Cold spray (CS) is a solid-state additive manufacturing process that can create high-density, high-performance deposits for many applications. Aluminum alloys have been the target of recent CS research due to their excellent mechanical behavior when cold-sprayed. The introduction of new Al alloys to CS is of interest as unique properties may be achieved, especially when powder is heat-treated prior

It was published that zirconate coatings containing Gd/Yb and yttria-stabilized zirconia (YSZ) coatings with high Y content had good calcium-magnesium-aluminum-silicate (CMAS) corrosion resistance. However, there are few reports on CMAS resistance of zirconia-based thermal barrier coatings (TBCs) doped with Y, Gd and Yb. This article intends to explore the role of Y, Gd and Yb in resisting CMAS corrosion

Magnesium (Mg) alloys have a high strength/weight ratio, high dimensional stability, good machinability, and the ability to be recycled. However, their poor corrosion resistance in humid environments limits their usage for exterior aerospace components. This study aims to improve the corrosion resistance of two Mg alloys (AZ31B and AZ91) by using aluminum coatings. The latter have been deposited by

Suspension plasma spraying (SPS) enables the production of various coating microstructures with unique mechanical and thermal properties. Aeronautical manufacturers have been working for fifty years to improve the thermal barrier coating (TBC) performances in gas turbines. Commercial plasma torches with a segmented anode that are characterized by stable plasma jets should enable a better control of

This study aims to minimize the mechanical, chemical and thermal damages on the blades of a compressor used in aerospace engines by developing a superhydrophobic coating on the blade surface. In the absence of any information in open literature for the fabrication of such coatings, an one-step plasma spray process was implemented. For this, a well mixed powder of Ni and Ti was used as feedstock material

Industrialization of cold spray introduces concerns regarding the cost and time efficiency of cold spray procedures. In this work, high rate deposition of tantalum was studied computationally and experimentally. Quasi-1D multiphase fluid simulations predicted minimal effects on the bonding conditions of particles with 5% to 14% increase in powder-to-gas mass flow ratio. Experimental specimens were

Metallization of polyethylene (PE) using thermal spray techniques has proved difficult due to its low melting point and softness. In this study, metallic coatings were applied on porous polyethylene substrates using a twin wire-arc spray process. Commercially available polyethylene sheets, 3 mm in thickness, were used as substrates. Copper (Cu), aluminum (Al), and zinc (Zn) were successfully deposited

Despite the existence of several methods for production of superhydrophobic coatings from various materials, their application in harsh environments is still a great challenge. In this work, WC-Co-Cr cermet coatings were prepared by means of high velocity oxy-fuel (HVOF) spraying. WC particles dispersed in Co-Cr metallic matrix allowed to form the multi-scale surface roughness and thus to achieve hydrophobicity

There is high demand for refurbishment of damaged mechanical components in power plants. Twin-wire arc spraying (TWAS) is promising for on-site proactive maintenance. In this paper, FeCr-based coating was prepared on AISI 1020 carbon steel substrate by TWAS. The coating microstructure was characterized in terms of porosity, oxides and constituent phases. The wear behavior of the coating was evaluated

The aim of this work is to quantitatively describe the carbide loss during plasma deposition of metal carbide coatings and link it to the microstructure and performance of the as-sprayed coatings. To do this, a carbide loss index is defined. The results suggest that the microstructure and performance of such coatings can be tailored by controlling the content of carbides based on the proposed carbide

Laser cladding is widely used for feature repair and manufacturing of large structural components. However, due to processing parameters and thus energy densities variation, defects can form in laser clad materials. There is a need to understand the relationship between energy densities and cladding quality. This study therefore investigates the critical parameters in producing structural Stellite®

CMAS corrosion is one of the significant failure mechanisms for thermal barrier coatings (TBCs). In this work, the corrosion behaviors and wettability of CMAS on M-YTaO4 at 1350 °C are studied to evaluate the M-YTaO4 ceramics’ potential to replace YSZ. The results show that the contact angles of CMAS on M-YTaO4 with different time (1 min, 0.5 h, 4 h, 10 h and 24 h) are around 14.3° (14.4°14.4°, 14

