bluuebunny/crossref_metadata_2025_split huggingface dataset:
Amorphous Phase Formation of Zr-Based Alloy Coating by HVOF Spraying
Authors: Kim H.J. , Seong B.G. , Lim K.M. , Park C.G. 
Published: July 2021

Abstract
This investigation was conducted to clarify the effects of process parameters on the formation of the new amorphous coating using Zr-based alloy, which is known as bulk metallic glass forming alloy, by a HVOF (High Velocity Oxygen Fuel) spraying process. Powders used for spraying was prepared by vacuum gas atomization and then crushed by a centrifugal mill. HVOF spraying experiments were carried out using a Tafa JP-5000 spraying gun. DTA (Differential Thermal Analysis) measurements have shown that the amorphous content of the coatings was measured up to about 65% depending on the spraying parameters. The amorphous fraction of the coatings is decreased with increasing the spray distance and the fuel flow rate. Microstructural observations and X-ray diffraction analysis of the spray coated layers reveal that the amorphization behavior during the spraying is attributed to the degree of the solidification of droplets and the oxide (ZrO2) formation in spray coated layers. Therefore, flame temperature and spray distance that can control the carrier gas temperature and undercooling effects of the droplets are the most crucial factors for the evolution of the amorphous phase using this bulk metallic glass forming alloy.
HVOF Sprayed Titanium Carbide Composite Coatings for Wear Protection
Authors: Wielage B. , Steinhäuser S. , Schnick T. , Ilyuschenko A. , Azarova A. 
Published: July 2021

Abstract
High Velocity Oxygen Fuel (HVOF) spraying established itself as an effective method in addition to the conventional thermal spray processes within a very short period. Self fluxing nickel alloys, cermets (e.g. WC-Co / Cr3C2-NiCr) as well as oxide ceramic coatings have proved themselves suitable for wear protection applications. Weight reduction, the care of resources and the increase of efficiency for structural components leads to the substitution of customary hard particles. Titanium carbide (TiC) characterizes itself on account of the material features such as the high hardness, the high melting point, the high strength and the low density for the substitution of conventional carbides. The Self Propagating High Temperature Synthesis (SHS) is a suitable process for the production of composite powders. The powders produced by SHS show a high carbide content, which is finely distributed with an almost stoichiometric composition of the TiC inside the powder particles. The carbides are protected against dissociation and oxidation during the thermal spray process by a complete velum of matrix alloy. The current investigations deal with the wear resistance of TiC-composite coatings produced by HVOF compared to conventional wear resistant coatings. The investigations contain the analysis of the microstructure by optical and scanning electron microscope (SEM) and the measurement of the microhardness of the deposited coatings. Special attention is drawn to the interface between the hard particles and the matrix alloy. The optimized coatings are tested with different wear tests, such as Taber-Abraser test, sliding and oscillating wear test and are compared with common wear resistant coatings in order to underline the high potential for different wear applications. Moreover an additional corrosion test (salt fog test) is carried out with regard to the corrosion resistance of the different matrix alloys.
New Chromium Carbide–Nickel Chrome Materials for High Temperature Wear Applications
Authors: Laul K. , Dorfman M. 
Published: July 2021

Abstract
A new low-cost chromium carbide-nickel chrome powder has been developed. Potential applications for these powders include hard-chrome replacement, boiler tubes and turbine engine components. The erosive and abrasive wear properties of the deposited coatings have been found comparable to commercially available nickel-chromium based carbide materials. A significant advantage of these powders is higher deposition efficiency and carbon retention when coatings are deposited using HVOF thermal spray equipment. Results indicate deposition efficiencies up to 50% higher than commercially available carbide powders in the market today. Higher deposition efficiency effectively reduces the application costs allowing these materials to be competitive in a wider range of applications. Powder characteristics and the application costs data are included in this paper. Also discussed are microstructure-property relationships of the various coatings. Data including abrasive slurry wear, hardness, high- and low-angle erosion and superfinished surface finish is reported. Comparisons have been made to commercially available chemical clad and blended CrC-NiCr powders.
Spraying Coatings by Supersonic Metallization
Authors: Karp I. , Rudoy A. 
Published: July 2021

