bluuebunny/crossref_metadata_2025_split huggingface dataset:
Life Cycle Assessment (LCA) of Thermal-Sprayed and Chromium Electroplated Coatings
Authors: Montavon G. , Vardelle A. , Krishnan N. , Ulloa P. , Costil S. , Liao H. 
Published: September 2022

Abstract
Electroplated chromium improves corrosion resistance while providing resistance to wear, fatigue and impact. However, hard chromium plating uses chromic acid, which releases fumes containing carcinogenic chromium +6 ions into air during the process. Therefore, numerous efforts have been carried out worldwide in the last decade to develop alternatives and several applications and processes were validated, among which trivalent chromium plating, electroless nickel and nickel alloy coatings, micro-welding, PVD, CVD, and thermal spraying. Nevertheless, these finishing processes have impacts on human health, ecosystems and resources. In this work, a Life-cycle assessment (LCA) methodology based on Eco-indicators 99 was used to compare the environmental impacts and benefits of thermal spraying (including APS- and HVOF-sprayed WC-Co coatings and TWEA- and APS-sprayed hard steel coatings) to conventional chromium plating.
Latest Technology for Commercially Available Cold Spray Systems
Authors: Richter P. , Hoell H. 
Published: September 2022

Abstract
The industrial use of cold spraying started in 2001 with the introduction of the Kinetic 3000 Cold Spray System from CGT. The heater is designed for a 24-hour operation and has proved its reliability in several installations. The powder feeder can run at the high feed rate of the Kinetic 3000 and is easy to operate. The nozzle design changed from a simple double cone-type to the latest MOC shape. The presentation will give an overview of the state-of-the-art technology in cold spraying.
Process Development of Brazed Aluminum Heat Exchanger Using a Kinetic Spraying Process
Authors: Yoon S.H. , Lee C. , Kim H.J. 
Published: September 2022

Abstract
The conventional manufacturing process of the automotive brazed heat exchanger includes complex preparation processes before brazing: aluminum brazing filler alloy is pre-claded on both sides of a fin by an extrusion method, and holed aluminum tubes are coated on both sides with Zn for corrosion protection by a wire arc spraying process. The intent of this study is to simplify the preparation process by kinetic spraying using all of the components, including Al-12%Si (for the brazing filler metal), Zn (for corrosion protection), and KAlF4 (flux powder). Four kinds of blended powder, with and without flux, were evaluated. The bond properties and composition distribution at the braze joint area were evaluated by SEM and an electron probe micro analyzer (EPMA). It was necessary to control the Zn content so that the corrosion resistance and brazeability of the aluminum heat exchanger would not be affected. An optimal kinetic spray condition was obtained, in order to fabricate the heat exchanger in this study. It was observed that the joints of the brazed specimens on each side of the brazing part were sounder than those achieved brazed by the conventional methods. Further, the kinetic sprayed heat exchanger showed acceptable corrosion protection.
Investigation of Spray Conditions and Performances of Cold-sprayed Pure Silicon Anodes for Lithium Secondary Batteries
Authors: Sakaki K. , Shinkai S. , Shimizu Y. 
Published: September 2022

Abstract
Currently, graphite is used for anodes of the lithium ion battery. The higher capacity of a battery with the lithium alloy anode requires the development of a larger theoretical electrochemical capacity than graphite. Silicon is a promising anode material, having a theoretical capacity more than 10 times that of the graphite used in these lithium alloy batteries. There are two common methods of fabricating silicon anodes: direct deposition techniques such as electron beam deposition and sputtering; and slurry coating of silicon particles with a binder. Alternative methods are being investigated. One of such methods is cold spray. In this study, numerical simulation of, and experiments investigating, cold spray conditions and the performances of cold-sprayed silicon anodes are presented. Silicon was cold-sprayed on copper foil substrates using three different starting materials (with particle sizes of 4.65 µm, 6.74 µm and 9.63 µm). First cycle efficiency was about 90%. Charge capacity initially improves with cycling (up to the 10th cycle). This is probably due to better electrolyte soaking during the first several cycles. A decrease in charge capacity is observed upon further cycling.
Pulsed-Cold Gas Dynamic Spraying Process: Development and Capabilities
Authors: Jodoin B. , Richer P. , Bérubé G. , Ajdelsztajn L. , Yandouzi M. , Erdi A. 
Published: September 2022

