bluuebunny/crossref_metadata_2025_split huggingface dataset:
Investigation of the Bonding Mechanisms of Al Coatings on Ceramic Substrates Deposited by Cold Gas Spraying and Magnetron Sputtering
Authors: Drehmann R. , Grund T. , Lampke T. , Wielage B. , Wüstefeld C. , Motylenko M. , Schreiber G. , Rafaja D. 
Published: August 2022

Abstract
The present work builds on investigations of cold gas-sprayed Al coatings on Al2O3, which strongly indicated that heteroepitaxial growth is a possible mechanism supporting the adhesion between metal and ceramic at their interface. The present study was focused on the deposition of Al on further ceramic substrates (AlN, Si3N4 and SiC). In particular, it should be clarified whether the different ionicity of the chemical bonding in these substrate materials influences the interface formation or not. Aluminum coatings were deposited alternatively by using cold-gas spraying (CGS) and magnetron sputtering. In CGS coatings, the effect of substrate roughness, substrate temperature and powder fraction on the adhesion of the coating was investigated. The magnetron-deposited coatings were used to evaluate the role of the heteroepitaxy in the interface formation and to identify microstructure defects in the metal/ceramic interface, which are caused solely by the lattice misfit between the counterparts and not by the impact-induced deformation that is typical for cold gas-sprayed coatings. Interface characterization was conducted by scanning electron and high resolution transmission electron microscopies combined with XRD.
Lithium Iron Phosphate Coatings Deposited by Means of Inductively-Coupled Thermal Plasma
Authors: Major K. , Brisard G. , Veilleux J. 
Published: August 2022

Abstract
Lithium-ion batteries have high energy efficiency and good cycling life and are considered as one of the best energy storage device for hybrid and/or electrical vehicle. Still, several problems must be solved prior to a broad adoption by the automotive industry: energy density, safety and costs. To enhance both energy density and safety, the current study aims at depositing binder-free cathode materials using inductively-coupled thermal plasma. In a first step, lithium iron phosphate LiFePO4 powders are synthesized in an inductively-coupled thermal plasma reactor and dispersed in a conventional polyvinylidene fluoride (PVDF) binder. Then, binder-free LiFePO4 coatings are directly deposited onto nickel current collectors by solution precursor plasma spraying (SPPS). These plasma-derived cathodes (with and without PVDF binder) are assembled in button cells and tested. Under optimized plasma conditions, cyclic voltammetry shows that the electrochemical reversibility of plasma-derived cathodes is improved over that of conventional sol-gel derived LiFePO4 cathodes. Further results related to the substitution of iron with manganese in the SPPS precursors (LiMPO4, where M = Fe or Mn) are discussed.
Mechanisation of the Grit Blasting Process for Thermal Spray Coating Applications
Authors: Begg Henry , Riley Melissa , Lovelock Heidi de Villiers 
Published: August 2022

Abstract
The bond strength between a thermal spray coating and substrate is critical for many applications and is dependent on good substrate surface preparation and optimised spray parameters. While spray parameters are usually carefully monitored and controlled, most surface preparation is carried out by manual grit blasting, with little or no calibration of blast parameters. Blasting is currently highly dependent on operator skill and often surface finish is only assessed visually, meaning a consistent, reproducible surface profile cannot be guaranteed. Mechanised blasting offers the promise of more tightly controlled surface preparation and presents an opportunity to improve coating adhesion. This paper presents investigations on the effect of blast parameters (including blast pressure, standoff distance, media feed rate, blast angle, traverse speed and media size) on surface profile for a range of metallic substrates using a mechanised, robotic blasting system. Substrates were characterised using contact profilometry and non-contact focus variation microscopy.
Metal-Ceramic Nanocomposite Coatings Produced by HVOF Thermal Spray and In-Situ Precipitation of Ceramic Components for Tribological Applications
Authors: Schulz R. , Savoie S. 
Published: August 2022

