bluuebunny/crossref_metadata_2025_split huggingface dataset:
Gas Substrate Heat Exchange during Cold-Gas Dynamic Spraying
Authors: McDonald A. , Ryabinin A. , Irissou E. , Legoux J.-G. 
Published: January 2023

Abstract
In this study, the temperature distribution of the surfaces of several substrates under an impinging gas jet from a cold spray nozzle was determined. A low-pressure cold-gas dynamic spraying unit was used to generate a jet of hot compressed nitrogen that impinged upon flat substrates. Computer codes based on a finite differences method were used to solve a simplified 2-D temperature distribution equation for the substrate to produce non-dimensional relationships between the surface temperature and the radius of the impinging fluid jet, the substrate thickness, and the heating time. It was found that a single profile of the transient non-dimensional maximum surface temperature could be used to estimate the dimensional maximum surface temperature, regardless of the value of the compressed gas temperature. It was found further that as the thermal conductance of the substrate increased, the maximum surface temperature of the substrate beneath the gas jet decreased. The close agreement of the numerical results with the experimental results suggests that the non-dimensionalized results may be applied to a wide range of conditions and materials.
Metallization of a Polymer Using Cold Spray: Application to Aluminum Coating of Polyamide 66
Authors: Giraud D. , Borit F. , Guipont V. , Jeandin M. , Malhaire J.M. 
Published: January 2023

Abstract
Numerous automotive and aircraft/aerospace applications involve metallic coating of organic matrix composite materials, e.g. for aesthetic, electric, or engineering functions. In the thermal spray process family, cold spray is very attractive for the achievement of metallization of low-temperature resistant materials such as organic composites, due to its “cold” characteristic. However, despite the current (and justified) craze for cold spray, little is still known about the potential of this process for this type of application. The work demonstrated the feasibility of cold spray for satisfactory metallization of PA66-matrix composites with Al. This paves the way for using cold spray as an advantageous substitute process for the industrial protection of polymer-based composites.
Comparison of the Characteristics of CoNiCrAlY Coatings Prepared by Cold Spray and LPPS Process
Authors: Sone M. , Fukanuma H. , Huang R. , Ohno N. 
Published: January 2023

Abstract
Cold spray is a new emerging coating technology in which particles in a solid state are deposited via plastic impact on a substrate at a high velocity and a temperature that is much lower than the melting point of the starting powder. Compared to the conventional thermal spray processes, dense coatings without any degradation can be obtained by cold spray process with high deposition efficiency. CoNiCrAlY coatings are widely used for land-based gas turbines to resist high-temperature oxidation and hot corrosion. Owing to the high cost of the low-pressure plasma spray (LPPS) or some degradation in the hyper-velocity oxy-fuel (HVOF) spray process, cold spray process is a prospective candidate for coating preparation. In the current study, CoNiCrAlY coatings were prepared by cold spray and LPPS processes, and a comparison of the coating’s properties between the LPPS and cold spray process was carried out. The spray conditions of cold spray were optimized by the measurements of deposition efficiency and the observations of microstructure.
Effect of SiC Particle Size on Microstructure and Properties of Cold Sprayed Al5056/SiC Composite Coatings
Authors: Yu Min , Li Wenya , Suo Xinkun , Liao Hanlin 
Published: January 2023

Abstract
In the present investigation, Al5056 alloy-based metal matrix composites having SiC particles of different sizes were prepared by cold spraying. The average particle sizes of the used SiC feedstock varied from 66.94 µm to 1.64 µm. The calculated results by the FLUENT software show that the velocity of SiC particle decreases with the increase of the particle size, while the kinetic energy is greatly increased with increasing the particle size. The addition of SiC particles effectively reduces the porosity of the composite coatings. Furthermore, the porosity of the composite coatings increases with the decrease of SiC particle size, while the content of SiC in the coatings decreases with the decrease of SiC size. In addition, two effects of SiC particles determine the coating properties, i.e., the advantageous peening effect and the disadvantageous effect that reduces the effective contact between the coating and substrate.
Passive and Pulse–Echo Ultrasonic Monitoring of Cold Spray Process
Authors: Maev R. Gr. , Titov S. , Leshchynsky V. 
Published: January 2023