Abstract
A new process, the Pulsed-Cold Gas Dynamic Spraying process is presented in this work. A description of the process and of the experimental set-up developed at the University of Ottawa Cold Spray Laboratory is presented. It is envisioned that this process could allow for the feedstock particles to be accelerated to high impact velocities and intermediate temperatures, in a non-reacting gas. That way, the intermediate particle impact temperature would lead to a lower critical velocity as compared with CGDS that could be easily reached while preserving the chemical and microstructural composition of the feedstock particles in the coating. Selected examples of the variety of coatings produced with the system are presented, illustrating the potential of the process to deposit various materials as well as its main benefits.
Adhesion of Cold Sprayed Coatings: Effect of Powder, Substrate, and Heat Treatment
Authors: Mäkinen H. , Lagerbom J. , Vuoristo P. 
Published: September 2022

Abstract
In cold spraying, various issues affect the mechanical properties of the coatings. Adhesion strength is usually considered to be the most crucial mechanical property. The aim of this study was to investigate the adhesion strength of cold sprayed copper and nickel chromium alloy coatings. The focus was especially in studying the influence of powders, substrates and heat treatments on adhesion strength. Three different copper and three nickel-20%chromium powders were tested. The substrate materials were carbon steel and copper. Furthermore, effect of substrate pre-treatment to the adhesion strength of the cold sprayed copper coatings was investigated. The influences of the powders and the substrates on the cold sprayed coatings were dependent on the materials. Adhesion strength of the cold sprayed Cu coatings was significantly higher on the Cu substrate than on the steel substrate. Moreover, heat treatment improved the adhesion strengths with increasing annealing temperature.
Effect of Substrate Temperature on the Formation Mechanism of Cold Sprayed Aluminum, Zinc, and Tin Coatings
Authors: Legoux J.G. , Irissou E. , Moreau C. 
Published: September 2022

Abstract
When describing the cold spray process, one of the most widely used concepts is the critical velocity. Current models predicting critical velocities take the temperature of the sprayed particles explicitly into account but not the surface temperature (substrate or already deposited layers) on which the particle impact. This surface temperature is expected to play an important role since the deformation process leading to particle bonding and coating formation takes place both on the particle and the substrate side. The aim of this work is to investigate the effect of the substrate temperature on the coating formation process. Experiments were performed using aluminum, zinc and tin powders as coating materials. These materials have a rather large difference in critical velocities that gives the possibility to cover a broad range of deposition velocity to critical velocity ratio using commercial low pressure cold spray system. The sample surface was heated and the temperature was varied from room temperature to a high fraction of the melting point of the coating material for all three materials. The change in temperature of the substrate during the deposition process was measured by means of a high speed IR camera. The coating formation was investigated as a function of (1) the measured surface temperature of the substrate during deposition, (2) the gun transverse speed and (3) the particle velocity. Both single particle impact samples and thick coatings were produced and characterized. Both the particle-substrate and interparticle bondings were evaluated by SEM and confocal microscopy
Mechanical Characteristics of Al-Co-Ce Coatings Produced by the Cold Spray Process
Authors: Sansoucy E. , Jodoin B. , Kim G.E. , Moran A.L. 
Published: September 2022

Abstract
Gas atomized feedstock particles of an Al-13Co-26Ce alloy system were sprayed using the Cold Spray deposition technique. The microstructures of the coatings produced are examined and the mechanical characteristics, in particular the bending fatigue and the bond strength, of the Al-Co-Ce coatings are reported. The results show that the Al-Co-Ce coating improved the fatigue behavior of AA 2024-T3 specimens when compared to uncoated and Al clad specimens. During the bond strength tests, the bonding agent failed and no delamination of the coating from the substrate occurred. The microstructural features of the feedstock powder were also found in the coatings. The coatings contained amorphous and crystalline phase contents similar to the ones found in the feedstock powder. It is suggested that the increase in the fatigue properties can be attributed to the residual compressive stresses induced in the coatings and to the high adhesion strength of the coatings to the substrates.
Mechanism Underlying Anelastic Properties of Thermal Spray Coating
Authors: Liu Y. , Nakamura T. , Srinivasan V. , Gouldstone A. , Sampath S. 
Published: September 2022

