bluuebunny/crossref_metadata_2025_split huggingface dataset:
The Role of Substrate Surface Chemistry on Splat Formation during Plasma Spray Deposition by Experiments and Simulations
Authors: Tran A.T.T. , Hyland M.M. 
Published: December 2022

Abstract
NiCr was plasma sprayed at room temperature on aluminum and stainless steel substrates that had been hydrothermally treated in deionized water for 30 minutes. A major difference was observed in that splat formation occurred only on the stainless steel. A numerical model was developed to simulate the impact of molten nickel splats on the treated substrates. The simulation closely matched experimental results in terms of splat morphology, porosity, delamination, and specific locations of substrate melting. Moreover, it confirmed that splat morphology is influenced, not by oxide thickness, but rather by water release from the dehydration of oxyhydroxide at the outermost surface. The insulating layer of released water inhibits heat transfer from the splat to the substrate, which reduces solidification rates, resulting in further spreading and thinning of splats. These findings shed light on splat spreading and solidification and provide insights on the effect of substrate surface chemistry on thermal spray splat morphology.
A Study on Arc Instability Phenomena of a Hollow Cathode Plasma Torch in a Low Pressure Environment
Authors: Stanisic J. , George A. , Mohanty P.S. 
Published: December 2022

Abstract
This study investigates arc instability phenomena associated with hollow-cathode plasma torches under low pressure. Stable and unstable regimes are evaluated based on Fourier analysis of gun voltage. For comparison, arc fluctuations with a solid-cathode torch are studied as well. Different internal hardware configurations are used during spraying to identify and assess important factors in the design of hollow and solid cathode guns. This work also characterizes a number of parameters that would exploit plume elongation and accelerated gas velocities under low-pressure conditions.
Modeling a New Spray Process Combining Plasma and HVOF
Authors: Martinez B. , Mariaux G. , Vardelle A. , Barykin G. , Parco M. 
Published: December 2022

Abstract
The aim of this study is to model a spray process that combines aspects of plasma and HVOF spraying. The process is characterized by its stability over a broad range of fuel-oxidant conditions and ability to produce coatings using relatively little gas with rather low gross heating values The mathematical model developed accounts for the formation of the plasma jet, the combustion process, and supersonic flow issuing from the spray torch. Simulating the new process made it possible to investigate the effect of the plasma on the velocity and temperature of the gas flow inside and outside the gun. The equations were solved using CFD code and predictions were compared with experimental observations. The benefits of the plasma jet are discussed on the basis of predictions and fuel combustion mechanisms.
Current Status and Future Prospect of Thermal Spray Coating Applications and Coating Service Market of Job Shops in Japan
Authors: Nakahira A. 
Published: December 2022

Abstract
According to a recent survey, the thermal spray market in Japan is approximately 100 billion yen. The market consists of three sectors, coating services (45 billion yen), in-house production (45 billion yen), and sales of thermal spray equipment and consumables (10 billion yen). This paper provides an overview of the coating services market broken out by application segments. It also discusses future trends.
Market Direction and Application Opportunities for Thermal Spray Growth in Korea
Authors: Lee C. 
Published: December 2022

Abstract
This paper provides a summary of the status and potential of thermal spray activities in Korea. It describes how various market sectors in Korea are using spray coating technology and presents annual sales estimates and share of market data broken out by industry, spraying technology, and patents awarded. It also reviews recent advancements in the development and use of thermal spray technology in Korea along with anticipated future impacts.
Thermal Spraying in India: Status and Prospects
Authors: Sundararajan G. , Mahajan Y.R. , Joshi S.V. 
Published: December 2022

Abstract
This paper provides a summary of the status and potential of thermal spray activities in India. A meaningful indicator of the future growth of thermal spray technology in India is the rapid rise in the number of job shops that offer thermal spray coating services. The number of captive units meeting in-house coating needs has also increased markedly in recent years. These trends have in part been fueled by an increase in the number of home-grown Indian companies manufacturing spray systems, handling equipment, and performance evaluation test rigs. Research in areas such as cold gas dynamic spraying (CGDS) and solution precursor plasma spraying (SPPS) is also on the rise in India.
Thermal Spraying of FeNiW Coatings to Improve the Performance of Casting Molds in the Aluminum Industry
Authors: Wilden J. , Jahn S. , Drescher V.E. 
Published: December 2022

