bluuebunny/crossref_metadata_2025_split huggingface dataset:
Study the Impact of Process Parameters of Laser Cladding Nickel-Chromium Alloy Powder on Substrate Melted Areas
Authors: Ahmed Rakan A. , Khan Raja S. , Qahtani Mohammed M. , Alsayoud Abduljabar , Bukhari Abdulhameed S. 
Published: August 2024

Abstract
This work focuses on the laser cladding process and the behavior or interaction between the powder particles and the laser beam, specifically examining how various process parameters might affect the creation of melt pool formations. The experiment focused on examining the influence of laser intensity and other important factors on the amount of metal in the substrate of 316L stainless steel, particularly while utilizing Inconel 625 powder. The study was conducted by utilizing cross-sectional images and quantifying the ratio of areas of the melted substrate material across a sliced cross-sectional area. The study also investigated the influence of recirculation patterns resulting from the Marangoni convection force on the formation of the melt region. The study's results indicate that a low powder feed rate is preferable, which in this study was 5 g/min, and provides better results with a symmetrical and profound melt profile. The melt shifts to asymmetrical profiles when the feed rate increases significantly over this value. The primary cause of this phenomenon is attributed to the Marangoni forces and the momentum transfer generated by the powder jets. The investigation also emphasizes the complex interplay among the process factors and highlights the crucial role of laser source power in triggering a fast escalation in the volume of melted material. In addition, the study supports the idea that maintaining the laser energy input as a constant helps to create a consistency in the total melt area even when the cladding speed is increased.
Improved Adhesion of Plasma-Sprayed Ceramic Coatings on Textured Ceramic Substrates
Authors: Ferrasse T. , Costil S. , Darut G. , Bouteiller B. , Auscher M. C. 
Published: August 2024

Abstract
Coating adhesion by thermal spraying method requires sufficient surface roughness on particle scale particles impacting the surface, particularly in the case of plasma spraying with particle melting state. Grit blasting process is mainly used to create the fine asperities required for spread particles to adhere. To further increase adhesion, the use of laser texturing for metallic substrates is benefit and is already well documented in literature. In the case of ceramic substrates such as alumina, grit blasting with corundum particles is no longer effective in creating a roughness of a few micrometers. Laser texturing therefore appears to be a potential candidate for generating adhesion in coatings. In this work, adhesion mechanisms of three different coatings produced by Atmospheric Plasma Spraying (APS) on a textured alumina substrate were investigated. The influence of substrate surface texturing by two different laser methods, a pulsed nanosecond laser and a continuous laser, was studied. YSZ was chosen as a potential Thermal Barrier Coating (TBC) and Al2O3 and Y2O3 were selected as bondcoats to observe the variation of adhesion mechanisms on ceramic substrates. Textured patterns and coating microstructures were observed by numerical and electron microscopy. Different adhesion mechanisms occurred depending on coating material. Either the geometrical parameters of the pattern and the surface roughness developed by a nanosecond laser and a continuous laser respectively, can promote mechanical anchoring and thus, a real adhesion.
Physics-Informed Neural Networks for Predicting Particle Properties in Plasma Spraying
Authors: Bobzin K. , Heinemann H. , Dokhanchi A. 
Published: August 2024

Abstract
Plasma spraying is a key industrial coating process that exhibits intricate nonlinear interactions among process parameters. This complexity makes accurate predictions of particle properties, which greatly affect process behavior, very challenging. Specifically, particle velocities and temperatures profoundly impact coating quality and process efficiency. Conventional methods often require empirical correlations and extensive parameter tuning due to their limited ability to capture the underlying physics within this intricate system. This study introduces Physics-Informed Neural Networks (PINNs) as a solution. By seamlessly integrating known physical laws and constraints directly into the model architecture, PINNs offer the potential to learn the underlying physics of the system. For comparison, Artificial Neural Networks (ANNs) are also developed. Computational Fluid Dynamics (CFD) simulations of a plasma generator and plasma jet model provide data to train both ANN and PINN models. The study reveals an improvement in particle velocity prediction through the proposed PINN model, demonstrating its capability to handle complex relationships. However, challenges arise in predicting particle temperature, warranting further investigation. The developed models can aid in optimizing the plasma spraying process by predicting essential particle properties and guiding necessary process adjustments to enhance coating quality.
Databased Optimization of Coating Characteristics—Challenges and Possible Solution
Authors: Rannetbauer Wolfgang , Hambrock Carina , Hubmer Simon , Ramlau Ronny 
Published: August 2024