Abstract
The microstructure of thermally sprayed ceramic coatings is characterized by the existence of various pores and microcracks. The porous microstructure makes coating desirable for thermal insulation, but this unique microstructural feature also gives rise to anelastic response under tension and compression loads. Detail investigations of curvature measurements of ceramic coated substrate indicate the coatings to exhibit anelastic behavior composed of nonlinear and hysteresis characteristics. In this paper, the mechanisms of such behaviors were studied from curvature-temperature measurements and finite element analysis through modeling the microstructure of yttria stabilized zirconia (YSZ) coating. Computational models contain numerous randomly distributed pores and microcracks with various sizes, aspect ratios, locations and orientations. The effects of such attributes of pores and microcracks on coating anelastic behavior were studied by simulations of curvature change during thermal cycles.
Modeling Vapor Deposition Assisted by Thermal Plasma
Authors: Cartel S. , Bansard S. , Mariaux G. , Vardelle A. , Vardelle M. , Menuey J. 
Published: September 2022

Abstract
This study deals with a plasma technique that combines two plasma spray torches to produce finely-structured zirconia coatings. Ideally, the deposition process path involves the vaporization of most of the particles injected in the plasma jet and the transport of the vapor to the substrate where it re-condenses. The arrangement of the plasma torches makes it possible to limit the deposition of non-completely evaporated particles onto the substrate. The experimental design of the vapor deposition process has been assisted by experimental characterization of the plasma temperature field and numerical simulations of the two plasma flow interactions and powder vaporization.
Modeling on Deformation Behavior of Al Particles Impacting on Al Substrate and Effect of Surface Oxide Films on Interfacial Bonding in Cold Spraying
Authors: Li W.-Y. , Liao H. , Coddet C. , Li C.-J. , Bang H.-S. 
Published: September 2022

Abstract
In this study, a comprehensive examination of deformation of Al particles impacting on Al substrate was conducted by using the Arbitrary Lagrangian Eulerian (ALE) method to clarify the deposition characteristics of Al powder and effect of surface oxide films in cold spraying. It was found that the deformation behaviour of Al particles is different from that of Cu particles under the same impact conditions owing to its lower density and thus less kinetic energy upon impact. The results indicate that the Al particles need a higher velocity to reach the same compression ratio as that of Cu particles. On the other hand, the numerical results show that the oxide films at particle surfaces influences the bonding condition between the particles and substrate. The inclusions of the crushed oxide films at the interfaces between the depostied particles inhibit the deformation.
Manufacturing Solid Oxide Fuel Cells with an Axial-injection Plasma Spray System
Authors: Tang Z. , Burgess A. , Kesler O. , White B. , Ben-Oved N. 
Published: September 2022

Abstract
Atmospheric plasma spraying has emerged as a cost-effective alternative to traditional sintering processes for solid oxide fuel cell (SOFC) manufacturing. However, the use of plasma spraying for SOFCs presents unique challenges, mainly due to the high porosity required for the electrodes and fully dense coatings required for the electrolytes. By using optimized spray conditions combined with appropriate feedstocks, SOFC electrolytes and electrodes with required composition and microstructure could be deposited with an axial plasma spray system. In this paper, the challenges for manufacturing SOFC anodes, electrolytes, and cathodes are addressed. The effects of plasma parameters and different feedstocks on coating microstructure are discussed, and examples of optimized coating microstructures are given.
Plasma Sprayed Biocompatible Coatings on PEEK Implants
Authors: Beauvais S. , Decaux O. 
Published: September 2022

Abstract
New advanced polymeric biomaterials such as implantable poly(etheretherketone) (PEEK) are changing the face of the implantable medical device industry. Due to its bioactive behavior in vivo, hydroxyapatite (HA) coatings are used to improve the bone growth and to repair around metallic implant. The objective of this work is to study the feasibility of plasma sprayed hydroxyapatite coating on PEEK material. Different PEEK (unfilled and composite) specimens were successfully coated with a 150 µm thick coating. Chemical and crystallographic compositions, adhesions and microstructures of HA coatings on PEEK and on Ti-6Al-4V were compared. The results showed that the structure of HA coatings were appreciably equivalent. Mechanical tests showed that the plasma spraying process did not severely degrade the initial properties of the PEEK substrate.
Preparation, Microstructure and Bioactivity of Plasma-Sprayed TiO2 Coating
Authors: Zhao X. , Chen Z. , Liu X. , Ding C. 
Published: September 2022