Cavitation erosion is a sever wear mechanism that takes place in hydrodynamic systems. Examples are turbine vanes of hydropower plants or components of valves and pumps in hydraulic systems. Nickel-titanium shape memory alloys (NiTi) are attractive materials for cavitation-resistant coatings because of their pronounced intrinsic damping mitigating cavitation-induced erosion. In this work, NiTi coatings

Thermally sprayed coatings from the single oxides and binary compositions of the Al2O3-Cr2O3-TiO2 system show multifunctional properties. Ternary compositions are promising for further improvement in their performance. The stability of the composition during coating formation is an important issue for blended feedstock powders in order to obtain the desired properties. This work focuses on the compositional

High-pressure cold spray (HP-CS) was used to deposit aluminum onto polyetherketoneketone (PEKK) composite substrates. Aluminum powders were sprayed using N2 and He carrier gas and a bond layer (BL) of commercial-purity Al (CP Al). Dense 7075 and CP Al deposits were achieved via combinations of BL-N2, 7075/BL-N2, and 7075/BL-He. Cold spray using 7075 Al particles or using He carrier gas yielded thinner

In thermal spray, grit blasting is the standard method used to prepare the substrate surface before coating deposition. This study examines the effect of the grit blasting parameters on the residual stresses, roughness and hardness of three metal alloys with widely different mechanical properties: low-carbon steel, Ti-6Al-4V and Inconel 718. It also estimates the density of dislocations using the Williamson–Hall

The bonding of thermal-sprayed coatings largely depends on the substrate surface morphology. This study examines the effect of the substrate surface texture shapes on the adhesion strength of coatings. For that, it used plasma-sprayed Ni-based MoS2 coatings deposited on grit-blasted and laser-textured surfaces, and investigated the coating bonding strength (ASTM 633 pull-off test), and cross-sectional

The high-temperature oxidation and solid particle erosion of thermal barrier coating (TBC) system which consists of a 8 wt.% yttria-partially stabilized zirconia (YSZ) top coat and CoNiCrAlY bond coat deposited on Inconel 718 substrate via air plasma spraying (APS) process are studied experimentally. Isothermal oxidation tests of the APS-TBCs are conducted at 1050, 1100 and 1150 °C in air for up to

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Compared with their metal counterparts, the insufficient erosion resistance of polymer matrix composites (PMC) is a key issue for application in aero-engines. In this study, multilayered coatings were deposited on carbon fiber reinforced bismaleimide polymer composites using detonation spraying to improve their erosion resistance. The coatings consisted of a polymer–aluminum mixed transition layer

Cold spray is a solid-state process in which solid particles are subjected to severe plastic deformation to form a coating. The effect of naturally occurring oxides on bonding in the cold spray was investigated in this work. Deposition characteristics of copper powder with different surface oxide thicknesses on steel substrate were examined using a local pull-off test. This enables the investigation

For lightweight constructions, joining dissimilar metals is often indispensable to achieve exceptional properties. A common challenge is the bonding of steel and aluminum parts. The use of cold-sprayed coatings as a bonding agent is an innovative approach for high pressure die casting (HPDC) aluminum-steel hybrid components in order to achieve a metallurgical bonding, although it comes with high requirements

Conventional and nanostructured NiCoCrAlY coatings were deposited using the high-velocity oxy-fuel thermal spraying technique. The nanostructured NiCoCrAlY powder feedstock for the coatings was produced by the ball-milling method. The microstructures of the as-received and nanostructured powders as well as their developed coatings were investigated by x-ray diffraction, a field-emission scanning electron

As solid-state deposition technique avoiding oxidation, cold gas spraying is capable of retaining feedstock material properties in the coatings, but typically fails to build up coatings of brittle materials. Ceramic MAX phases show partial deformability in particular lattice directions and may thus successfully deposit in cold spraying. However, deformation mechanisms under high strain rate, as necessary

