstract":"","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 2-3","pages":"531 - 532"},"PeriodicalIF":3.3,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147606420","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":"Comparative Analysis of HVAF and Cold Spray Methods for Aluminum Alloy Coatings for Engine Bearings","authors":"I. Ozdemir,&nbsp;T. Grund,&nbsp;S. Joshi,&nbsp;S. Björklund,&nbsp;B. Bulbul,&nbsp;R. Drehmann,&nbsp;T. Lampke","doi":"10.1007/s11666-026-02194-6","DOIUrl":"10.1007/s11666-026-02194-6","url":null,"abstract":"<div><p>The use of advanced aluminum-based bimetal bearings is critical for addressing modern automotive demands such as downsizing, higher loads, and improved fuel efficiency. Traditional roll bonding methods, widely employed for manufacturing bimetal bearings, face significant limitations when applied to next-generation aluminum alloys due to their complexity, cost, and inflexibility. This study evaluates thermal spray techniques, specifically cold spray (CS) and high-velocity air fuel (HVAF) deposition, as alternative manufacturing methods for aluminum-based bimetal bearings. Cold spray trials showed that the AlMn1Cu bond coat achieved &gt; 88% deposition efficiency (DE) at 500-600 °C, while the AlZn5SiCuMgBi top coat reached only 32.69% at 650 °C. The lower DE of the top coat is attributed to its higher hardness and the presence of preexisting intermetallic phases (e.g., Bi₂Mg₃), which are only partially reduced during deposition and may undermine particle bonding.</p><p>Experimental comparisons between HVAF and cold spray (CS) coatings revealed significant differences in mechanical and tribological performance. HVAF coatings exhibited superior hardness of 151 HV compared to cold spray, which had 94.5 HV, indicating a more robust and potentially wear-resistant surface. In terms of wear behavior, HVAF demonstrated lower wear depth of 83.3 µm and volume loss of 0.137 mm³, which are 21.5% and 22.5% lower, respectively, compared to cold spray, which had wear depths of 106.1 µm and volume loss of 0.1767 mm³. These results reflect the denser microstructure and improved bonding achieved by HVAF. Additionally, friction coefficient (COF) measurements showed that HVAF with a COF of 0.5 outperformed cold spray with a COF of 0.625, further emphasizing its superior tribological properties.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1499 - 1511"},"PeriodicalIF":3.3,"publicationDate":"2026-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11666-026-02194-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829801","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":"Effect of La2O3 on Microstructure, Wear Resistance and Corrosion Resistance of Laser Cladded WC-Fe Coatings","authors":"Lun-ye Sun,&nbsp;Yong-gang An,&nbsp;Biao Chen,&nbsp;Shi-ang Liu","doi":"10.1007/s11666-026-02192-8","DOIUrl":"10.1007/s11666-026-02192-8","url":null,"abstract":"<div><p>40CrNiMoA alloy is widely used in key components of energy equipment, but it is prone to wear, corrosion, and other forms of degradation in dusty and humid environments. To solve this issue, this study employed laser cladding technology, incorporating La₂O₃ into a WC-reinforced Fe-based composite coating to enhance the surface performance of the alloy. By adjusting the La₂O₃ content, the impact of La₂O₃ on the coating’s phase composition, microstructure, microhardness, and wear and corrosion resistance was investigated. The findings indicated that adding a suitable amount of La₂O₃ increased the wetting angle of the single-pass coating and reduced pore number by improving coating fluidity. The coating primarily consisted of α-Fe, γ-Fe, M_xC_y, and La₂O₃ addition contributed to grain refinement. When the La₂O₃ content was 1 wt.%, the coating exhibited a maximum average hardness of 544.25 HV_0.2, representing a 20.43% increase in relation to that achieved by the coating without La₂O₃. Furthermore, its wear resistance was significantly improved, with the specific wear rate loss reduced by 32.6 %, with the wear mechanism dominated by mild adhesive and abrasive wear. Notably, La₂O₃-induced grain refinement effectively hindered Cl⁻ penetration, thereby endowing the composite coating with excellent corrosion resistance.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 4","pages":"1272 - 1290"},"PeriodicalIF":3.3,"publicationDate":"2026-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829851","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":"Unsupervised Process Window Identification in Thermal Spray Operations with the AccurasprayHUB","authors":"T. Garcin,&nbsp;A. Sabsabi,&nbsp;D. Georgaris,&nbsp;J. F. Henri,&nbsp;D. Lessard,&nbsp;W. Jibran,&nbsp;J. N. Robert,&nbsp;A. Nadeau","doi":"10.1007/s11666-026-02188-4","DOIUrl":"10.1007/s11666-026-02188-4","url":null,"abstract":"<div><p>Thermal spray practitioners have long struggled to define robust plume characteristics process windows—combinations of particle temperature, velocity, and plume geometry that reliably yield acceptable coatings—especially as powder characteristics, equipment wear, and ambient conditions evolve. The <i>AccurasprayHUB</i> addresses this challenge by unifying data capture, structuring, and analysis within a single platform. During an initial lab deployment, the Hub continuously collects summary statistics (mean temperature, velocity, and geometry) for each spray run and automatically enriches them with detailed metadata—stand-off distance, gas and powder flow rates, powder batch IDs, gun maintenance records, and laboratory data when available. These per-run feature vectors are then subjected to density-based clustering to identify the natural “normal” operating regimes without requiring explicit “bad coating” examples. From the resulting high-confidence clusters, the Hub derives multidimensional min–max envelopes that define process windows tailored to specific powders and gun health states. By delivering reproducible data pipelines, transparent feature engineering, and modular analytics, the <i>AccurasprayHUB</i> not only accelerates the discovery of stable operating conditions—but also bridges the longstanding divide between thermal spray experts and the machine learning community, paving the way for scalable, data-driven process control.</p></div>","PeriodicalId":679,"journal":{"name":"Journal of Thermal Spray Technology","volume":"35 6","pages":"2267 - 2282"},"PeriodicalIF":3.4,"publicationDate":"2026-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148807314","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}