Abstract
Thermal Spraying of tungsten carbide is usually performed to optimize surface hardness. However, often there are additional coating or process requirements, e.g., low porosity, low roughness, or high deposition efficiency, that must be met to satisfy the customer or increase the process efficiency. Such optimizations are difficult because various influencing factors, e.g., lambda (λ), standoff-distance, or powder feed rate, have different effects on the individual coating and process properties. In this study, several trials were performed and analyzed (technically & databased) to understand how each influencing factor affects these coating and process properties. It could be determined that there is no general best performance parameter but that only individual solutions depending on prioritized importance of the properties can be obtained. Using data, one way of solving the challenge is the performance of multi-objective optimization. With the help of this method, the challenges of optimization can be solved using test data. The simultaneous optimization can be visualized in a 2D/3D graph. A boundary line can be observed where different process and coating characteristics are optimized. Applying such databased methods can help to work more efficiently as well as more sustainable in development and application.
Experimental and Numerical Study of the Spattering Dynamic Mechanisms in Selective Laser Melting
Authors: Qin Shaocong , Zhang Wenyou , Yin Shuo , Lei Shenghui 
Published: August 2024

Abstract
Spattering is an unavoidable phenomenon in the selective laser melting (SLM) process, which can cause various printing defects and harmful powder recycling. Since the size of powder spattering is too small at the micron level, it is difficult to investigate the entire dynamic spattering process experimentally. The comprehensive understanding of the intricate dynamics of powder spattering during the SLM process remains incomplete. Therefore, we develop a new multiphase flow model to study the transient dynamic behaviors of the gas phase and powder spattering, which agrees well with the experimental observation result. It is the first time that the whole transient dynamic process of powder motion from starting to move induced by the vapor jet to falling to the substrate wall and stopping completely was observed. Powder spattering motion dynamics induced by metal vapor jet and argon gas flow, as a function of time, laser parameters, and location, are presented. The moving speed, total amount, and dropping distribution on the substrate of powder spattering that varies with laser parameters are quantified.
The Effect of Powder Particle Size on Mechanical and Fracture Properties of Cold Sprayed Al
Authors: Kovarik O. , Wick F. , Wiehler L. , Huang C. , Cizek J. , List A. , Gärtner F. , Klassen T. 
Published: August 2024

Abstract
Thick deposits were produced from pure Al powder of three different sieve sizes using cold spraying at the same process parameters. The in-plane mechanical and fracture properties of the deposits were investigated using bending of small specimens in four specimen orientations. It was shown that increasing the Al particle size by approximately 50% and 100% leads to small, but statistically significant differences of yield strength. Further, the increase in the powder particle size led to higher fracture toughness KIC but lower fatigue crack growth threshold ΔKthr. This can be attributed to two different fracture mechanisms in the cold sprayed deposits. A trans-particular fracture in the near-threshold fatigue regime is controlled by the microstructure and work hardening of the particles. At higher cyclic loads and in quasi-static regime, the particle decohesion and the resulting crack path determine the fracture behavior instead. However, the observed effect of particle size was rather small, much smaller than the effect of spray process parameters observed in the previous research.
Plasma-Sprayed Bulk-Like Ni-Based Alloy Coating Enabled by Boron-Containing Powder Design with Exceptional High Tensile Strength
Authors: Li Chang-Jiu , Dong Xin-Yuan , Song Jiu-Jing , Zhu Yong-Sheng , Luo Xiao-Tao , Zhang Li 
Published: August 2024