Abstract
A technology and a specialized equipment complex based on supersonic arc spraying gun, where a supersonic stream of combustion products of hydrocarbon-gas (HC-gas) with air is used as an atomizing gas, have been developed. Durable and safe work of coated parts functioning under conditions of intensive loading is determined (except general requirement to coatings: wear resistance, hardness) to a large extent by the fatigue strength, porosity and stability of the properties of coatings. New possibilities for satisfying all the requirement to coatings on parts type are opened up by a high speed spraying of wire. This is provided at the expanse of raising the kinetic energy of particles under spray, increase of their concentration in metal stream, lowering of the spread of parameters in the vicinity of a substrate. This, in its turn, determines the increase of adhesive and cohesive strength of coating, the decrease of oxidation, the improvement of stability and reproducibility of its properties. The results of the investigations of the influence of the variable parameters of the process on the listed above properties of coatings are presented. This technology and equipment complex is appreciated for repair of wearied motor component and deposition of corrosion protective coatings.
High Velocity Pulsed Wire-Arc Spray
Authors: Kincaid R.W. , Witherspoon F.D. 
Published: July 2021

Abstract
Wire arc spraying has traditionally filled metallic coating needs for low end users, while higher quality coatings required the use of higher cost systems. A new high velocity wire arc spray device has been developed through a NASA SBIR project whose high particle velocity capabilities could provide high quality coatings while keeping costs well below those associated with HVOF and plasma spray approaches. In addition, this technique achieves these high velocities in an extremely short acceleration path. This new device employs a pulsed plasma as the accelerative medium for the molten droplets. This pulsed plasma is capable of accelerating the droplets from the tips of the wires up to high velocities and atomizing them to very fine size. This results in a fine microstructure in the deposit. Recent experiments using a Control-Vision system measured velocities for aluminum droplets in the range of 950-1500 m/s and stainless steel droplets in the range of 850 m/s and 925 m/s. These velocities are achieved with an acceleration distance of only 3.2 cm, thus making this process an ideal candidate for coating the interior of automotive cylinder bores and other areas where only a short acceleration region is available.
Benefits and Technology Developed to Arc Spray 3/16 Inch (4.8mm) Diameter Wires Used for Corrosion Protection of Steel
Authors: Rogers F.S. 
Published: July 2021

Abstract
It has been generally accepted that amperage and voltage are the only variables used to determine spray rate with the twin wire arc spray process. This belief has led to the common practice of defining spray rates in terms of kgs (pounds) per amperes. The "pounds to amperes" theory has been disproved with die advent of equipment capable of successfully arc spraying 4.8 mm (3/16 inch) diameter wires of zinc, aluminum, or 85/15 (zinc/aluminum). Changes in equipment design, that allowed the use of the larger diameter wires, resulted in the issue of a U.S. patent for arc spraying wires over 3.2 mm (1/8 inch) diameter. To achieve production capabilities for spraying 4.8 mm (3/16 inch) diameter wire, numerous problems needed to be solved, which led to additional patent claims.
High Definition Single-Wire-Arc-Spray
Authors: Carlson R.R. , Heberlein J.V.R. , Hussary N. , Shi K. 
Published: July 2021

Abstract
Wire arc spray is a process for producing coatings and forming structures through the deposition of metal droplets. Wire arc spray has the advantage of low material coast and low power requirements when compared to other thermal spray technologies. This article elaborates on the assumptions made for using single consumable wire geometry, discusses experiments performed to test these assumptions, presents droplet generation results, and addresses required future work. Experiments revealed a critical relationship between wire polarity, wire position, and droplet beam dispersion. The article identifies a critical relationship between wire polarity, wire position, and spray pattern divergence in a single wire arc spray device.
Splashing of Nickel Droplets During Plasma Spraying
Authors: Pershin V. , Thomson I. , Chandra S. , Mostaghimi J. 
Published: July 2021

