Graphene nanosheets (GNSs)/ZnO/Al2O3 composite coatings with different GNSs content were prepared by air plasma spraying technique. The scanning electron microscope results show that the GNSs were homogeneously dispersed in the powders and coatings. The influence of different GNSs content on complex permittivity and microwave absorption properties have been systematically investigated at the frequency

This paper investigated the solid particle erosion behavior of partially oxidized NiCrBSiFe and NiCr coatings by varying temperature and impact angle. The challenge in the current situation is to process a new system of powders containing metallic and oxide phases. Partially oxidized powders containing metallic and oxide phases were processed by flame spraying the alloy powders into distilled water

Marine biofouling is a ubiquitous and serious problem in maritime engineering. Here, we reported an effective antifouling approach through facile fabrication of laminated-structured Cu-X composite coatings by plasma spraying of mechanically blended Cu and X powders, in which X is a type of metal nobler than Cu. The Cu-X coatings were designed to controlled release Cu ions from Cu/X micro-galvanic cells

In developing wettable TiB2-based cathodes for Al production, the main problem encountered for decades is the difficulty to sinter or melt this refractory material. Here, suspension plasma spray (SPS) is used as this process makes it possible to use micrometric TiB2 particles to favor a high heat transfer per particle. In addition, an argon gas shield is used to protect the inflight TiB2 particles

Magnesium-based alloys are appropriate materials for transportation applications owing to their high strength-to-weight ratio. However, the poor corrosion performance of Mg alloy limits its lifetime. In this study, the pure Al coating was deposited onto an AZ91D substrate by cold spraying, and then modified by friction stir-spot-processing. The interfacial microstructure and phase were studied in detail

The Al2O3-MoS2 ceramic-based lubricating coating was prepared via introducing MoS2 dry film lubricant into the micro-defects of thermally sprayed Al2O3 coating by paint spraying method. The microstructure, mechanical properties and tribological behaviors of the as-received Al2O3-MoS2 coating are thoroughly evaluated. The results illustrated that MoS2 was mainly concentrated on the shallow surface of

Abradable coatings are used in gas turbines to minimize the clearance distance between the stationary components and rotating blade tips. In this study, the effect of microstructure refining on the properties of abradable AlSi-polyester coatings was investigated. The coatings were deposited by conventional atmospheric plasma spraying system (APS) and high efficiency supersonic atmospheric plasma spraying

Lubrication mechanisms of plasma-sprayed Cr2O3-Ag nanocomposite coatings were studied by using ball-on-disk friction tests against tungsten carbide counterface at temperatures ranging from 25 to 500 °C. The Cr2O3-Ag nanocomposite coatings were fabricated from agglomerated granules of chromium oxide and silver nanoparticles by plasma spraying process under optimized parameters. The presence of semi-molten

A biodegradable Mg/MgO composite coating was deposited onto AZ31B magnesium alloy by high-velocity suspension flame spraying technique using nano-sized MgO and micron-sized Mg powders. Phase constitution, microstructure, mechanical property and corrosion behavior of Mg/MgO composite coatings with different Mg/MgO ratios were investigated. Mg/MgO composite coatings with different Mg/MgO ratios presented

Thermal barrier coatings (TBCs) are used to protect the hot sections of gas turbines and jet engines. A typical TBC system consists of a substrate, bond coat, and a TBC top coat (TC). To develop a high-performance TBC, it is essential to accurately evaluate the residual stress evolution during the thermal spray process (deposition and post-deposition cooling) of TBCs. In this study, a simple analytical

Cold spray is a newly developed solid-state metal deposition technology, which allows for preparing various functional coatings and repairing damaged metal components, as well as fabricating freestanding parts. In order to obtain the deposits with the desired shape and accuracy, the coating profile, including its thickness and distribution, is an important indicator to monitor and control. In this

Cold spray deposition is a process in which bonding between solid microscale particles and a substrate occurs due to high energy impact. In this process, adhesion forms between the impacted particle and the substrate within a certain multi-parameter (material, temperature, particle size, etc.)-dependent impact velocity range. The present work analyzes the effects of particle diameter (for a range of