Hydrogen generation from renewable energy sources will play a key role in the concerted endeavor to constrain climate change. One environmentally friendly route, powered by sunlight, is the photoelectrochemical water splitting cell (PEC). This technology employs electrodes coated with thin films of semiconductor materials to capture light and generate charge carriers that directly drive the water splitting

Owing to low-temperature deposition conditions and high deposition rate, cold spray offers unique advantages in manufacturing a wide variety of metallic and composite coatings including metal matrix composites produced from physically blended powders. One of the challenges of producing composite coatings using cold spray is the deviation of coatings composition from the blended feedstock powder composition

There have been ever-growing demands for disinfection of water and air in recent years. Efficient, eco-friendly, and cost-effective methods of disinfection for pathogens are vital to the health of human beings. The photocatalysis route has attracted worldwide attention due to its highly efficient oxidative capabilities and sustainable recycling, which can be used to realize the disinfection purposes

As the number of aircraft that park in ocean environments increases, the corrosion of coatings used in their engines becomes inevitable. Previous studies have focussed on the abradability of as-sprayed seal coatings in high-speed rubbing tests with a blade. This study deals with the investigation of the effect of corrosion on the abradability of seal coatings. It uses metallographic analysis and hardness

“Thermal swing” coatings have recently been of great interest to automotive researchers for their potential to insulate internal combustion engines, reduce cooling requirements, and increase their efficiency. Plasma-sprayed yttria-stabilized zirconia, ceramics in the MgO-Al2O3-SiO2 system (cordierite, mullite, and steatite), and silicate-yttria-stabilized zirconia composite thermal barriers have been

High-enthalpy hybrid water/argon-stabilized plasma (WSP-H) torch may be used for efficient deposition of coatings from dry powders, suspensions, and solutions. WSP-H torch was used to deposit two complete thermal barrier coatings (TBCs) with multilayered top-coat. NiCrAlY was used as bond-coat and deposited on nickel-based superalloy substrates. Top-coat consisted of up to three sublayers: (i) yttria-stabilized

The impact of thermal shock upon the scatter of flexural strength data of free-standing thin flame-sprayed Al2O3 coatings was examined. As published in the literature, thermally sprayed ceramic systems exhibit superior thermal shock resistance and against this background, the statistical evaluation of strength data prior and after the thermal shock was intensified. Thus, the Weibull parameters m and

Carbon nanotubes (CNTs) have a large specific surface area and, thus, are expected to have applications as electrodes, e.g., in fuel cells. A CNT-containing composite metal film with high electrode performance could be realized by implementing a large number of CNTs on the film. However, a composite film with a high density of CNTs has not yet been obtained. In the thermal spray field, including cold

The primary affiliation of author Judyta Sienkiewicz should be listed as: Research Center for Structural Materials, National Institute for Materials Science, Tsukuba-Shi, Japan, and the secondary affiliation as: Institute of Armament Technology, Faculty of Mechatronics and Aerospace Military University of Technology, Warsaw, Poland.

Thermal-sprayed aluminum (Al) coatings are widely used for corrosion protection in marine environments. The corrosive nature of seawater and the synergy with marine microbes make for aggressive service environments for Al coatings. In this study, Al coatings were deposited on 316L stainless steel (316L SS) substrates by using wire arc spraying. Chlorella vulgaris, a typical marine fouling algae, was

Developing dense, well-adhered coatings with minimal heterogeneity via cold spray deposition has been a challenge because in-flight and layer-by-layer diagnostics has not yet been adequately adapted to complement existing post-deposition analyses and parameter process mapping. This study presents an empirical and analytical approach for development and optimization of requisite spray parameters via

The powder aerosol deposition (PAD) method is a well-known process to fabricate dense layers at room temperature directly from the powder. It is particularly suitable for the deposition of ceramic materials. Compared to these, the use of metal powders (here iron), which are significantly more ductile and have a higher density than typical ceramic powders, has not yet been investigated in detail for