Abstract
The lifetime of casting molds in the aluminum industry is strongly limited by the corrosiveness of aluminum melts and alternating thermal and mechanical loads. With the added protection of sintered tungsten pseudoalloy inlays, casting molds have been known to last as much as 1000 times longer, and the work presented here indicates that it may be possible to replace the massive liners with a twin wire arc or plasma sprayed coating that can be tailored by varying spraying parameters.
Microstructure Evolution and Dielectric Properties of Plasma Sprayed BaTiO3 Coatings
Authors: Kim Y.-M. , Baik K.-H. , Park K.-S. 
Published: December 2022

Abstract
BaTiO3 coatings are very promising for a wide range of applications in microelectronics because of their high dielectric constant and low leakage current. In this study, atmospheric plasma spraying is used to produce thick BaTiO3 coatings and their microstructural features and dielectric properties are examined. The coatings were mainly composed of amorphous phase with small amounts of crystalline phase due to the incorporation of partially-molten droplets. The as-sprayed coatings were crystallized to BaTiO3 by low temperature heat treatment and a mixture of BaTiO3 and BaTi2O5 at higher temperatures. At 1200 °C, the coating formed an equiaxed grain structure due to sintering effects and the dielectric constant was significantly improved.
Development of Kinetic Sprayed Coatings for the Application of Die Soldering Resistance
Authors: Khan F.F. , Bae G. , Kang K. , Kumar S. , Na H. , Kim J. , Lee C. 
Published: December 2022

Abstract
This study assesses the potential of kinetic-spray coatings for dealing with the effects of soldering and erosion on aluminum casting dies. In the experiments, molybdenum-boride cermet and cobalt-based alloy powders are cold sprayed onto SKD61 substrates. Coating microstructure is assessed via SEM and XRD analysis and several mechanical properties are measured. In order to evaluate soldering resistance, the coatings are immersed in a molten aluminum bath. Although cold-sprayed CoCrNiWC exhibited high coating density and low porosity, its soldering resistance was significantly lower than that of MoB-NiCr. The boride cermet coating not only exhibited superior soldering resistance, but also higher hardness, bond strength, and wear resistance. However, its deposition efficiency needs further improvement.
Defect Reduction in Semiconductor through Thermal Spray Technology
Authors: Wang H. 
Published: December 2022

Abstract
Bead blasting and thermal spray coatings are often applied on process kits used in vacuum deposition chambers to improve adhesion between kit surfaces and deposited films. This study shows that in order to maximize chamber service time and reduce processing defects, thermal expansion mismatches must be considered between chamber components, sprayed coatings, and vacuum deposited films. When a titanium sheet coated with arc sprayed aluminum was placed in a titanium nitride deposition chamber, significant particle spiking was observed. However, during the same period of chamber service time, particle performance was stable for titanium coated with arc sprayed molybdenum. It should be noted that the thermal expansion coefficients of Ti and Mo are much closer than those of Ti and Al. By further optimizing the cohesion strength of the arc-sprayed Mo coating, even lower particle counts have been achieved, corresponding to fewer processing defects and prolonged chamber kit lifetime.
Direct Write of Antenna Aperstructures and Electronic Interconnects Using Kinetic Metallization
Authors: Tapphorn R.M. , Henness J.A. , Gabel H. 
Published: December 2022

Abstract
A direct write method of fabricating antenna structures onto doubly curved dielectric surfaces has been developed using low temperature kinetic metallization. This paper describes the process and its use for depositing copper on various dielectrics and silver on alumina substrates and copper lead frames.
Electrically Conductive Plasma Sprayed Oxide-Metal Coatings on Glass Ceramic Substrates
Authors: Floristán M. , Gadow R. , Killinger A. 
Published: December 2022