As a novel processing technology, plasma spray-physical vapor deposition (PS-PVD) enables coatings to be deposited mainly from vapor phase. To explore the potential advantages of such a plasma spray-based processes, the deposition mechanisms and their dependency on process conditions should be better investigated. In this work, yttria partially stabilized zirconia thermal barrier coatings with quasi-columnar

The present study compares prerequisites for cavitation-resistant bronzes production by different coating techniques, namely cold spraying, HVOF spraying, warm spraying and arc spraying. If optimized to maximum cavitation resistance, the deposited coatings can increase the service life of ship rudders significantly. Furthermore, these methods could enable repair processes for ship propellers. This

High-entropy alloy powders synthesized by mechanical alloying were used as feedstock to prepare FeCoNiCrAl and FeCoNiCrMn coatings by atmospheric plasma spraying. The microstructure and phase composition of the coatings were analyzed by scanning electron microscopy, energy-dispersive spectroscopy, x-ray diffraction, and transmission electron microscopy. The microhardness and wear behavior of the coatings

TiC + TiB2 + Ti2Ni-reinforced Ni-based laser-clad coatings were prepared on Ti-6Al-4V by CeO2 modification. The forming quality, microstructure, element distribution, microhardness and wear resistance of the coatings were studied. The results showed that adding 2 wt.% CeO2 effectively eliminated cracks but led to the micro-pores. The coatings mainly consisted of TiC, TiB2, Ti2Ni and matrix α-Ti. When

For the first time, the low-pressure cold spray (LPCS) process was used to manufacture gallium nitride (GaN) films to enhance its photocatalytic properties and decrease its manufacturing cost. The deposition behavior of the GaN powder on stainless steel substrates was investigated. Several specimens, with sparsely deposited agglomerated GaN particles, were prepared under different spray conditions

This study aims to improve the wear resistance of nickel-aluminum bronze (NAB) substrates by micro-arc oxidation (MAO). As this treatment is difficult to apply to NAB surface, cold spraying (CS) was first used to deposit aluminum with a purity of 99.5% onto the NAB substrates. The aluminum-coated substrate was then treated by MAO to convert the aluminum layer into Al2O3 coating in order to enhance

In the high velocity oxygen fuel (HVOF) spray process, coating properties are sensitive to the characteristics of in-flight particles, which are mainly determined by process parameters. Obtaining a comprehensive multi-physical model or analysis of the HVOF process remains challenging because of the complex chemical and thermodynamic reactions that occur during the deposition procedure. This study proposes

Techno-economic assessment of thermal-sprayed coatings for temperature control and protection of water distribution steel pipes against freezing and subsequent bursting was conducted. A data-intensive model was developed to compare the technical and economic implications associated with fabrication, shipping, installation, operation, and maintenance of multilayered coatings, as heating systems, with

Carbon fiber reinforced plastic (CFRP) is a competitive and promising material that is employed in various industries, including the aerospace industry. Metallized CFRPs and multimaterials based on metals are highly attractive for such applications. In this study, we deposited Sn on an epoxy-based CFRP via cold spraying and investigated the effects of gas temperature on Sn deposition behavior. A continuous

To study the effect of deposition behavior of the reinforcement on microstructure and property of cold-sprayed metal matrix composite coating, four Al5056 composite powders containing 15 wt.%, 30 wt.%, 45 wt.% and 60 wt.% SiC were mixed to prepare the composite coatings by cold spraying. Effect of the SiC deposition behavior on microstructure, SiC distribution, micro-/nanohardness, surface residual

To obtain dense Al-based quasicrystalline (QC) coatings with high content of quasicrystal phase, the QCs were deposited by the high-velocity air fuel spray process with different feedstock powder sizes. The phase composition, microstructure, chemical composition, tribological, and mechanical properties of the coatings were analyzed using x-ray diffraction, scanning electron microscopy, energy-dispersive

