bluuebunny/crossref_metadata_2025_split huggingface dataset:
Prediction of Coating Formation in Shockwave-Induced Spray Process Through Modeling
Authors: Karimi M. , Rankin G.W. , Jodoin B. 
Published: January 2023

Abstract
Computational Fluid Dynamics (CFD) is used to model the Shock-wave Induced Spray Process (SISP). SISP utilizes the kinetic and thermal energy induced by a moving shock-wave to accelerate and heat powder particles, similar to Cold Gas-Dynamic Spraying (CGDS), where the particles impact the substrate and deform plastically to produce a coating. Individual powder particles reach the substrate at different velocities and temperatures depending on their location within the unsteady flow regime. The critical velocity correlated to particle impact temperature and a CFD model are used to predict whether a particle traveling within this unsteady flow regime will bond to the substrate upon impact or bounce off. This information is then used to predict if a coating can be formed under a specific set of spray conditions.
Restoration of Damaged Aircraft Skin by Cold Spray Technique: The Advantages and the Challenges
Authors: Yandouzi M. , Jodoin B. 
Published: January 2023

Abstract
The recent development of cold spray technology has made possible the deposition of low porosity and oxide-free coatings with good adhesion and with almost no microstructure change of the coated parts. This work focuses on the performance of low pressure cold spray (LPCS) in repairing damaged Al-based thin aircraft skin. The coating quality is investigated through the evaluation of microstructure, microhardness, adhesion strength, surface finish and corrosion resistance of the coatings.
Cold Spraying of Nickel Using High-End Parameter Sets
Authors: List A. , Buschmann S. P. , Gärtner F. , Klassen T. 
Published: January 2023

Abstract
Even though cold spraying is well established today, the handling of some materials, as for example nickel, is still challenging because of nozzle clogging at higher process gas temperatures. Due to these process limitations in the past, it was not possible to produce coatings of sufficiently high quality. These problems can be solved by nozzle modifications. By a more effective nozzle cooling system, nozzle clogging during cold spraying of nickel can be avoided. This enables the use of high-end spray conditions, attainable by a modified cold spray gun heating system. For the presented study, the coatings were produced by varying the spray parameters up to a process gas temperature of 1000 °C at a pressure of 5 MPa with a gas flow of about 160 m3/h - conditions that were not within reach in cold spraying so far. Coating microstructures are nearly fully dense, with negligible porosity below 0.1%. The coatings processed under these high-end parameters show high tensile strength of 570 MPa, similar to that of highly deformed bulk material and a low hardness of 200 HVIT similar to that of pure nickel. The results demonstrate that the quality of cold-sprayed nickel coatings significantly improves with higher process gas temperatures and pressures, pushing cold spraying to new limits. This may also apply to other high-strength metals and alloys, opening the opportunity to meet the quality requirements for many new applications.
Robot Trajectory Generated on Free-Form Work Pieces for Thermal Spraying
Authors: Cai Zhen-Hua , Deng Si-Hao , Liao Han-Lin , Zeng Chun-Nian , Coddet Christian 
Published: January 2023

Abstract
Off-line programming software is widely used to simulate the robot-assisted work environment. RobotStudio, a product of ABB, offers off-line programming technology for industrial robot applications. Several software products that extend RobotStudio capabilities have been developed to meet special purposes. One such product is the Thermal Spray Toolkit. With the help of TST, RobotStudio can load the mesh information generated by ANSYS analysis software and then create the trajectory of robot spray operations with it. A method of arranging the index of grid nodes generated by ANSYS software is described in this article. The results show that TST can be successfully used to create a smooth robot trajectory, which corresponds to the requirements of industrial applications.
Effect of Surface Roughness, Wettability and Temperature on Ceramic Droplet Flattening
Authors: Bidron G. , Goutier S. , Denoirjean P. , Vardelle M. , Fauchais P. 
Published: January 2023