Abstract
Individual splats are the building blocks of any thermal spray coating. Near the coating-substrate interface, they affect coating properties like adhesion strength. This article examines the effect of substrate heating on droplet splashing. Nickel powder was plasma-sprayed onto a polished stainless steel substrate at various temperatures and the resulting splats were analyzed. Droplet splashing was observed experimentally for three different cases: low substrate temperature, high substrate temperature, and droplet-splat interaction. Mechanisms for splashing were explained with the help of computer-generated nickel droplet impacts. The article proposes that the jetting of molten metal is not triggered by the formation of a central splat but rather a solidified ring on the periphery of the splat. It was observed that, on substrates below 350 deg C, splashing is triggered by solidification at the edge of the spreading droplet. Interactions with previously deposited splats also cause droplets to splash.
Plasma Technology TRIPLEX for the Deposition of Ceramic Coatings in the Industry
Authors: Barbezat G. , Landes K. 
Published: July 2021

Abstract
As a new plasma gun technology the TRIPLEX system has been introduced in the industrial field two years ago. The core of the TRIPLEX technology is a plasma gun with three cathodes and a long cascaded nozzle consisting of several insulated rings. Only the last ring with a relatively long distance to the cathode is operated as anode. Because of the equal and constant lengths of the three independent arcs, stretching from the three cathodes to the common anode, a stationary plasma jet is generated. Compared to conventional torches, the improved stability of the plasma jet allows a more uniform powder treatment and a higher deposition efficiency as well as the powder feed rate can be increased using a triple injection system. A significantly longer life time of the electrodes reduces the cost for quality control in the coating process. The characteristic properties of oxide ceramic coatings are improved in comparison with the coatings produced by conventional plasma torches. The results of two years industrial application of the innovative torch system TRIPLEX are presented in the paper.
The Development of Corrosion Resistant Coatings by HVOF Spraying
Authors: Harvey D. , Lunder O. , Henriksen R. 
Published: July 2021

Abstract
Coatings have been prepared using the Diamond Jet hybrid and JP5000 high velocity oxyfuel (HVOF) systems with the objectives of improving corrosion resistance and reducing costs through increasing deposition efficiency. Models relating deposition efficiency, coating oxygen content and corrosion resistance to process parameters including fuel flow rate, oxygen flow rate and stand-off distance have been developed. A corrosion test cell has been designed and a procedure determined for studying the corrosion behaviour of large numbers of thermally sprayed coatings in an efficient manner. A significant improvement to the corrosion resistance of HVOF sprayed coatings has been achieved by spraying parameter optimisation and investigation of powder size and distribution. The project has also investigated the influence of spray angle on coating performance with a view to future onsite application. Coating materials tested and compared include nickel alloys Hastelloy C276 and 59, cobalt alloy Ultimet, duplex stainless steel S32750 and an experimental iron-based spray-fuse composition.
Wear Resistance of Laser Alloyed ZrB2 Coatings on Mild Steel
Authors: Gadkari A. , Khanna A.S. , Dahotre N.B. 
Published: July 2021

Abstract
Borides are promising materials with good wear and corrosion resistance properties. Boride coatings are expected to perform better where wear and corrosion resistances are simultaneously required. Zirconium diboride is an important emerging material for such applications, due to its high hardness, high melting point, good wear resistance and corrosion as well as high temperature oxidation resistance. Special properties of laser beam like beam directionality, high intensity and spatial resolution makes laser alloying a fast and efficient technique for producing improved wear resistance coatings. In the present work, mild steel was laser alloyed with ZrB2, using "two-stage" technique of laser alloying. These coatings after characterization by optical microscopy, SEM, EDAX and XRD techniques were tested on a "Pin-on-Disk" machine for determining their wear resistance.
Ten Year Interim Report of Thermal Sprayed Zn, Al, and Zn-Al Coatings Exposed to Marine Corrosion by Japan Association of Corrosion Control
Authors: Kuroda S. , Takemoto M. 
Published: July 2021