Abstract
Plasma spraying is the most versatile coating process for depositing a wide range of materials to enhance material performance in harsh conditions. However, severe oxidation during the plasma spraying of metal coatings often results in coatings with high oxide content, limiting interlamellar bonding. Consequently, as-sprayed metal coatings offer inadequate protection against severe corrosion and wear. To address this challenge, we developed Ni-, Cu-, and Fe-based materials containing boron as a deoxidizer. This innovative approach effectively suppresses in-flight oxidation, producing oxide-free molten droplets and enabling the formation of bulk-like metal coatings with sufficient metallurgical bonding between splats. We employed a modified tensile test to evaluate the adhesive and cohesive strengths of these coatings. The Ni-based coatings exhibited adhesive strength exceeding 150 MPa on Fe-based substrates, while cohesive strength surpassed 260 MPa with a novel bond coat. Corrosion and gas penetration tests confirmed the creation of dense, bulk-like Ni-based alloy coatings, demonstrating their potential for various applications in severe service environments.
Opportunities and Limitations of a Holistic Process Monitoring System for Arc Processes
Authors: Weis Sebastian , Brumm Stefan , Grunert Robin , Halmaghi Manuel , Morgenschweis Jan , Bosler Jürgen 
Published: August 2024

Abstract
Thermal spraying, especially wire arc spraying, represents a strong growing and developing technology due to the possibility of current modulation. However, achieving consistently high coating quality in an automated production environment is strongly influenced by a large number of sensitive process parameters, including base current, pulse current, pulse duration, impulse frequency, alternating current frequency, and wire speed. To monitor and store the coating process data, a holistic process monitoring system was designed and tested numerous times. The scalable system is able to compare a wide variety of different process signals on one timeline. In addition to arc spraying, it can also be used for other arc processes. Custom software enables the comparison and analysis of selected process data sets in order to identify and correct irregularities in the process and the resulting coating. This article uses selected examples to demonstrate the opportunities and limitations of the system.
A Comparative Investigation of Feedstock Materials on Multiple Properties of HVOF-Formed Cr3C2-NiCr Coatings: Size Effects of Powders and Carbides on Sliding Abrasive Wear Behavior
Authors: Ma Xinqing , Ruggerio Peter 
Published: August 2024

Abstract
Nowadays, Cr3C2-based cermet coatings by HVOF process are widely recognized for their corrosion and erosion resistance, particularly at high temperatures. These coatings also offer the advantage of being lightweight and exhibiting superior wear, corrosion and cavitation resistance in room-temperature applications. Their lightweight nature and high temperature capability make them an attractive alternative to WC-based alloy coatings and hard Cr plating coatings. The objective of this study is to develop optimal Cr3C2-NiCr coatings by comparing different feedstock materials, including feedstock with nanocrystalline and/or submicron sized Cr3C2 phases. The focus of the investigation is on understanding the impact of feedstock features such as particle size, morphology, and carbide sizes, as well as sliding abrasive wear conditions (specifically SiC grit size and working load), on the coating properties and sliding wear performance. The results of the study indicate that the sliding wear resistance of the Cr3C2-NiCr coatings is highly influenced by the features of the Cr3C2 carbides. The presence of nano, submicron and few microns sized carbides in the coatings improves their density and hardness, leading to a significant reduction in wear rates under test conditions. Furthermore, the size of the abrasive SiC grit on the counter surface plays a significant role in determining the sliding wear behavior of these coatings. Based on the analysis of the test data, the mechanisms behind the performance of the Cr3C2-NiCr coatings have been investigated and used to interpret their sliding wear behaviors. A high microhardness in the coating is considered a reliable indicator of high quality, full density, and satisfactory wear resistance. This study has identified and recommended optimized materials for improved coating properties based on the key findings. These findings contribute to the understanding of the relationship between feedstock features, sliding abrasive wear conditions, and the wear rates of HVOF-sprayed Cr3C2-NiCr coatings.
Dynamic Impact Wear Behavior of HVOF Sprayed Hardmetal Coatings
Authors: Houdková Š. , Duliškovič J. , Vostřák M. , Taranda T. , Skála O. , Musilová R. , Daniel J. , Berger L.-M. 
Published: August 2024