Abstract
This work deals with the flattening of alumina molten particles, called droplets, on stainless steel substrates either smooth or blasted and preheated at different temperatures. The blasted surface roughness has been limited to Ra= 1.4 µm to image the flattening droplet. Besides flattening and splat cooling, the wettability of melted millimeter-sized alumina drops on the same substrates was measured. The transition temperature, Tt, has been shown to be different between smooth and rough surfaces. For a smooth surface, Tt, is 170°C, and at 200°C 100% of disk shaped splats are obtained. For the rough surface, Tt is close to 300°C with porous splats, becoming almost dense at 450°C. Close to alumina melting temperature, wettability does not vary with the substrate preoxidation, which may not be the case when the temperature is much over the melting one as in plasma spray conditions.
Effect of Base Metal on the Thermal Cycle Properties of Heat-Resistant Plasma Sprayed Coatings
Authors: Sonoya K. , Sunahara H. , Nakamura M. , Ishida K. 
Published: January 2023

Abstract
The thermal cycle test of Al2O3 sprayed 1%Cr-0.5%Mo steel and 18%Cr-8%Ni steel was performed, and the failure type of thermally sprayed coating on both steels was compared. The results obtained are follows. (1)The thermal cycle fatigue life of thermal sprayed 1%Cr- 0.5%Mo steel was shorter than that of thermal sprayed 18%Cr-8%Ni steel. (2)In the case of thermally sprayed 18%Cr-8%Ni steel that is difficult to oxidize at high temperature, during thermal cycle, a tensile stress occurs in a sprayed coating and a compressive stress occurs in a substrate. Thus the thermal strain occurs at the interface of sprayed coating and substrate. The sprayed coating delaminates when the thermal cycles reach the limit value. (3)In the case of thermal sprayed 1%Cr-0.5%Mo steel that is easy to oxidize at high temperature, during thermally cycle, dense oxide film forms at the interface between the sprayed coating and substrate, and adhesive strength in the interface becomes low. Thus the sprayed coating delaminates under the lower thermal strain.
Cold-Sprayed WC-Ni-Cu MMC Coatings with Improved Hardness
Authors: Melendez N. , McDonald A. , Fisher G. 
Published: January 2023

Abstract
Cold-gas dynamic spraying (“cold-spraying”) at low pressure (1034kPa/150 psig) was used to fabricate WC-Ni-Cu metal matrix composite (MMC) coatings. Tungsten carbide (WC)- based powder was mechanically blended with nickel (Ni) and copper (Cu) powder at various compositions. X-ray diffraction (XRD), scanning electron microscopy (SEM), and Vickers micro-hardness testing were conducted on the cold-sprayed coatings. Image analysis was used to determine the WC content in the coatings. XRD profiles showed that no decarburization or oxidation of the WC reinforcing particles occurred in any of the coatings. The WC content in the coatings increased as the WC content in the powder increased, but did not increase further beyond 96 wt. % WC content in the powder blend. The results from Vickers micro-hardness testing confirmed that the coatings with the highest amount of WC had the highest hardness value. The coatings fabricated with a powder composition of 96 wt. % WC + 2 wt. % Ni + 2 wt. % Cu yielded a hardness of 385 ± 73 HV0.3/10 (n = 50). These results suggest that it is possible to use cold-spraying at low pressure to fabricate WC-based MMC coatings with improved hardness.
Effect of Particle Velocity on Cold Sprayed Stainless Steel Deposits
Authors: Huang Renzhong , Ma Wenhua , Fukanuma Hirotaka 
Published: January 2023