Optimization of the cold spray process is extremely challenging due to the involvement of a large number of process parameters as well as material properties. Modern approaches for modeling the cold spray process have relied largely on numerical simulations. In this paper, we shall present a simplified mathematical model which will be benchmarked against experimental and numerical measurements available

The present work discusses the comparative wear behavior of composite (amorphous/nanocrystalline) blast furnace pig iron coatings deposited on a mild steel substrate using high velocity oxygen fuel and air plasma spray techniques. The study has been carried out using a ball-on-disk tribometer with the coated specimen and tungsten carbide ball as disk and counter body, respectively. A composite structure

Aerosol deposition (AD) is a novel deposition process for the fabrication of dense and rather thick oxide films at room temperature. The bonding of the deposited ceramic particles is based on a shock-loading consolidation, resulting from the impact of the ceramic particles on the substrate. However, the deposition mechanism is not fully understood. In addition, many technical challenges have been observed

This study deals with the improvement of the wear resistance of aluminum alloys by metal matrix composites (MMCs). The latter were fabricated by implanting high-speed solid particles into the metal surfaces. For that, stainless steel and Fe-based amorphous alloy particles were accelerated to the substrates using high-pressure nitrogen. The effect of multi-particle implantation, particle material properties

A new concept of composite phase ceramic had been proposed for the topcoat of a durable thermal barrier coating (TBC) system which is one of the critical technologies for advanced turbine engines. The composite phase TBCs showed promising performance related benefits over conventional single phase TBCs, including durability, material affordability, thermal stability and low thermal conductivity. The

The effects of coating thickness on the fatigue lives of AISI 1045 steel shaft-bending specimens with WC-10%Co-4%Cr high-velocity oxygen fuel (HVOF) coatings and hard chrome electroplated coatings under cyclic loading conditions are investigated. Residual stress distributions of the HVOF-coated layer and the hard chrome-plated layer were measured. During cyclic fatigue testing, cracks are initiated

Compared with ceramic materials, the fabrication of dense metal films requires higher impact velocity in vacuum cold spraying (VCS), also known as aerosol deposition method. In this study, a supersonic nozzle for the fabrication of dense, thin and narrow copper lines was designed. The acceleration behavior of gas and copper particles was investigated through CFD numerical simulation. And the impact

(Pb0.89La0.11)(Zr0.70Ti0.30)O3 (PLZT 11/70/30) relaxor ferroelectric (RFE) films were fabricated on Pt/Si substrates by aerosol deposition, which not only enabled the deposition of a film at room temperature but also increased the dielectric breakdown strength. Perovskite phase and microstructural analyses were carried out by x-ray diffraction and scanning electron microscopy techniques. A PLZT 11/70/30

In multilayer coatings, the bonding mechanisms between the different layers determine the cohesive strength of the coatings, which in turn to a large extent controls the mechanical properties of coatings under different loading conditions. In this study, the interfacial bonding state and adhesive strength of a plasma-sprayed single-layer coating (Al2O3), a double-layer coating (Al2O3/BaTiO3), and a

As the demand for flexible devices has increased, polymers have become very promising materials for these applications because they have excellent flexibility, lightweight, and low cost. Vacuum kinetic spraying can be a good alternative technology for film fabrication on polymers as dense ceramic films can be fabricated even at room temperature without thermal degradation of the polymer substrate.