Abstract
Coating operations over glass ceramic substrates represent a new field for thermal spray applications. Due to the unique thermal and mechanical properties of glass ceramics, especially the low or even negative CTE, coating processes must be adapted to reduce the distribution of thermal stresses in the system and to not damage the substrate. This study investigates the deposition of a complex-shaped ceramic-metallic multilayer coating system that could potentially serve as a heating element in a glass ceramic cooking plate. To ensure coating adhesion, the substrates are preheated and their surfaces are grit blasted. In order to minimize stresses associated with the deposition of metal, the movement of the spraying mechanism was automated with robot control and new masking concepts were developed to ensure the accuracy of the shape and placement of the coating. The influence of spraying parameters on coating properties and residual stress distribution is analyzed as well.
Plasma Sprayed Ceramic Tray Members for Firing Ceramic Capacitors
Authors: Yamakawa O. , Nihonmatsu H. , Morisasa M. , Hotta H. 
Published: December 2022

Abstract
Multilayer ceramic chip capacitors (MLCCs) are produced in large numbers for use in automobiles, cell phones, flat panel displays, and other products. Like many circuit components, they are being required in more compact sizes, larger capacities, and reduced costs year by year. MLCCs are kiln-fired on stacked carriers made from Al2O3-SiO2 covered with a Y2O3-stabilized ZrO2 topcoat and an Al2O3 basecoat. This paper presents the rationale behind the selection of the coating materials and evaluates processes by which they can be applied. It compares the microstructure and properties of sintered, atmospheric plasma sprayed (APS), and water stabilized plasma sprayed (WSP) yttria-stabilized zirconia and discusses the advantages and disadvantages of each process.
Optimized Arc Wire Sprayed Fiber Prepregs for Advanced Manufacturing of Metal Matrix Composites (MMCs)
Authors: Silber M. , Gadow R. 
Published: December 2022

Abstract
The production of light metal matrix composites (MMCs) using coated fiber prepregs processed by thixoforging offers several advantages over well-established technologies like squeeze casting and diffusion bonding. In order to obtain the required globular microstructure prior to thixoforging, reinforcement fibers are coated with the matrix material by twin wire arc spraying. Damage to the sensitive fibers is avoided by reducing the thermal load via optimized cooling. This study analyzes the influence of spraying parameters on the microstructure and mechanical properties of MMCs. An innovative method for automated the coating of reinforcement fibers is presented.
Parameters Affecting Bond Strength and Surface Roughness in Twin Wire Arc Spray Aluminum Coatings
Authors: Watson M. , Gansert R. 
Published: December 2022

Abstract
Twin wire arc sprayed aluminum coatings are used extensively in semiconductor processing equipment. In certain applications, such as metal reclamation, rough coating textures are desirable as the added surface area facilitates the collection of metals and lowers manufacturing costs. There are many factors that affect the surface roughness of twin wire arc sprayed coatings. This study investigates coating conditions that produce rough textures and the influence of surface roughness on bond strength. Traditional theory of arc spraying has been that to obtain a rough coating, particle velocity should be reduced by decreasing the atomizing air pressure of the system. Decreasing air pressure, however, may have a negative impact on bond strength, the extent of which is assessed in this study.
High Temperature Corrosion Behavior of Cold Spray Ni-20Cr Coating on Boiler Steel in Molten Salt Environment at 900 °C
Authors: Bala N. , Singh H. , Prakash S. 
Published: December 2022

Abstract
In this investigation, Ni-20Cr alloy powder was deposited on SA 516 boiler steel by cold spraying. The oxidation kinetics of both coated and uncoated samples, evaluated in molten salt, followed a parabolic rate. The rate constant of the Ni-20Cr coated steel was much lower than that of the bare boiler steel. X-ray diffraction, SEM-EDX, and X-ray mapping were used to analyze the oxidation products of the coated and uncoated boiler steel. The uncoated steel exhibited intense spalling and peeling of its oxide scale, which may be due to the formation of Fe2O3 oxides. The Ni-20Cr coating reduced the weight gain of the steel by more than 87% possibly due to the formation of nickel and chromium oxides.
Corrosion and Erosion Resistant Thermal Spray Coatings of Fe-Si Intermetallics
Authors: Okagaito T. , Fukuda Y. 
Published: December 2022