Three different double rare-earth modified SrZrO3 coatings [Sr(Zr0.9Yb0.05Gd0.05)O2.95 (SZYG-1), Sr(Zr0.85Yb0.075Gd0.075)O2.925 (SZYG-2) and Sr(Zr0.8Yb0.1Gd0.1)O2.9 (SZYG-3)] were prepared by solution precursor plasma spray. X-ray diffraction results show that the SZYG-1 coating is composed of SrZrO3 solid solution and ZrO2 solid solution with fluorite structure, while the SZYG-2 and SZYG-3 coatings

Cold spraying (CS) is a solid-state coating technique that has been applied as a novel additive manufacturing (AM) method to fabricate freestanding metal components. Recent advances in cold spray additive manufacturing (CSAM) technology call for new process implementation to improve manufacturing accuracy and flexibility. In this study, a concept of modular systems is presented to design and implement

The internal diameter (ID) coating by means of thermal spraying is currently experiencing growing interest in science and industry. In contrast to the well-established plasma- and arc-based spray techniques, there is a lack of knowledge concerning kinetic processes such as HVOF, HVAF and warm spray (WS). A major challenge represents the necessity of short spray distances and the compact design of novel

For the present study on Aerosol Deposition of MAX-phase materials, Ti3SiC2 was chosen as model system due to the availability of property data and commercial powder. The as-received powder was milled to different nominal sizes. For revealing details on coating formation and possible bonding mechanisms, Aerosol Deposition experiments were performed for different particle size batches and process gas

Cold spraying has a potential application prospect in the field of repairing and additive manufacturing. The critical velocity of the cold spray is a key factor that determines the adhesion of particles during the cold spraying process, and it only depends on the particle parameters under the same working conditions. In the present study, the relationship between particle parameters and critical velocity

The yttria-stabilized zirconia (YSZ) ceramic has been proved to be a promising material for abradable seal coatings. In this research, abradable seal coatings named C-YSZ and M-YSZ were prepared by applying the conventional plasma spraying method with improved nanostructured powders and by the mixed solution precursor plasma spraying technique, respectively. A study on the microstructure, mechanical

In previous studies at McGill University, tin has successfully been cold sprayed onto carbon fiber reinforced polymers (CFRPs) and, with the idea of improving the coating conductivity, other metal powders (aluminum, copper and zinc) were added to tin and also sprayed. Results indicated that addition of any of the aforementioned secondary components (SCs) provided a noticeable increase in deposition

High-velocity oxy-fuel (HVOF)-sprayed WC-10Co-4Cr coatings were deposited with thickness of 150, 300 and 450 µm in the present work. The structural and mechanical properties, adhesion strength and residual stress were analyzed as a function of coating thickness. With increasing coating thickness, an increase in hardness and a drop in fracture toughness were observed. The compressive residual stresses

Recently, laser cladding has been widely investigated for the preparation of Co-based coatings for high-temperature applications. However, there is a highly cracking tendency in Co-based alloys due to the reinforcing hard phases. In this work, a single layer of CoCrMoSi coating was prepared with laser cladding on 304 stainless steel. By proper preheating, cracking was avoided during deposition. The

In suspension spraying, two most frequently used solvents are water and ethanol. In this study, we test the potential of using alternative, high molecular weight solvent and demonstrate the associated advantages. For that, two organic solvents are directly compared: ethanol (serving as a benchmark, suspension formulated at 10 wt.% solid load) and di-propylene glycol methyl ether (two suspensions at

In the present study, APS Al2O3-YAG layers containing 10, 20, and 40 wt.% YAG were deposited as the intermediate layer between the MCrAlY bond coat and the YSZ top coat of double-ceramic-layered TBC (DCL-TBC) on the Ni-based superalloy substrate. Then, the effect of its YAG content on the oxidation behavior of the coated sample was investigated. Microstructural studies of the coatings showed that adding

The global thermal spray coatings market was valued at USD 10.1 billion in 2019 and is expected to grow at a compound annual growth rate of 3.9% from 2020 to 2027. Carbide coatings form an essential segment of this market and provide cost-effective and environmental friendly tribological solutions for applications in aerospace, industrial gas turbine, automotive, printing, oil and gas, steel, and pulp