Abstract
Cold spraying is a new emerging coating technology and has been widely used to produce coatings of various materials. It has been widely accepted that particle velocity prior to impact is one of the most important parameters for the cold spray process, and bonding occurs when the impact velocities of the particles exceed a critical value. As we know, particle velocity is influenced by many parameters, such as nozzle design, particle size, particle morphology, working gas pressure and temperature. In this work, three types of commercial stainless steel powders with different sizes or morphologies were employed to prepare coatings. Their respective particle velocities were also measured. With a non-clogging nozzle developed in Plasma Giken Company, Ltd., the particle velocities can be adjusted by changing the working gas pressures and temperatures to values as high as 4 MPa and 1000°C, respectively. The in-flight particle velocity was monitored via the DPV-2000 system. The results show that the particle velocity was influenced by the working gas pressure, temperature, particle diameter and morphology. Much denser coatings can be obtained with higher particle velocities, and consequently higher micro-hardness values of the coatings can also be achieved.
Epitaxial Grain Growth during Splat Cooling of Alumina Droplets Produced by Atmospheric Plasma Spraying
Authors: Yang E.-J. , Yang G.-J. , Luo X.-T. , Li C.-J. , Takahashi M. 
Published: January 2023

Abstract
Alumina splats were deposited on the polished single crystal alumina substrates with two different crystalline facet orientations of [001] and [110] by atmospheric plasma spraying (APS) at a substrate preheating temperature of 900°C to examine the epitaxy during splat cooling. The cross-sectional samples for high resolution transmission electron microscopy examination was prepared by focused ion beam assisted scanning electron microscopy (FIB-SEM). The results show that the whole splats with a thickness ranging from ~600 to ~1000nm exhibited the same crystalline structure as the substrate. Moreover, the splat deposited on the single crystalline alumina substrates exhibited exactly the same orientation as the substrate. The results evidently indicate that the epitaxial grain growth occurs after alumina droplets impact on single crystal alumina substrate. The present results suggest that the crystalline structure of alumina deposit formed by plasma spraying can be possibly controlled by the substrate preheating temperature.
Adhesive Strength and Cohesive Strength of Thick LPPS W Coating on CuCrZr Substrate
Authors: Deng C.-M. , Liu M. , Deng C.-G. , Zhou K.-S. , Kuang Z.-Q. 
Published: January 2023

Abstract
Advanced materials are the crucial factors determining the successful application of future nuclear fusion energy. Plasma facing materials (PFMs) are one of the most important armor materials in nuclear fusion experiment devices for direct facing with the extremely high thermal load, thermal shock and strong irradiation of high energy particles. W coated CuCrZr substrate has been considered as one of the candidates to the armor materials due to its high melting point, chemical stability and good thermal conductivity. However it was a challenge to obtain high strength thick W coatings because of the major difference of CTE between the W and CuCrZr substrate. In this paper, graded W/Cu layers were deposited as the bond layer via Low Pressure Plasma Spraying (LPPS) on the CuCrZr substrate. Subsequently, thick LPPS W coatings over 1.5 mm were prepared as the top layer. The adhesive and cohesive strengths for thick W coatings on CuCrZr substrates were evaluated according to the standard of ASTM C633. The results showed that the oxide formation on the W coating surface rapidly deteriorated the coating microstructure and properties.
Effect of Processing Parameters on the Deposition Characteristics and Microstructure of Vacuum Kinetic Sprayed TiN Layer
Authors: Cao F. , Park H. , Yong W. , Lee C. 
Published: January 2023

Abstract
Vacuum kinetic spray (VKS) is a relatively new coating process by which dense, low porosity nanostructured ceramic coatings can be produced. Titanium nitride films with thickness of 0.5-5 µm on glass were fabricated by VKS method for a mechanism and microstructure study. Deposition behavior and structure with different gas consumption and gun traverse speed were studied based on X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM). The as-deposited titanium nitride film consisted of ~20 nm grains is well condensed and expected to have excellent mechanical properties.
In Vitro Cytocompatibility of Plasma-Sprayed Dicalcium Silicate/Zirconia Composite Coatings
Authors: Xie Y.T. , Zheng X.B. , Huang L.P. , Ding C. X. 
Published: January 2023