Abstract
Protective coatings with high wear, erosion and corrosion resistance are of great importance in many fields of application and in particular, in the electric power generation sector. In this paper, the HP-HVOF (high-pressure high velocity oxy-fuel) technique is used to produce dense rapidly quenched metal-ceramic nanocomposite protective coatings. The powders for the thermal spray process are produced by high energy ball milling using mechanochemical displacement reactions to synthesize ceramic components in-situ at the nanometric scale. Boron nitride solid lubricant is used as a source of nitrogen and boron to precipitate nitride and boride phases in a corrosion resistant iron aluminide metal matrix. The formation of the hard phases during milling and/or thermal treatments is investigated using various analytical methods. The tribological properties of the coatings with and without ceramic additives are reported.
Modeling of the APS Process—From the Arc to the Coating Effective Properties
Authors: Bolot R. , Aubignat E. , Planche M.P. , Montavon G. , Allimant A. , Billières D. 
Published: August 2022

Abstract
Atmospheric Plasma Spray is widely used for tens of years to elaborate protective coatings on parts for several applications. However, our understanding of the APS process can still be improved, requiring a fine modeling of the process in parallel with some corresponding experiments. In the present work, a complete series of models was applied to reinforce our knowledge of the process: the case of an alumina coating was considered. A 3D CFD model was first used to study the internal arc within the torch. Interactions between the external plasma jet and the injected particles were then computed in a second step. At this level, the predicted in-flight particle characteristics were compared with some corresponding measurements recorded with the DPV 2000 diagnostic tool. A third model was then applied to investigate the particle flattening on the substrate/coating material. SEM pictures of coating cross-sections were then captured and a last model was finally applied to estimate the coating effective thermos-mechanical properties based on calculations performed directly on the SEM micrographs. This set of models allows investigating the APS process from the DC arc within the torch to the coating properties.
On the Relationship of Tungsten Composition to Coating Properties
Authors: Colmenares-Angulo Jose , Molz Ronald , Hawley David , Seshadri Ramachandran Chidambaram 
Published: August 2022

Abstract
Industry today has an increased awareness of environmental, health, and safety issues. This, together with recent Nuclear Regulatory Commission changes concerning source material (e.g. thorium) have added complexity in the supply chain of thoriated tungsten commonly used in plasma spray gun spares. In the interest of a safer and more sustainable work environment Oerlikon Metco has developed non-thoriated material solutions proven to have longer service life than conventional thoriated spares. This work reports on the effect, if any, caused by tungsten compositional changes and extended service life in coating properties. Microstructure, coating efficiency parameters, hardness, particle state and in-situ stress are evaluated over the duration of the nozzle, comparing coatings with thoriated and non-thoriated nozzles and electrodes with the same spray parameters.
Parametric Study of Plasma Torch Operation Using a MHD Model Coupling the Arc and Electrodes
Authors: Alaya M. , Chazelas C. , Vardelle A. 
Published: August 2022

Abstract
Coupling of the electromagnetic and heat transfer phenomena in a non-transferred arc plasma torch is generally based on a current density profile and a temperature imposed on the cathode surface. However, it is not possible to observe the current density profile experimentally. To eliminate this boundary condition and be able to predict the arc dynamics in the plasma torch, the electrodes were included in the computational domain, the arc current was imposed on the rear surface of the cathode, and the electromagnetism and energy conservation equations for the fluid and the electrodes were coupled. The solution of this system of equations was implemented in a CFD computer code to model various plasma torch operating conditions. The model predictions for various arc currents were consistent and indicated that such a model could be applied with confidence to plasma torches of different geometries, such as cascaded-anode plasma torches.
Splat Formation of Copper and Copper Alloy on Ceramic Substrate in Plasma Spray Process
Authors: Tran Anh T.T. , Hyland Margaret M. , Fukumoto Masahiro , Munroe Paul 
Published: August 2022