Abstract
Thermally sprayed wear resistant coatings have proven their effectiveness in many applications. Their benefit is unquestionable in the case of mutual sliding contact or abrasive stress caused by hard particles. However, for the case of dynamic impact loading, either single or cyclic, the lifetime of different types of coatings is rarely described, probably due to the complex influence of many parameters. The paper deals with the evaluation of resistance to dynamic impact loading of two types of HVOF-sprayed Cr3C2-rich binary hardmetal coatings (Cr3C2-42%WC-16%Ni and Cr3C2-37%WC-18%NiCoCr) with respect to the variation of their deposition parameters and compares them to a well established Cr3C2-25%NiCr coating. For each coating, a Wohler-like curve was constructed based on a failure criterion of sudden increase in impact crater volume. Besides, coatings deposition rate, residual stress, microstructure and hardness were evaluated. Differences in the coatings dynamic impact wear resistance was found, related to their residual stress. The failure mechanism and crack propagation mode are analyzed using SEM of impact surface and cross-sections. Deformation and related stress changes in coated systems during dynamic impact loading are described using FEA analyzes.
Enhancing the Optimized HEA Bond Coating in TBC Systems via HVAF Technique
Authors: Shahbazi Hossein , Lima Rogerio S. , Stoyanov Pantcho , Moreau Christian 
Published: August 2024

Abstract
To achieve higher engine combustion efficiency while reducing emissions, it is necessary to address the challenges posed by elevated operating temperatures. High Entropy Alloys (HEAs) have emerged as promising materials for this purpose, offering exceptional properties at high temperatures, including synergistic effects and excellent resistance to oxidation and corrosion. In this study, a FeCoNiCrAl HEA was investigated as a bond coat material due to its excellent balance of strength and ductility, coupled with outstanding oxidation resistance. It was deposited using HVAF M3 and i7 guns equipped with different nozzles/powder injectors and pressures. Notably, this research marks the first study of the i7 gun globally for the HEA bond coat, coupled with the optimization of HVAF parameters for both i7 and M3 guns. Characterization of both powder and as-sprayed samples was carried out using X-ray Diffraction (XRD), Energy-dispersive X-ray spectroscopy (EDS), and Field Emission Scanning Electron Microscopy (FESEM) techniques. The results revealed the formation of a dense and homogeneous microstructure. Additionally, isothermal oxidation tests were conducted to analyze the behavior of the thermally grown oxide. After 50 hours at 1000 °C, a dense, uniform, and thin alumina TGO layer was observed to have formed. These tests revealed that FeCoNiCrAl HEA exhibits significant potential to enhance oxidation resistance at high temperatures.
The Performance of Metal Based Abradable Sealing Coatings Based on Peeling Medium Particle Structure Design
Authors: Guo Dan , Liu Jianming , Liu Tong , Wu Chao 
Published: August 2024

Abstract
In order to overcome the problem of insufficient abradability of existing metal based coatings that cannot meet the requirements of harsh working conditions, this article designs two types of metal based abradable sealing coating materials based on the particle structure of "peeling medium", and studies the basic performance and simulated working condition service performance of the coatings. The research shows that, after undergoing a 1000 hour heat exposure test at high temperature, the two coatings still maintain good hardness, bonding strength, and abradability, indicating that under long-term high-temperature service environment, the two coatings can fracture at the location where the abradable components are exposed, thereby maintaining the abradability and good thermal stability that meet the requirements of use.
Fluid Velocity Sensors Made by Thermal Spray
Authors: Hanna Andre , Chandra Sanjeev 
Published: August 2024