Abstract
Dicalcium silicate/zirconia composite coating with 70 wt.% zirconia and 30 wt.% dicalcium silicate was prepared by plasma spraying. In vitro behaviors of human osteoblast cells on the coating were studied. As a result of rapid exchange of Ca and H in the culture media and dissolution of the dicalcium silicate component from the coatings, a large amount of Si-OH functional group was produced on the coating. These OH bonds were favorable to the adhesion of proteins and cells attachment and thus, the good cytocompatibility of the coatings. Honeycomb-like Ca-P minerals were formed on the coating surface after only 1 day incubation in the culture media. The deposition rate of the Ca-P minerals was greatly improved by the existence of proteins. It may be attributed to the increased Ca ion concentration in the culture media resulting from the dissolution of dicalcium silicate and the good protein adhesion properties of the coating.
Flattening Mechanism of Thermal Sprayed Particles
Authors: Fukumoto M. , Yang K. , Yoshida S. , Mano D. , Yamada M. , Yasui T. 
Published: January 2023

Abstract
Flattening mechanism of thermally sprayed single particles onto the flat substrate surface was investigated by using a metallic powder and stainless steel substrates. As the flattening pattern of the particles occurs quickly after the impact with the substrate surface, “pattern formation” mechanism was investigated. To perform this investigation, particles were thermally sprayed onto flat substrates through controlled substrate temperature and ambient pressures. The top surface, bottom surface and cross section microstructure of the splats were systematically investigated. By summarizing the results obtained, it was inferred that the initial solidification in peripheral region (starting at splat-substrate interface) might have a role on the formation of disk shaped splat.
Improvement of Aluminum Coating Behaviours by Hybrid Process Including Plasma Spraying and Laser Ablation
Authors: Costil S. , Verdy Ch. , Montavon G. , Wittmann-Teneze K. , Methout S. , Bianchi L. 
Published: January 2023

Abstract
To answer current issues adequately considering technical, economic, as well as environmental requirements, material transformation and especially surface treatment industries must be source of innovations to be proactive. As a result, developing new alternative solutions to existing ones had become a top priority. Considering surface treatment processes, conventional ones (thermal spraying, plasma transferred arc) do not allow to consider this approach since the processes themselves (co-treatment of different powders) do not permit to guarantee the initial composition nor do they ensure a sufficient homogeneity to the coating structure. If indeed the dry surface treatment processes have already shown large potential, several limits remain such as an inefficient adhesion, an environmental impact over the life cycle or almost no materials on the market. To overcome these issues hybrid coating technologies (combining several processes) are likely to be developed. From all of them, laser technology seems to be very promising due to its high flexibility considering all the potential parameters (varying power, continuous or pulsed beam, etc.) and the localised treated area. For instance, combining simultaneously a laser with a thermal spray process enables the elaboration of a thick coating showing a good adherence. The ablation laser applied on the substrate surface just before the impacting particles as promoted in the PROTAL process permit to insure a suitable surface state favourable to the particles adhesion. The control of the coating microstructure was not so much studied. That is why, to complete the knowledge in this area, this work aims at studying the influence of laser technology in association with plasma spraying on the coating microstructure and more precisely on the coating mechanical properties. Coatings were characterized by SEM and void content was evaluated through image analysis and Archimedean porosimetry. Mechanical properties were assessed by the four points bending test for evaluating the coating apparent Young modulus.
Investigation of Wear and Corrosion Protection of AlSi20 Coatings Produced by Thermal Spraying and Laser Cladding on AZ31B
Authors: Bobzin K. , Kopp N. , Warda T. , Schulz C. , Rolink G. , Weisheit A. 
Published: January 2023

Abstract
Magnesium and magnesium alloys are the lightest structural materials with an approximate density of 1.7 g/cm³ (density of aluminium ~2.7 g/cm³). Due to the poor corrosion and wear resistance properties, they need to be coated for usage in lightweight constructions. AlSi20 was found to be a suitable coating material to improve the properties of parts made of the magnesium alloy AZ31B. Within this work, coatings are applied by thermal spraying, laser cladding and the combination of both processes. These coatings were investigated regarding corrosion protection in 3.5 % chlorine solution in a three electrode setup to obtain electrochemical corrosion characteristics. Abrasive wear was investigated using a pin-on-disc tribometer and abrasion rate was calculated. Resistance against shock loads was tested by applying a cyclic load at 50 Hz in order to investigate the resistance against impact stresses.
In-Situ Processing of Functional Graded Coatings by Means of Atmospheric Plasma Spraying
Authors: Tillmann Wolfgang , Hagen Leif , Laemmerhirt Iris-Aya 
Published: January 2023