Abstract
In the present work, we have examined the role of active elements in controlling the extent of splashing of plasma sprayed splats. Splats of Copper (Cu) and Copper alloyed with Al, Zr were deposited by plasma spray or as free-falling droplet. The splat formation and splat-substrate interfaces were characterised using SEM and FIB. It was found that the presence of Zr, either in the splat material or the substrate, enhanced disk splat formation in free falling droplets. Similarly, the presence of aluminium in plasma sprayed Cu- 10%Al increased the portion of favourable disk-shaped splats compared to pure copper. It was also found that the disk-shaped splat proportion of Cu-10%Al at room temperature is nearly identical to that of Cu splat at 300°C, indicating that the addition of Al in the alloy leads to the improvement of splat formation, correlating with the improvement in the interface bonding with the substrate.
Structure and Mechanical Properties of Thick Copper Coating Made by Cold Spray
Authors: Leshchynsky V. , Maev R.Gr. , Strumban E. , Dzhurinskiy D. , Kocimski J. , Maeva E. 
Published: August 2022

Abstract
The main purpose of this study was to form cold sprayed copper coatings on A 516 low carbon steel, which is considered a prospective material for manufacturing used nuclear fuel containers. The 3 mm-thick Cu coatings were formed using the high pressure cold spray method with N2 as the propellant gas. To increase the adhesion strength of the deposited coatings a copper sublayer was formed first, using He as the propellant gas. The deformation of copper particles during the deposition process was studied. The obtained SEM images of the Cu layer-A 516 low carbon steel substrate cross-sections demonstrated that the Cu sublayer had a dense microstructure, and local jet-metallic mixing areas. The Cu particles were deformed considerably more severely in the sub-layer than in the following layers. The steel substrate underwent severe deformation due to the impact of Cu particles. The mutual severe deformation of Cu particles and steel substrate resulted in a considerable increase of adhesion strength up to 120MPa. The structure of coatings and coating-substrate interface was studied by OIM, SEM and EDS.
Study on Cu-Ag-Zn Abradable Seal Coatings by Cold Spraying
Authors: Shen Yanfang , Cui Xinyu , Wu Jie , Li Ming , Xiong Tianying 
Published: August 2022

Abstract
This paper presents a study on Cu-Ag-Zn abradable seal coatings prepared by cold spraying. The micro-morphologies of the coatings were analyzed using scanning electron microscopy and electron dispersion scanning. The hardness of the coatings was analyzed. Thermal shock tests were conducted to evaluate the combination strength between the coating and the substrate. The friction and wear properties of the coatings were also tested. Two methods, annealing the coatings in vacuum and heating the feed powders in cold spraying, were tried to improve the combination strength and quality of the coating. The results showed that Cu-Ag-Zn coatings made by cold spraying with powder heating exhibited better combination strength and anti-friction properties compared to coatings annealed in vacuum and the original samples. The paper also proposed a combination mechanism for the Cu-Ag-Zn coatings.
Surface Preparation for Ceramics Functionalization by Thermal Spraying
Authors: Scheitz S. , Toma F.-L. , Kuntze T. , Leyens C. , Thiele S. 
Published: August 2022

Abstract
Dense sintered technical ceramics demand special surface preparation in order to be coated by thermal spraying. Sandblasting results in the damage of the interface region and leads to bonding defects. On the contrary, by varying the laser conditions, different laser structured surfaces were generated, which at Rz roughness values in the range of 40 μm, allowed to achieve thick and well bonding coatings. Therefore, laser ablation is proved to be the best method for surface preparation of ceramic substrates. In the case of porous ceramics (including pre-sintered ceramics) substrate preparation can be omitted, depending on their porosity level. Ceramics with porosity content up to 60 % can be coated by APS, whereas HVOF can be used on ceramics with porosity up to 30 %. On ready-to-get-coated pre-sintered ceramic parts (without substrate preparation), followed by co-firing of the substrates and coatings, the development of new ceramic components is possible.
Synthesis of Thermal Spray Grade Silicon Carbide Feedstock Powder for Plasma Spray Deposition
Authors: Mubarok F. , Espallargas N. 
Published: August 2022