Abstract
To fully understand particle interactions with both substrate and neighboring particles in cold spray, ultrasound wave generation and ultrasonic monitoring of particle impacts were studied. The multi–channel ultrasonic system works in pulse– echo and passive modes. In pauses between pulse–echo data acquisition frames the system is in the passive mode receiving the signals generated by the particle impacts. The particles being deposited generate the ultrasonic signals in a very wideband frequency range at more than 40 dB signal-to-noise ratio. The particle impact signals are considered as a sum of the background wideband noise and the sparse strong pulses observed when the nozzle passes over the location of the transducer. It was shown that these components of the particle impact signal can be separated by threshold processing. The results of the passive monitoring are confirmed by the ultrasonic pulse–echo and direct measurements of a deposited coating geometry.
Thermal Spray Coatings: Semiconductor Equipment Design and Process Chamber Requirements for 40 nm and Beyond
Authors: Sommers J. 
Published: January 2023

Abstract
Thermal spray coatings are used for a broad range of purposes in the semiconductor equipment industry. A primary use of thermal spray coatings for thin film applications is to provide surfaces on process chamber components that promote particle reduction and contamination control during chamber operations. Coatings are also used to provide the desired dielectric properties for critical components such as electrostatic chucks (ESC) and heater pedestals; to prove chemical and corrosion-resistance for process kit components and showerheads; as well as serving a wide range of other purposes. This paper reviews future needs for thermal spray coatings in semiconductor equipment and identifies some of today’s coating challenges. Areas discussed include coating design considerations; chemical, corrosion and plasma erosion issues influencing the selection of materials, coatings and processes. Brief discussion will be provided for future anticipated needs in materials, coatings, processing and the manufacture of thermal spray coatings for such applications.
Improving the Properties of Plasma and HVOF Sprayed Alumina Coatings by Chromia Addition
Authors: Hyvärinen L. , Hakalahti J. , Kylmälahti M. , Silvonen J. , Niemi K. , Vuoristo P. 
Published: January 2023

Abstract
Alumina is a relatively low-cost material and easily processable by thermal spraying into wear and corrosion resistant coatings. However, thermally sprayed alumina coatings show inferior corrosion resistance versus chromia coatings, particularly in low and high pH electrolytes. Further, alumina possesses decreased mechanical properties in the as-sprayed state. In the present study, the effect of chromia addition on the properties of the plasma and HVOF sprayed alumina coatings were studied. Pure alumina powder and four different Al2O3-Cr2O3 powders were prepared in two different atmospheres and produced to coatings with APS and HVOF methods. Phase composition of the powders and coatings were studied by X-ray diffraction. Electron microscopy was used for the examination of the microstructure of the powders and coatings. The mechanical properties of the coatings were studied by hardness and abrasion resistance tests. The chemical properties of the coatings were examined by corrosion exposure tests. Results indicate that with chromia addition it is possible to improve the mechanical and chemical properties of the thermally sprayed alumina coatings.
Thermally Enhanced Bonding and Mechanical Properties of Kinetic Sprayed Al Deposit for Double-Layered Cu Liner
Authors: Won J. , Bae G. , Kang K. , Lee C. , Kim S. , Lee K. , Lee S. 
Published: January 2023

Abstract
Pure Al coatings were fabricated on Cu substrates via kinetic spraying for double-layered Cu liner. The coatings need to endure the high strain rate severe plastic deformation during explosion, in this study, the process optimization of Al deposition was initiated with a definition of “critical velocity” of Al particle in kinetic spraying on a basis of numerical modeling and computations using ABAQUS finite element codes. The simulation results revealed that the critical velocity of Al particle at room temperature (RT) was 780 m s-1, and the critical velocity decreased as particle temperature increased. On the basis of simulation results, mechanical properties such as bond strength of the coatings formed under various process conditions were evaluated and compared. These properties were discussed in terms of the processing-structure-property relationships.
Thermal Spray Coatings for Application in Petrochemical Field: A Comparison of Tungsten Carbide, Chromium Carbide and Inconel 625
Authors: Scrivani A. , Giorgetti A. , Bianchi F. , Campanini L. , Coppelletti L. , Keller H. 
Published: January 2023