Abstract
Thermal spray committee of Japan Association of Corrosion Control (JACC) has been conducting a corrosion test of thermal sprayed Zn, Al and Zn-Al coatings at coastal area since 1985. Twelve kinds of sprayed coating were deposited onto steel pipe by arc- and flame-spraying at varied thickness and subjected to various post-spray treatment. The samples were set vertically into the seawater at a port 80 km south from Tokyo. Corrosion performance were inspected annually by recording the appearance and coatings' thickness at sea air-, splash- and tidal-zones. No significant changes were observed for five years exposure. After 7 years, however, Zn coatings with and without sealing started to suffer degradation in the immersed portion. Contrary to this, Al and Zn-Al coatings still exhibit superb corrosion performance. The test will be continued till 2001 to finish a 15 years field test. This paper reports the summary of corrosion performance of sprayed coating during the first 10 year period.
Thermal Conductivity Behavior of Sol-Gel Post-Treated Thermal Barrier Coatings
Authors: Lima C.R.C. , Senturk U. , Lima R.S. , Berndt C.C. 
Published: July 2021

Abstract
Thermal barrier coatings have been extensively used in several industrial segments. The material used as an insulator in such systems has been partially stabilized zirconia (PSZ) plasma sprayed over a metallic bond coat layer. The ceramic layer is usually porous, thus improving insulation properties. The porosity also increases gas permeability and, therefore, reduces oxidation resistance of the coating. Post-treatments have been applied to reduce the open porosity and improve oxidation resistance. In this work thermal barrier coatings were applied on low carbon steel substrates using two sets of bond coat, i.e., metallic and metal-ceramic. The metallic bond coat was NiCrAlY. The metal-ceramic bond coat was a mixture of NiCrAlY and 8% yttria partially stabilized zirconia, which were applied by simultaneous feeding to the plasma torch from two powder feeders. A sol-gel method was employed to impregnate the porous ceramic top coat with alumina or zirconia. The samples in the as-sprayed and post-treated condition were characterized using mercury intrusion porosimetry (MIP), thermal conductivity. KEY WORDS: Thermal Conductivity, TBCs, Sol-Gel.
Application of Plane Fractal Geometry to Adhesion Strength of Thermal Sprayed Coatings
Authors: Amada S. , Hirose T. 
Published: July 2021

Abstract
Adhesion of ceramic coatings considerably depends on the surface characteristics of blasted substrates. The roughened surfaces have two kinds of topographical characteristics, one is of their cross section and the other is of planar. The roughened surfaces is generated by angled grit-blasting process which can be expected to improve the adhesion of ceramic coatings. The topography of the roughened surfaces has fractal characteristics in their cross section and has been more effectively related to the adhesive strength of ceramic coatings than average surface roughness traditionally used. This paper presents that fractal characteristics is evaluated in the planar topography of the blasted surfaces and shows that the planar fractal characteristics is closely related adhesion of ceramic coatings. The planar fractal dimension is evaluated by SIA (Slit Island Analysis) which needs the height data on the roughened surface. Those data are obtained by a laser-microscope in confocal type.
Practical Applications of Spray Plume Sensors in the Aeronautic and Automotive Industries
Authors: Nadeau F. , Pouliot L. , Blain J. 
Published: July 2021

Abstract
Three actual applications of spray plume sensors for industrial coating operations are presented. Two of these are in the aeronautic industry and one in the automotive industry. Depending on the application, different types of sensors were used ranging from plume shape monitoring (particle trajectories) to full plume characterization including in-flight measurement of individual particle properties. In each case, the process monitoring scheme developed depended on the manufacturer's requirements as well as the nature of the information provided by the sensor. The significant differences in usage and working conditions compared to an R&D environment are examined. Advantages and drawbacks in each of the three situations are detailed. A tentative forecast of coming developments in this field is also given.
Thermal Spray Coatings for Ball Valves Used in Nickel/Cobalt Pressure Acid Leaching
Authors: Kim G.E. , Brzezinski T.A. , Leblanc L. , Kharlanova E. 
Published: July 2021