Abstract
Novel synthesis of thermal spray grade silicon carbide (SiC) feedstock powder is necessary to allow deposition of this material using atmospheric plasma spraying (APS) method. SiC particles with average size of 1.0 µm are treated using co-precipitation techniques to deliver yttrium aluminum garnet (YAG) binder from its solution precursor as a nano-film onto SiC particles surface. The YAG nano-film will protect SiC core from direct interaction with plasma jet thus hindering their decomposition as well as providing matrix phase within the SiC particles vicinities. The modified SiC particles are sintered and crushed and then sieved to separate 25-45 µm and 45-90 µm size powders, which are then plasma sprayed to deposit SiC coatings of about 300 µm in thickness. Both the feedstock and the coatings were analyzed and compared with regards to their phase composition and microstructures.
The Effect of Fuel Ratio on Activity of Suspension Flame Sprayed Titania Coatings
Authors: Robinson B. , Parkin I.P. , Darr J.A. , Tabecki A. , de Villiers Lovelock H.L. , Jose D. , Mills A. 
Published: August 2022

Abstract
The photocatalytic properties of titania are widely known with applications including solar water disinfection, solar hydrogen production and as anti-bacterial surfaces. Herein, we report the use of suspension flame spraying for the deposition of conformal TiO2 coatings. This process is carried out using aqueous titania suspension (ca. 5 wt%) injected into an acetylene flame (ca. 3100 °C), via an atomiser. Coatings deposited were adherent, majority anatase phase and retained their nanostructure after coating. In this study the acetylene/oxygen ratio was altered to determine the effect on the photoactivity of titania coatings produced, with photoactivity determined by photocurrent generation under illumination. All coatings produced were shown to be photoactive with a marked difference in photocurrent observed between coatings produced in the varying flame conditions. Photocurrent generation increased by up to 3.7 times with decreasing fuel ratio. This difference was attributed to the build-up of reduced titania species in the coating.
The Importance of Optimizing Nozzle Dimensions for Cold Spray Process
Authors: Huang Renzhong , Fukanuma Hirotaka 
Published: August 2022

Abstract
Particle velocity is one of the most crucial parameters to determine coating’s properties in cold spray process, such as coating’s densification and bonding strength. To achieve a high particle velocity, the common way is to increase the working gas temperature or pressure, sometime using the extremely expensive helium gas. In this study, computational fluid dynamics (CFD) method was employed to optimize the nozzle dimension in order to improve particle velocity. Particle velocity was also measured with DPV-2000 to verify the simulation results. Furthermore, coatings were deposited with the optimized nozzle, and their mechanical and electric properties were tested. The results show that the optimized nozzle benefited to improve the adhesive strength with substrate and electric properties of cold-sprayed coatings.
The Importance of Temperature Management in Thermal Spraying and the Respective Advantages of CO2 for Cooling
Authors: Kroemmer Werner 
Published: August 2022

Abstract
Different directions characterize the advances being made in thermal spraying today. On the one hand, spray processes are becoming colder, on the other hand, high-performance systems are being designed which enable a higher powder throughput, thus making production faster and more efficient. The current spectrum of substrate materials is much broader and even more versatile, as can be seen with new materials which prevent thermal stresses from arising during the production process. More and more applications require the use of special cooling methods to increase the cooling efficiency and, in turn, optimize the process. An ongoing objective of the gas industry is to offer the user hardware which not only exploits all the advantages of CO2, for example, but which is also suited to new applications.
Transplantation of Thermal Sprayed Coatings
Authors: Knödler P. , Otten M. , Möhwald K. , Maier H.J. , Freiburg D. , Peuker A. , Biermann D. 
Published: August 2022

Abstract
Be it to save the environment or to save money, engineers everywhere attempt to use materials which can’t normally withstand the surface stress they will be exposed to on their own. This is one of the reasons for the constant interest in new and innovative coating technologies. One such innovation is the transplantation of thermal sprayed coatings. In the transplantation process the coating is integrated into a high-pressure die casting process. In contrast to the conventional process chain, the coating is not directly applied to the work piece, but to a mold insert. During the pressure casting the melt infiltrates the coating and thus creates a join. This way the coating is indirectly applied to the die-cast work piece after removal from the mold. Additionally, depending on the materials involved, a material bonding connection similar to brazing is possible and results in an increased adhesion of the coating. A potentially very interesting trait of the transplantation process is, turning an internal coating process into an external coating process. This allows the coating of inside diameters well below the usual limit of an internal spray gun. Due to the high geometric accuracy of the process this can be potentially done without any need for additional finishing steps.
Tribological Properties of Hard Metal Coatings Sprayed by High Velocity Air Fuel Process
Authors: Lyphout C. , Sato K. , Houdkova S. , Smazalova E. , Lusvarghi L. , Bolelli G. , Sassatelli P. 
Published: August 2022