Abstract
An important problem for the petrochemical industry is the behaviour of materials in aggressive environments, when hydrogen sulphide, carbon dioxide and sand, which contribute to corrosion erosion of the surface, are present. Generally, the use of hard materials such as thermal sprayed tungsten carbide and chromium carbide reduces this problem. Cemented carbides are quite suitable for this purpose: they are composite materials of pure carbides with binder metal alloys of low melting point and high ductility; the selection of the binder metals depends mostly on its ability to wet the surface of the carbide particles to ensure secure coating adhesion. Among the cemented carbides, namely tungsten carbide cobalt-chromium based (WC/CoCr) is considered as the standard for application to ball valve bodies and seats in the petrochemical field, while chromium carbide nickel-chromium based (Cr3C2/NiCr) is suitable for particular applications. Inconel 625 is also used in this field and usually applied by welding. This paper addresses the characterization of corrosion behavior of HVOF coated samples of WC/CoCr, Cr3C2/NiCr and Inconel 625 in aggressive environments, and in particular ferric chloride test according to standard ASTM G48-92 and H2S/CO2 test based on NACE standards has been carried out. According to the test results, WC/CoCr based coatings show the best behavior both in terms of corrosion, thus confirming to be very versatile and useful for the application in petrochemical field.
Spray Operating Parameters Optimization Based on Artificial Intelligence during Plasma Process
Authors: Liu T. , Planche M.-P. , Deng S. , Montavon G. , Kanta A.-F. 
Published: January 2023

Abstract
During plasma spray process, many intrinsic operating parameters allow tailoring the in-flight particle characteristics (temperature and velocity), thus affecting the final coating characteristics. Among them, plasma enthalpy, thermal conductivity, momentum, density, etc. result from the selection of extrinsic operating parameters such as the plasma torch nozzle geometry, composition and flow rate of plasma forming gases, the arc current intensity, etc. The complex relationships among those operating parameters make it difficult to fully predict their effects. Moreover, temporal fluctuations (anode wear for example) require "real time" corrections to maintain particle characteristics to targeted values. In addition, substrate temperature has to be maintained to targeted values depending upon the feedstock to be sprayed, the geometry of the part to be coated, its thermal capacity, etc. An expert system was built to optimize and control some of the main extrinsic operating parameters. This expert system includes two parts: 1) an artificial neural network (ANN), which predicts an extrinsic operating window and 2) a fuzzy logic controller (FLC) to control it. The paper details the general architecture of the system, discusses its limits and typical characteristics. An example is finally presented.
Measurement of the Young’s Modulus of Thermal Spray Coatings by Means of Several Methods
Authors: Tillmann W. , Selvadurai U. , Luo W. 
Published: January 2023

Abstract
Thermally sprayed coatings are usually defined by their hardness, porosity, roughness and wear resistance. Even though the Young’s modulus is an essential property, which describes the mechanical behavior of the coated components during their use, only few efforts were made to determine this property. The most common measurement methods of the Young’s modulus of thermally sprayed coatings are tensile tests, bending tests, and nanoindentations. During the tensile and bending tests a sliding of the splats can occur due to the laminar structure of the thermally sprayed coatings, influencing the measurement value. When using the nanoindentation test, only the elastic behavior of a single splat can be determined because of a minimal measuring volume. However, the Young’s Modulus of thermally sprayed coatings can also be determined by means of a resonant method, called impulse excitation technique (IET). In this paper, the values of the Young’s moduli of thermally sprayed coatings, measured by several methods are compared with each other and correlated to the microstructure of the coatings, investigated by means of scanning electron microscopy.
Influences of Spray Conditions on the Morphologies of Copper Splat in Cold Spray Process
Authors: Ma Wenhua , Huang Renzhong , Fukanuma Hirotaka 
Published: January 2023

Abstract
The deposition mechanism of cold spray process has not been fully understood at present. It has been widely accepted that particle velocity prior to impact is one of the most important parameter for cold spray process, and bonding occurs when the impact velocities of particles exceed a critical value. For cold spray, the splat is the basic element of coatings and determines the coating properties, such as porosity, bonding strength. Therefore, the study of splats is helpful to understand the deposition mechanism of cold spray process. In this work, copper powder was utilized to prepare splats on three substrates, aluminum alloy, copper and stainless steel, under different spray conditions. Particle velocities were measured by DPV-2000 system experimentally. The morphologies of copper splats and cross sections were characterized by scanning electron microscope (SEM). In order to control the cross sections of splatted particle passing the center of particle as much as possible, the cross sections were polished by a new method with ion beam. The influences of particle velocity on cold-sprayed splat morphologies and cross-sections were discussed.
The Influence of Titanium Sub-Oxides in Thermal Sprayed Coatings
Authors: Gardon M. , Guilemany J. M. 
Published: January 2023