This study aims at evaluating the effects of surface mechanical attrition treatment (SMAT) on mechanical properties and corrosion resistance of NiCrBSi coatings deposited by high-velocity oxygen-fuel (HVOF) spraying. The as-deposited coating has a typical HVOF-sprayed morphology with unmelted and deformed particles, associated with voids and porosities, whereas after SMAT, the affected zone morphology

Cold spraying was first used for the purpose of preparing nickel-based high-temperature lubrication coatings. High-quality In625-Cr2O3-Ag composite coatings were deposited by a high-pressure cold-spray system, and their tribological properties were evaluated at 20 and 1000 °C by a high-temperature tribometer. The microstructure, composition, and wear mechanisms of the coatings were analyzed by x-ray

Aluminium-polymethyl methacrylate-copper (Al-PMMA-Cu) composite coatings were developed using cored wire arc spraying. The bacteria Bacillus sp. was used to evaluate the antifouling performances of the coatings. The microstructures and antifouling mechanisms of the coatings were investigated and discussed. The results show that the composite coatings presented improved antifouling performances, and

Plasma spraying of fine particles promises uniform microstructure and improved properties for ceramic coatings due to the formation of small splats with reduced residual stress and pore size. Although spraying fine particles is challenging due to the poor rheological properties of particles (e.g., low flowability and agglomeration), the potential improvements to the coatings make it an attractive option

Prior work has demonstrated greater antipathogenic efficacy concerning the nanostructured copper cold spray coatings versus conventional copper cold spray coatings, while both the nanostructured and conventional cold spray coatings maintain greater contact killing/inactivation rates relative to other thermal spray deposition methods. Recent work has more heavily focused upon the nanostructured cold

To eliminate the thermal expansion mismatch and improve the bonding strength between ZrSiO4 coating prepared by supersonic atmospheric plasma spraying and C/C composites, a layer with porous structure was produced on the substrate by a preliminary air oxidation treatment. The morphology and microstructure of the ZrSiO4 coating were characterized by SEM and XRD. The results showed the coating prepared

Cold spray is an effective solid-state process for the fabrication of metal matrix composites where metallic, ceramic, or intermetallic reinforcements are embedded in a metallic matrix. Cold-sprayed metal matrix composites (CS MMCs) enable combining favorable properties of their constituent phases. Combinations of the ductility of metals with the high strength of ceramics or with the creep resistance

A novel self-sealing structure for metal-supported solid oxide fuel cells (MS-SOFCs) is designed by applying brazing technology between the metal support and interconnector to solve the sealing problem on the anode side of planar SOFCs. A high-reliability self-sealing effect is thus realized at the anode side of the MS-SOFC. Plasma spraying technology is used to prepare cell functional layers including

A particular YSZ feedstock for very low-pressure plasma spraying (VLPPS) has been designed which can be automatically divided into less than 5 μm YSZ molten particles in the long plasma jet. Fully molten particles were deposited on the substrate at different deposition distances of 250, 350 and 450 mm, respectively. The deposition behavior of less than 5 μm YSZ molten particles were studied aiming

Titanium alloys have high specific strength and excellent high temperature and corrosion resistance but low hardness and poor wear resistance. In this study, TiC-reinforced Ti2Ni/Ti5Si3 eutectic matrix composite coatings were fabricated on TC21 titanium alloy substrates by laser cladding. The phase composition and microstructure of the coating with micro- or nano-sized SiC addition as well as the microhardness

Ti2AlNb alloys are often used to fabricate high-pressure compressor blades and casings in aircraft engines with high thrust/weight ratios. In this study, a three-layered seal coating, NiCrFeAlBN-YSZ-NiCrAl, was prepared by thermal spraying on a titanium alloy (Ti2AlNb) substrate. The microstructure, surface hardness, and bond strength of coatings as well as their thermal cycling performance and abradability

Diamond-like carbon (DLC) films have a high hardness and a low friction coefficient. Therefore, DLC films are applied in industrial fields to reduce energy consumption. However, DLC films can only be obtained as coatings, and DLC films of only micrometer thickness can be deposited on substrates. In this study, we focused on the cold spray (CS) technique as a means of obtaining a DLC-containing metal

A hybrid analytical heat conduction model was developed to predict the transient thermal evolution at the particle–substrate interface during the deposition of cold spray process. First, three-dimensional heat conduction model based on classical diffusion approach was developed to predict the transient surface temperature of the substrate. To that end, the traveling wave solution technique was utilized