Abstract
This study evaluates Fe-Si intermetallic powders as an alternative to powders currently used to coat furnace walls in pulverized coal fired boilers. The developed powder mainly consists of Fe2Si, which has a relatively low melting point among iron silicides. The powders were deposited on CrMo steel substrates by HVOF and atmospheric plasma spraying and the resulting coatings were subjected to corrosion and erosion testing. Under conditions simulating the operating environment in a low NOX boiler, the HVOF sprayed Fe-Si coatings exhibited sulfidation resistance nearly equal to that of Cr-Ni layers, and in high-temperature erosion tests, the APS intermetallic coatings with boron additions were found to be more erosion resistant than conventional Cr3C2-NiCr coatings.
Wire Arc Sprayed High Quality Anti-Corrosion and Wear-Resistant Coatings
Authors: Wilden J. , Jahn S. , Reich S. , Drescher V.E. , Durham R. , Schütze M. 
Published: December 2022

Abstract
Due to its easy handling and low operating costs, wire arc spraying has become one of the most established processes for applying protective coatings to components used in waste incineration plants. This paper discusses the development of relatively low-cost Fe-Cr-Si coating materials for incinerator applications and the corrosion and wear properties that have been achieved using conventional arc spraying methods.
High-Velocity Collision of Hot Particles with Solid Substrate under Detonation Spraying: Detonation Splats
Authors: Zlobin S.B. , Ulianitsky V.Yu. , Shtertser A.A. , Smurov I. 
Published: December 2022

Abstract
The aim of this study is to analyze the shape of splats deposited by detonation spraying and correlate splat morphology with the velocity and temperature of particles as they hit the substrate. The obtained results are in good agreement with numerical calculations for nickel splats and show that the thermo-physical properties of composite particles can be estimated from their splat characteristics as well. An understanding of these relationships for various materials is necessary to calculate particle heating in the detonation barrel.
Further Developments in Internal Diameter HVOF Application of WC-CoCr for Hard Chrome Replacement in Critical Applications Such as Landing Gear
Authors: Matthäus G. , Henry J. , Ackermann D. , Brandl W. 
Published: December 2022

Abstract
This paper describes an inner diameter HVOF spraying technique and associated tests methods. In the experiments, WC-CoCr was applied to an internal diameter of 150 mm and evaluated using a dedicated pin-on-disk wear test and standard axial fatigue tests. The results are presented and discussed along with the potential for further development of the inner diameter HVOF spraying technique.
Vapor Phase Deposition Using LPPS Thin Film
Authors: von Niessen K. , Gindrat M. , Refke A. 
Published: December 2022

Abstract
Low-pressure plasma spray thin film (LPPS-TF) is a recently developed vacuum plasma spray technology that makes it possible to deposit coatings not only by melting feedstock material, but also by vaporizing injected particles. This capability fills a gap between conventional vapor deposition and thermal spray processes. The vaporizing of coating material and formation of layers out of the vapor phase result in unique coating microstructures with superior properties. This paper reports on the progress made in the development of functional coatings built up from the vapor phase of metal and oxide ceramics.
A Novel Single Cathode Plasma Column Design for Process Stability and Long Component Life
Authors: Mohanty P.S. , George A. , Pollard L. , Snyder D. 
Published: December 2022

Abstract
Arc instability in dc plasma guns has a detrimental effect on coating quality and electrode life. This paper investigates the impact of a single-cathode plasma column design on process stability, versatility, and component life. The design increases arc length and minimizes restrike, enabling high voltage, low current operation as well as the use of ternary gas to increase enthalpy. Arc behavior is assessed by monitoring fluctuations in electrical signals and correlated with particle temperature and velocity. The takeover-steady mode is shown to be the typical operating mode of the plasma jet for this design, resulting in steady particle characteristics over long periods of maintenance-free operation.
Investigation of Plasma Spraying with Internal Axial Powder Injection
Authors: Gao Y. , Yang D-M. , Yan Z.-J. 
Published: December 2022