During cold-spraying processes, the deposited particles play a crucial role owing to the subsequent particle collisions with surface. Herein, using finite-element modeling, we numerically analyze the particle behavior under three models: impact of a single Ti6Al4V (TC4) particle, deposited particle hammered by a subsequent TC4 particle, and deposited particle impacted by a large shot peening particle

TiNi shape memory alloy exhibits an excellent cavitation erosion resistance. Therefore, it is an effective method for preventing cavitation erosion to apply this material as a coating. In this paper, different amounts of Cr3C2-NiCr powders were added into TiNi alloy powder in order to produce TiNi-(Cr3C2-NiCr) composite coatings sprayed by atmospheric plasma spraying. The cavitation erosion behavior

During cold spraying of ceramic and metal mixtures, there is an interaction between the ceramic and metal particles during the spray process; as a result, under certain conditions, a non-monotonic dependence of deposition efficiency on the content of ceramic particles in the initial powder mixture is observed. In the present work, a numerical Monte Carlo model is put forward for the first time to simulate

Photoactive tetragonal bismuth oxide powder with different semiconducting characteristics was synthesized from Bi-pellets by flame spray oxidation. The effect of feedstock particle size and standoff distance (SOD) on the physical properties of β-Bi2O3 keeping constant the fuel/oxygen ratio is here reported. The flame spray oxidized powder was collected either from evaporated or in-flight particles

For more than one decade, suspension spraying has been gaining interest for the development and manufacture of coatings for wide range of applications such as photocatalysis, thermal barrier coatings, wear resistance, biomaterials or superhydrophobicity. Even though these coatings are already promising, a modification of their surface properties can further improve their functionality and lifetime

The integrity and properties of ceramic coatings produced by atmospheric plasma spraying are highly controlled by the splat morphology and splat interconnection. In this study, the influence of selected parameters (spray angle, surface velocity of the spray gun, and substrate temperature) on splat morphology and coating microstructure was investigated. A favorite set of spray gun parameters, of which

A set of processing conditions for cold spray deposition of an embedded particle layer on a polymer substrate has been established using a dynamic impact model and verified experimentally. This research utilizes a three-network polymer model based on high strain-rate impact tests to capture the nonlinear and time-dependent response of polymer deformation during the cold spray impact with both rigid

Yttria-stabilized zirconia (YSZ) is used extensively as a ceramic top coat of thermal barrier coating (TBC) system in land-based gas turbines and aero engines. TBC enables modern engines to operate at significantly higher gas temperatures. TBCs are subjected to solid particle erosion at elevated temperature, especially during the operation of aero engines in sandy terrain. Thus, the objective of the

Although overlay coatings deposited via plasma transferred arc welding (PTAW) can effectively prolong the service life and improve the performance of components, cracks and pores tend to occur in the high-hardness and wear-resistant coating during the deposition process. Further treatment is thus necessary to improve the coating quality. Herein, PTAW-deposited Ni-based overlay coating was remelted

Yttria stabilized zirconia (YSZ) is used extensively as a ceramic top coat of thermal barrier coating (TBC) system in land-based gas turbines and aero engines. TBC enables modern engines to operate at significantly higher gas temperatures. TBCs are subjected to solid particle erosion at elevated temperature, especially during the operation of aero engines in sandy terrain. Thus, the objective of the

Glassy deposits mainly comprising of calcium–magnesium–alumina–silicate (CMAS) accelerate the spallation of thermal barrier coatings (TBCs). In this work, an Al2O3 layer was produced on yttria-stabilized zirconia (YSZ) coating by plasma spray–physical vapor deposition (PS–PVD). The effects of processing parameters during PS–PVD process on the microstructures of the deposited Al2O3 coatings were investigated

The CoCrFeNi-based high-entropy alloy coatings were prepared by atmospheric plasma spraying. The microstructure, phase, microhardness and corrosion resistance of the coatings were characterized. The tribological properties of the coatings sliding against GCr15 balls under dry and oil-lubricated sliding conditions were investigated. The results show that the phase composition of the CoCrFeNiAl coating