Abstract
Functionally graded coatings exhibit outstanding thermomechanical performances that meet economic demands. By influencing the microstructural formation of the layers of the coated tool, the distribution and transfer of heat from the impact zone into the forming process is determined. Thus, largely affects the tool’s life cycle and microstructure in the surface area of the parts to be formed. With respect to graded coatings, examinations on simple substrates have already shown the applicability of different microstructure formations of coatings. In these approaches, varied parameter settings were investigated to identify the most significant factors and their effects on the formation of the microstructure. Furthermore, using different grain-sized powder materials and utilizing other thermal spraying methods, it is possible to generate either porous or dense coatings according to their requirement profile. The utilization of different thermal spray methods particularly leads to high costs caused by increased setup times. As opposed to traditional thermal spray deposition process parameters for graded coatings, generated by an in-situ process, need to become coordinated with the movements of the robot. In this study, we investigated the dependencies between the spray parameters of Atmospheric Plasma Spraying, such as spray distance and spray angle, and the formation of microstructures. The investigation focusses on the utilization of Alumina (Al2O3) which is widely used as a wear and corrosion resistant coating.
In Situ Synthesis of FeAl Dense Coatings by Very Low Pressure Reactive Plasma Spraying
Authors: Zhu L. , Bolot R. , Liao H. , Coddet C. , Zhang N. 
Published: January 2023

Abstract
With the purpose of elaborating high-quality FeAl coatings, a so-called very low pressure reactive plasma spray technique that combines VLPPS and SHS processes was used in the present study. A dense and homogeneous FeAl coating was thus successfully in situ synthesized by reactive plasma spraying of an Al/Fe2O3 composite powder under 1 mbar. The phase composition and microstructural features of the coating were characterized by XRD and SEM. Results indicated that the B2 ordered FeAl phase was synthesized, and the coating featured a dense and defect-free microstructure. The fracture mechanism of the coating remains mainly a brittle failure but the appearance of some dimples in local zones suggests some unexpected toughness.
Aluminum Nitride Coating Fabricated by Reactive Plasma Spraying of Al2O3
Authors: Shahien M. , Yamada M. , Yasui T. , Fukumoto M. 
Published: January 2023

Abstract
Reactive plasma spraying (RPS) has been considered as a promising technique for in situ formation of aluminum nitride (AlN) based thick coatings. This study investigated the reactive plasma spraying of AlN coating with using Al2O3 powder and N2/H2 plasma. It was possible to fabricate a cubic- AlN (c-AlN) based coating. The phase composition of the coating consists of c-AlN, α-Al2O3, Al5O6N and γ-Al2O3. Understanding the nitriding process during coating deposition is essential to control the process and improve the coating quality. The nitriding process was performed by spraying, collecting the particles into a water bath (to maintain its particle features) and observing their microstructures and cross sections. During the coating process, the sprayed particles were melted, spheroidized and nitrided in the N2/H2 plasma to form the cubic aluminum oxynitride (Al5O6N). The particles collided, flattened, and rapidly solidified on the substrate surface. The Al5O6N is easily transformed to c-AlN phase (same cubic symmetry) by continuous reaction through plasma environment. Improving the specific surface area by using smaller particle sizes enhances the surface nitriding reaction and improves the nitriding conversion. Furthermore, using AlN additives enhances the nitride content in the coatings. It was possible to fabricate thick and uniform coatings with high AlN content by spraying fine Al2O3/AlN mixture. Furthermore, the N2 gas flow rate improved the nitriding conversion and the coating thickness.