Abstract
The plasma spray process is used to create titanium oxide coatings under the current stoichiometry of titania and titanium suboxides. This study used feedstock powder with Magnéli phases TinO2n-1, slightly reduced titania TiO2-x, and rutile. A factorial design of experiments approach was used to better understand the influence of operational parameters on coating quality, in particular, the electric resistivity and the degree of oxidation of the titanium oxide during the spraying. Firstly, arc current intensity and stand-off distance were studied; the results show strong correlations between particle temperatures and the electric resistivity of the coating. Then, different plasma compositions were used in order to understand the influence of hydrogen in the formation of titanium sub-oxides. The hardness of the most significant coatings was analyzed.
Solid Oxide Fuel Cells Produced by Atmospheric Plasma Spray Technology: Structural and Electrochemical Characterization
Authors: Torrell M. , Cano I.G. , Miguel J.M. , Guilemany J.M. , Laguna-Bercero M. A. , Orera V. M. 
Published: January 2023

Abstract
The use of ceramic materials in the production of solid oxide fuel cells (SOFCs) is one of the most innovative applications of these materials in recent years. The aim of this work is to assess how to obtain a complete, self-assembled SOFC (supported by electrolyte) using atmospheric plasma spray (APS) to spray the three different ceramic layers of the assembly. One of the main problems of SOFC production is the high cost of the process; the hypothesis is that these costs can be reduced by forming the three ceramic layers of the SOFC by APS technology. The anode (YSZ-NiO), cathode (LSM), and electrolyte (YSZ) layers can be produced by APS with reasonable efficiency. Another problem with SOFC manufacture is assembly and adhesion of the three layers; the creation of gradual transition layers by APS improves these aspects of the production process. Chemical and structural characterization of the feedstock powders and resultant ceramic layers was performed by laser scattering, XRD, SEM, and confocal microscopy, and the results confirmed the efficiency of the attained APS-SOFC components.
Effects of Substrate Treated by Dry-Ice Blasting on the Formation of CoNiCrAlY Splats
Authors: Dong S.-J. , Song B. , Liao H.-L. , Coddet C. , Hansz B. 
Published: January 2023

Abstract
Dry-ice blasting, as an environmental-friendly method, was used to pretreat the substrate to be coated. In the present paper plasma-sprayed CoNiCrAlY splats were examined on the dry-ice blasted substrate. The cleaning effect of dry-ice blasting was demonstrated accompanying the condensation phenomenon, which is also harmful for the formation of ideal disk-like splat. A solution of ensuring the substrate temperature over dew point temperature was proposed for the proper application of dry-ice blasting during droplet flattening.
High-Temperature Oxidation Behavior of Fe-25Cr-5Al Arc Spraying Coatings
Authors: Korobov Yu. , Filipov M. , Nevezhin S. , Karabanalov M. 
Published: January 2023

Abstract
According to our modeling of oxygen input into particles at arc spraying (AS) a cored wire of Fe-25Cr-5Al type was developed. The oxidation behavior of AS coatings from this wire was studied in air under atmospheric pressure at 700°C. Influence of Si, Ti was studied by means of mass-change measurements, X-ray diffraction (XRD) and scanning electron microscopy (SEM). It is determined that addition of Si and Ti lead to preventing formation of complex carbides like (Fe, Cr)7C3, spinels like (Fe, Cr)2O3 and nitrides like AlN. Absence of these carbides, spinels and nitrides leads to significantly improving a protective property of surface oxide layer of Al2O3. Heat resistance of developed coatings was compared with austenitic steels like Tempaloy A-1 and TP 310 ASME SA312 and with ferritic steels like T11 and T122 ASME A213 which are widely used as boiler materials.
Void Formation and Spatial Distribution in Plasma Sprayed Nd-Fe-B Coatings
Authors: Gan J. A. , Berndt C. C. , Wong Y. C. , Wang J. 
Published: January 2023