Abstract
Plasma spraying with axial powder injection inside the anode nozzle is a method considered to markedly enhance deposition efficiency and reduce plasma power compared to the most general method of injecting powder at the nozzle exit. However, powder injecting inside the nozzle will also likely cause problems from powder deposition on the nozzle wall and clogging of the particle feed channels. In this study, spherical stainless steel 316 and angular alumina powders with a mean size of 20-40 μm are used to deposit coatings via axial powder injection. The effect of powder feed rate, gas flow rate, and plasma power on deposition efficiency and particle clogging are investigated. The results show that particle clogging can be avoided by reducing powder feed rate and increasing the velocity of the plasma jet.
Plasma Spraying of Refractory Cermets by the Water-Stabilized Spray (WSP) System
Authors: Ctibor P. , Chraska P. , Brozek V. , Cheong D.-I. , Yang S.-H. 
Published: December 2022

Abstract
The goal of this study is to find applicable spray conditions for producing tungsten (W), zirconium carbide (ZrC), and W-ZrC cermet layers. In the experiments, W and ZrC powder mixtures were fed into the plasma of a water-stabilized plasma gun and coatings approximately 1 mm thick were sprayed on graphite substrates. Pure W and pure ZrC were deposited under similar conditions. Microhardness, surface roughness, XRD, XRF, dilatometry, and spectroscopic techniques were used to characterize the coatings. The resulting coatings were found to be hard with a high elastic modulus.
The Influence of Spray Parameters on the Characteristics of Al2O3 Particles and Coatings Sprayed by Detonation Spray
Authors: Sun B. , Fukanuma H. , Ohno N. 
Published: December 2022

Abstract
This study investigates the influence of high-frequency pulse detonation (HFPD) spraying parameters on particle characteristics and coating quality. A dual-slit velocimeter was used to measure the velocity and temperature of Al2O3 particles as fuel flow ratio and spray distance were adjusted. Experimental results show that particle velocity varied from 600 to 820 m/s as the fuel flow ratio was changed, but particle temperature remained relatively constant at about 2200 °C. Spraying distance had essentially no effect on in-flight particle properties although it influenced deposition efficiency, as did fuel flow ratio.
Particle Image Velocimetry Diagnostics for Suspension Plasma Spraying
Authors: Marchand O. , Bertrand G. , Planche M.P. , Bailly Y. , Girardot L. 
Published: December 2022

Abstract
In this investigation, particle image velocimetry (PIV) diagnostics were employed to analyze the spray produced by a two-fluid atomizer as used in suspension plasma spraying (SPS). This led to a change in the design of the atomizing nozzle in order to achieve a high-speed spray with narrow distributions in droplet size. The resultant spray was characterized and the diagnostic was adapted accordingly. Various suspensions of YSZ powders were then injected into the plasma under different conditions and particle velocities were determined and correlated with the coating morphologies obtained.
Influence of Convergent-Divergent Nozzle Design on Plasma Properties and Resultant Coatings
Authors: Caron N. , Macqueron C. , Meillot E. 
Published: December 2022

Abstract
The peculiar microstructure of plasma-sprayed coatings affects their physical properties. Many of these properties are, to a great extent, dominated by the influence of the spraying process on in-flight particle parameters. In order to improve the quality of plasma-sprayed coatings and to enhance the efficiency of plasma spray deposition, a wide range of anode nozzles have been developed for air plasma torches. The objective of this work is to investigate the influence of two convergent-divergent nozzle designs on plasma-sprayed YSZ particles at impact and the permeability, porosity, and microstructure of the resulting coatings.
Alumina Splat Investigation: Visualization of Impact and Splat / Substrate Interface for Millimeter Sized Drops
Authors: Goutier S. , Vardelle M. , Labbe J.C. , Fauchais P. 
Published: December 2022

Abstract
The aim of this work is to investigate the effect of substrate surface chemistry (e.g., oxidation and atom diffusion) on the flattening of a single millimeter-sized alumina drop. To that end, a new technique to produce such drops with different impact velocities has been developed. It consists of a rotating crucible heated by a transferred plasma arc and a piston that controls substrate velocity and, as a result, the impact velocity of the drop. A fast camera working in concert with a fast pyrometer precisely records drop flattening and cooling. This system makes it possible to study interface phenomena, such as desorption and wettability, as well as the effects, at impact, of the kinetic energy or Weber number of the flattening drop.