Abstract
Lowering the thermal energy and increasing the kinetic energy of sprayed particles by newly developed HVAF systems can significantly reduce material decarburization, and increases sliding wear and corrosion resistance of hard metal coatings, making HVAF coatings attractive both economically and environmentally over its HVOFs predecessors. Two agglomerated and sintered feedstock powder chemistries, respectively WC-Co (88/12) and WC-CoCr (86/10/4), with increasing primary carbides grain size from 0.2 to 4.0 microns, have been deposited by the latest HVAF-M3 process onto carbon steel substrates. Respective dry sliding wear behaviours and friction coefficients were evaluated at room temperature via Ball-on-disk (ASTM G99-90) wear tests against Al2O3 counterparts, and via Pin-on-disk (ASTM G77-05) wear tests against modified martensitic steel counterparts in both dry and lubricated conditions. Sliding wear mechanisms, with formation of wavy surface morphology and brittle cracking, are discussed regarding the distribution and size of primary carbides. Corrosion behaviours were evaluated via standard Neutral Salt Spray (NSS), Acetic Acid Salt Spray (AASS), accelerated corrosion test and electrochemical polarization test at room temperature. Optimization of coating tribological properties are discussed regarding the suitable selection of primary carbide size for different working load applications.
A Feasibility Study on Hybrid Use of Thermal Spray Coating and Ultrasonic Nanocrystalline Surface Modification
Authors: Amanov Auezhan , Kim Jun-Hyong , Pyun Young-Sik , Tripathi Khagendra , Lee Soo-Wohn , Lee Hae-Ryong , Kim Taehyung 
Published: August 2022

Abstract
An ultrasonic nanocrystal surface modification (UNSM) technique was applied to the thermally sprayed yttria-stabilized zirconia (YSZ) ceramic thermal barrier coating (TBC) deposited onto a hot tool steel substrate to improve the mechanical and tribological properties. The surface microstructure of the as-sprayed and UNSM-treated coatings was examined using a scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and Raman spectroscopy, while the hardness of the coatings was measured by Vicker`s hardness tester. The friction and wear behavior of the coatings was assessed using a ball-on-disk tribometer against bearing steel (SAE52100) ball at temperatures of 25 °C and 200 °C under dry reciprocating conditions. Results showed that the UNSM-treated coating had smoother surface, lower friction and higher resistance to wear compared to that of the as-sprayed coating. It was found that hybrid use of thermal spray coating (TSC) and UNSM technique is meaningful to bring together synergy effect of two emerging surface technologies.
Columnar Structured YSZ Coating Formation by PS-PVD Using Conventional Plasma Spray System Assisted Through Droplet Filtering
Authors: Chen Qing-Yu , Li Cheng-Xin , Li Chang-Jiu , Luo Xiao-Tao , Yang Guan-Jun 
Published: August 2022

Abstract
It is only performed light of sight deposition in atmospheric plasma spray (APS) and electron beam physical vapor deposition (EB-PVD). The PS-PVD processing is realized no light of sight deposition which bridge the gap between APS and EB-PVD. In this study, shielding deposition process was used to produce YSZ coatings and the microstructure and deposition behavior were also researched. A shrouded plasma torch was used to proceed on PS-PVD working. Multiple samples were placed on the same straight line to realize multistage shielding. The surface morphology and cross section morphology of coatings were observed by SEM. It is found that the surface is shown an island structure and the nano particles consist of island are grown smaller with the increased shielding stage. The cross section morphology of fracture coatings is shown columnar structure. This confirmed that the YSZ coatings are deposited via vapor phase at the condition of shielding. The deposition behavior of multi-stage shielding is also researched.