The two-layer structured YSZ/NiCrAlY coatings were modified with dot shape by laser remelting. The microstructure, phase composition and thermal cycling behaviors of the as-sprayed and laser-treated coatings with different laser dot distances were investigated. The thermal cycling behaviors of the as-sprayed and laser-treated coatings were studied systematically at 1000 °C. The results indicated that

This study adopts a novel structure design of large-area planar metal-supported solid oxide fuel cell (MS-SOFC), which exhibits the characteristics of self-sealing and high thermal cycling resistance. The self-sealing structure of MS-SOFCs is achieved by brazing technology. Plasma spraying is performed to prepare all functional layers of cells. The size of cells is 10 × 10 cm2. The coefficients of

The suspension plasma spray process is now emerging at the industrial scale, and open questions remain regarding the formation of coatings through this process, especially regarding the relationship among particle impact, spreading and build-up into columns. Furthermore, concerns have been raised regarding the behavior of the suspension droplets in the plasma jet stagnation zone since it is a zone

Microbial and viral pathogen contamination of touch surfaces contributes to the rapid transmission of diseases. It has been known for decades that microbes and viruses are rapidly inactivated when exposed to copper and its alloys. Consequently, the use of thermal spray technologies to coat surfaces in healthcare and public settings has been receiving a considerable amount of interest during recent

In plasma spraying, instabilities and fluctuations of the plasma jet have a significant influence on the particle in-flight temperatures and velocities, thus affecting the coating properties. This work introduces a new method to analyze the stability of plasma jets using high-speed videography. An approach is presented, which digitally examines the images to determine the size of the plasma jet core

In this study, the effects of time and temperature of heat treatment on Ni-20 wt.% Al flame spraying coatings were studied. The objectives are to find the optimal sample in terms of microstructure and compare its oxidation resistance with the as-sprayed coating. The coatings were deposited by flame spraying on low carbon (St 37) steel substrate. The specimens were heat-treated in vacuum at 850 °C and

There are many sets of information in the literature (e.g., papers, books and websites) about the great achievements that are expected for aerospace gas turbine engines by the employment of ceramic matrix composites (CMCs) and thermally sprayed environmental barrier coatings (EBCs) in their hot zones (e.g., combustion chambers, vanes, shrouds, blades and afterburners). Among these achievements, it

Loss of mechanical integrity due to thermal aging and subsequent spallation of the ceramic top layer is one of the dominant failure mechanisms in thermal barrier coating systems. In order to predict and avoid such mechanical failure, a strain-based lifetime assessment model is presented for a novel double-layer thermal barrier system. The investigated ceramic system consists of a gadolinium zirconate

Besides conventional industrial demands, thermally sprayed coatings are increasingly used for innovative products. Such an application is the additive manufacturing of electrical components in automotive engineering. In particular, heating units are currently manufactured by a combination of various spray technologies. At present, simpler spraying processes like flame spraying are investigated with

This study deals with Al2O3-13wt.%TiO2-reinforced CoCrFeMnNi high-entropy alloy (HEA) composite coatings prepared by plasma spraying. The effect of the Al2O3-TiO2 ceramic phase on the microstructure, mechanical properties and high-temperature tribological performance of the as-sprayed composite coatings was investigated. The results showed that the composite coatings consisted of a HEA phase with a

Up to now, the role of particle sizes on the impact behavior of ceramic particles in aerosol deposition not yet fully understood. Hence, with the aim to supply a more general understanding, modeling series of low strain rate compression and high-speed impact were performed by molecular dynamics on single-crystalline particles in sizes of 10-300 nm that are tuned to match mechanical properties of TiO2-anatase

Aerosol deposition (AD) is a thick-film deposition process that can produce films tens to hundreds of micrometers thick with densities greater than 95% of the bulk at room temperature. However, the precise mechanisms of bonding and densification are still under debate. To better understand and predict deposition, a self-consistent approach is employed that combines computational fluid dynamics (CFD)

Thermally sprayed coatings improve component lifespan and protect the underlying substrate in high temperature and corrosive environments. The coating adhesion is one of the most important properties with respect to coating performance. Before coating, surfaces are typically cleaned and roughened via manual grit blasting to promote mechanical interlocking of the coating with substrate. With recent