Abstract
Pressure acid leaching (PAL) of lateritic nickel ores requires the use of extremely severe processing conditions (250 °C, &gt; 4000 kPa, 98 % H2SO4). In addition to the severe corrosive nature of the acid solution, up to 30% of abrasive solids are present in the slurry. PyroGenesis Inc. has applied its expertise in materials science and thermal spray technologies into developing and commercially applying coatings for the protection of ball valve components used in PAL autoclaves. Vacuum plasma spray (VPS) and atmospheric plasma spray (APS) processes are used to apply coatings of metals and ceramics for corrosion and wear resistance, respectively. A comparative study on the microstructure and mechanical properties of different coatings, applied with the two processes, will be presented. Although APS coatings provide enhanced abrasive resistance, VPS coatings have shown the potential for superior properties. The extreme temperatures and pressures associated with the actual PAL conditions are too severe to simulate in laboratory conditions, hence, corrosion testing was not possible. Microstructural analysis, microhardness, adhesion, and abrasion testing were determined for each coating/processing combination.
Synthesis, Thermo-Mechanical Properties, and Frictional Response of NiCrAlY-Zirconia Composite and Graded Coatings
Authors: Sampath S. , Prchlik L. , Kishi K. 
Published: July 2021

Abstract
NiCrAlY-PSZ graded materials with two different gradients were synthesized using the plasma spray technique. Their microstructure, thermal and frictional response were evaluated, and the response was compared to that of single layered composite materials. The hardness and frictional properties of PSZ could be successfully optimized by an addition of small amount of NiCrAlY. The results of testing revealed the potential of ceramic/metallic materials systems and can be used to further optimize the spraying process of composite/graded structures subjected to contact damage at high temperatures. The study also revealed new tribo-effects that can be encountered in potential applications of graded structures.
Standards for the Thermal Spray Industry
Authors: Bhusari M.M. , Sulit R.A. 
Published: July 2021

Abstract
Thermal-spray standards in the United States are developed by several professional societies that include American Society for Testing and Measurement (ASTM) for test & measurements methods and composition specifications; American Welding Society (AWS) for feedstock, equipment acceptance, application process, training & certification; American Water Works Association (AWWA) for thermal-sprayed zinc as potable water tank lining; International Association of Corrosion Engineers (NACE) for corrosion protection processes and inspection; and Society of Protective Coatings (SSPC) for test & measurement methods, application specification & inspection in regards to protective coatings for the protection of steel. This paper provides information on various standards set by these bodies.
Characterization of Cracking Within WC-Co Coated Materials by an Acoustic Emission Method During Four Points Bending Tests
Authors: Dalmas D. , Benmedakhene S. , Richard C. , Laksimi A. , Gregoire T. 
Published: July 2021

Abstract
The aim of this work is to study the adhesion of WC-Co coatings using acoustic emission testing. The coatings were produced by HVOF spraying then subjected to four-point bending while in situ acoustic emission measurements were made. The test specimens were then examined under a microscope, revealing regularly spaced transverse cracks on the coating surface as well as interfacial cracking. An analysis of the acoustic emission data revealed two types of acoustic events based on absolute energy and amplitude. This appears to be linked to the cracks that were observed forming the basis for an interfacial cracking model.
Plasma Spraying of Spray-Dried AI2O3 Powders
Authors: Bertrand G. , Hansz B. , Tourenne F. , Coddet C. 
Published: July 2021

Abstract
Today, powder particles diameter used for thermal spraying is generally comprised between 5 and 100µm with a preferred range around 40µm for APS applications. Actually, the future trends in plasma spraying are directed to the use of fine or ultrafine powders and the reduction of the steps between raw materials and coatings. So, the present paper investigates the way to use directly spray dried ceramic powders in suppressing the sintering stage. AI2O3 based powders were obtained by the spray drying process. By optimizing the parameters (slurry composition and injection as well as drying characteristics), a narrow grain size distribution was achieved. Chemical composition and shape of synthesized powders were analyzed by scanning electron microscopy (SEM) equipped with energy dispersive spectrometry (EDS). The crystallographic structure was identified by X-ray diffraction (XRD). Demonstration was made that it is possible to obtain coatings using directly spray dried ceramic powders. The plasma spray process parameters (such as current intensity, gas flow rate, powder feed rate and injection mode, cooling stage,...) have to be managed to achieve cohesive coatings. The structure and chemical composition of these coatings were studied. In this way, the direct use of spray dried powders appears as a promising way to realize ceramic coatings.