Abstract
Formation of voids is inevitable in plasma sprayed coatings, and the role of voids on coating properties has long been established. In fact, the void content within coatings is often adjusted by manipulating the process parameters to obtain coatings with desirable performance. Quantification of voids via image analysis allows the determination of not only the void content within a coating, but also the spatial distribution of the voids. Void content in plasma sprayed neodymium iron boron (Nd-Fe-B) coatings was varied from 1.8 to 8.2% by changing the standoff distance (SOD). Spatial distribution parameters, including near-neighbor distance (dmin), nearest-neighbor distance (dmean), and nearest-neighbor angle (θn), were determined via the Dirichlet tessellation method. Coefficient of variation (COV) values of dmin and dmean allow the determination of inhomogeneity and degree of clustering of the voids within a coating. The θn values show the anisotropy behavior of the voids within plasma sprayed coatings. The influence of void content and its spatial distribution within the coatings on the microhardness and elastic modulus of the coatings was determined.
Mechanical Properties of Yttria and Ceria Stabilized Zirconia Coatings Obtained by Suspension Plasma Spraying
Authors: Łatka L. , Pawłowski L. , Cattini A. , Denoirjean A. , Chicot D. , Kozerski S. , Petit F. 
Published: January 2023

Abstract
Plasma generated by an SG-100 torch was applied to spray suspension formulated with the use of ZrO2+8 wt% Y2O3 (8YSZ) and ZrO2+24 wt% CeO2+2.5 wt% Y2O3 (24CeYSZ) as solid phases. The solids have the mean size of about 4.5 µm for 8YSZ and 3.9 µm 24CeYSZ and were obtained by milling of commercial powders Metco 204 NS and Metco 205NS, respectively. The suspensions were formulated with the use of 20 wt% solid phase, 40 wt% water, and 40 wt.% ethanol. The plasma spray parameters were optimized by keeping constant: (i) the electric power at 40 kW (ii) the working gases composition 45 slpm of Ar and 5 slpm of H2. On the other hand, the spray distance was varied from 40 to 60 mm and torch linear speed was varied from 300 to 500 mm/s. The coatings were sprayed onto stainless steel substrates to reach the thickness ranging from 70 to 110 µm (8YSZ) and about 70 µm (24CeYSZ). The coating microstructures were analyzed with the use of a scanning electron microscope. Mechanical properties were tested with the use of indentation and scratch tests. The indentation test was carried out with various loads ranging from 100 to 10,000 mN to determine elastic modulus and Martens microhardness. Young’s modulus of the coatings was in the range 71 to 107 GPa for 8YSZ and 68 to 130 GPa for 24CeYSZ. Scratch tests were conducted to determine the scratch macrohardness.
Influence of Spray Parameters and Characteristics of Solutions on Microstructure and Phase Composition of Solution Precursor Atmospheric Plasma Sprayed (SPPS) Mn-Co Spinel Coating
Authors: Puranen J. , Laakso J. , Hyvärinen L. , Kylmälahti M. , Vuoristo P. 
Published: January 2023

Abstract
Manufacturing of MnCo2O4 spinel coatings by solution precursor plasma spraying (SPPS) was studied in order to produce thin ceramic coating on a ferritic stainless steel interconnect for SOFC’s. The main purpose to use MnCo2O4 coating in SOFC devices is to prevent the migration of harmful CrO3 and Cr2(OH)2 compounds to the triple phase barriers (TPB) of the cathode. In this study Mn(NO3)2•4H2O and Co(NO3)2•6H2O were diluted to deionized water and mixture of deionized water and ethanol at 3 M mixture rate. The solutions were sprayed on 0.5 mm thick Crofer 22 APU substrate by Sulzer Metco F4-MB plasma gun with a modified solution feeder. Microstructural characterizations for the as-sprayed coatings were done by using a field-emission scanning electron microscopy (FESEM) with SE-mode. Elemental analyses were done with energy dispersive spectroscopy (EDS) and an X-ray diffraction (XRD) was used for crystallographic studies. The coating with full equivalence of the crystallographic structure of MnCo2O4 spinel was sprayed using argon-helium plasma and water based solution. Plasma gas with hydrogen as a secondary or ternary gas and ethanol based solutions caused the formation of the mixed phases of CoO and MnCo2O4. Although the microstructures of sprayed coatings were still quite porous, the influence of relevant gun and solution parameters were found in order to improve coating denseness in further studies.