Abstract
Sensors to measure gas velocities in high temperature flows need to be robust, low-profile so that they do not obstruct the flow, and easy to apply on metal surfaces. Thermal spray offers a method of making low-cost sensors that can be applied on large areas. Plasma spray was used to deposit an electrically insulating layer of alumina on a 316 stainless steel block. A 17 mm diameter heater coil was deposited on top of the alumina layer by spraying Nichrome from a twin wire arc spray system through a 3D printed polymer mask. A thermocouple junction was built next to the heater by inserting an insulated Constantan wire through a vertical hole drilled in the steel block and spraying steel on the top of the hole to close it and form an electrical connection between the wire and the surrounding substrate. The junction of the wire and the steel formed a thermocouple whose output voltage was calibrated. A flow loop was built to calibrate the sensor by passing air over it at velocities of up to 5 m/s. A series of 2 min long voltage pulses were applied to the heater, increasing its temperature by approximately 5°-10°C each time, before letting it cool. A calibration curve was developed of the air velocity as a function of the time constant for cooling of the sensor.
Improvements in Cavitation and Slurry Wear Erosion of Inconel 718 Laser Cladding through the NiNb Addition
Authors: Fals Hipolito D. C. , Sabino Simone R.F. , Pukasiewicz Anderson G.M. , Pacheco Jeferson T. , Veiga Marcelo T. 
Published: August 2024

Abstract
The development of materials and alloys for coatings has been increasingly important for reducing costs in different manufacturing processes. The Inconel alloy is widely used due to its chemical inertness and high resistance to high temperatures, but it does not present adequate resistance to erosive wear. In this context, the resistance to wear from cavitation erosion and slurry erosion was evaluated of samples with depositions obtained by laser cladding (Laser directed energy deposition - L-DED) of Inconel 718 and Inconel 718+10%NiNb. The cavitation erosion wear tests were carried out following the ASTM G32 standard (2016), and the ASTM G73-10 standard (2017) was used to evaluate the resistance to slurry erosion wear. The scanning electron microscopy technique (SEM-EDS), and X-ray diffraction (XRD) were used to characterize the cross-section and the surface after wear. The wear mechanism was checked and identified. Microhardness profiles of the cladding cross-section were carried out. The mass loss and wear rate due to cavitation and slurry jet erosion of Inconel 718 and Inconel 718+ 10% NiNb coatings were determined. It was proven that the addition of 10% NiNb in the formation of the cladding caused a 45% increase in average microhardness in the cross-section of the Inconel 718 cladding. The addition of 10% NiNb to the Inconel 718 cladding caused a decrease in mass loss due to slurry erosion from 38.9 mg to 21.9 mg (33%) when the erodent impact angle was 60°.
Design and Development of Cost-Effective Equipment for Tribological Evaluation of Thermally Sprayed Abradable Coatings
Authors: Bertuol K. , Rivadeneira F. R. E. , Castilho B. C. N. M. , Moreau C. , Stoyanov P. 
Published: August 2024

Abstract
Thermally sprayed abradable coatings are essential for improving the performance of gas turbine engines. They act as a protective barrier between the stationary casing and rotating blades. Though a lot of research has been done on abradable coatings, little attention has been paid to comprehending wear mechanisms in the abradable-blade tip interaction. The goal of this project is to create a cost-effective test rig that can evaluate different thermally sprayed abradable coatings and understand how they interact with titanium blade tips under application-relevant conditions. Blade tip velocity, incursion rates, incursion depths, reaction forces, and interfacial temperatures are some of the inputs and outputs that the testing rig can provide. Aiming to validate the rig, this study examined the wear behavior of aluminum, thermally sprayed polyester, and AlSi-40Polyester abradable coating. The reaction forces for aluminum and polyester were overall higher when compared to AlSi-40Polyester. However, thermally sprayed polyester showed the highest interfacial temperatures of all materials tested. The difference in the reaction forces and interfacial temperature correlates well with the different wear mechanisms and thermal conductivities. Overall, the equipment showed to be a promising pre-screening methodology to evaluate and develop novel thermal spray abradable coatings.