Abstract
In this paper, nano-structured TiO2 coatings have been successfully deposited onto titanium alloy substrates by atmospheric plasma spraying technology using optimized plasma parameters. A chemical treatment method was employed to induce bioactivity on the TiO2 surface. The bioactivity of as-sprayed and chemical treated TiO2 coatings were evaluated by investigating the formation of apatite on their surface after they were soaked in simulated body fluids (SBF) for a period of time. Microstructure and the phase composition of the as-sprayed coating and apatite were analyzed by Field-emission scanning electron microscopy (FESEM), transmission electron microscopy (TEM), X-ray diffraction (XRD) and energy-dispersive X-ray spectrometry (EDS). The results obtained indicate that as-sprayed TiO2 coating consists of rutile, anatase and suboxide such as Ti3O5. The surface of nano-TiO2 coating is covered by nano particles of about 50nm in size. The bonding strength of TiO2 coating with Ti alloy substrate is as high as 40 MPa. The corrosion resistance performance of nano-coating in SBF is better than that of Ti-6Al-4V alloy. The surface of as-sprayed TiO2 coating can not induce bone-like apatite formation. Chemical treatment, such as acid and alkali, can improve bioactivity of TiO2 coating surface.
Sintering Kinetics of Plasma-Sprayed Zirconia TBCs
Authors: Cipitria A. , Golosnoy I.O. , Clyne T.W. 
Published: September 2022

Abstract
A model of the sintering exhibited by EB-PVD TBCs, based on the principles of free energy minimization, was recently published by Hutchinson et al. In the current paper, this approach is applied to the sintering of plasma-sprayed TBCs and comparisons are made with experimental results. Predictions of through-thickness shrinkage and changing pore surface area are compared with experimental data obtained by dilatometry and BET analysis respectively. The sensitivity of the predictions to initial pore architecture and material properties are assessed. The model can be used to predict the evolution of the contact area between overlying splats. This is in turn related to the through-thickness thermal conductivity, using a previously-developed analytical model.
Nanostructured Ceramic HVOF Coatings for Improved Protection
Authors: Turunen E. , Kanerva U. , Varis T. , Knuuttila J. , Leivo J. , Silvonen J. 
Published: September 2022

Abstract
The potential of the high velocity oxy-fuel (HVOF) thermal spray process to produce coatings with reduced porosity is well known. The ability to produce high density ceramic coatings offers potential in high performance applications in the fields of wear, corrosion resistance and dielectric coatings. It has been, however, demonstrated that benefits from HVOF ceramic coatings can be obtained only if particles are melted enough and good lamella adhesion is produced. Therefore, due to the operational limits of the HVOF process, the process-structure- relationship must be well optimized. One strategy to improve melting of ceramic particles in the relatively low flame temperatures of the HVOF process is to modify particle crystal structure and composition. In this paper, the effects of the powder structure and the composition on coating microstructure and deposition efficiency of the HVOF spray process are studied. The effect of fuel gas, hydrogen vs. propane, was also demonstrated. The studied materials were agglomerated alumina- and titania-based pure and composite powders. Coating properties such as microstructure, hardness, and abrasive wear resistance, were compared to the coating manufactured by using conventional fused and crushed powders.
About the Dependence of the Stabilization of α-Alumina on the Spray Process
Authors: Stahr C.C. , Saaro S. , Berger L.-M. , Dubský J. , Neufuss K. 
Published: September 2022

Abstract
In result of the spray process normally a phase change from α-alumina (corundum) in the feedstock powder to predominantly α-alumina in the coating takes place. This is a well known but often neglected fact in the preparation and use of alumina coatings. This is of special interest since the high usage properties of thermally sprayed alumina coatings are generally derived from sintered alumina ceramics which consist of corundum. It is expected that the prevention of this phase transformation will significantly change the mechanical, electrical and other properties of thermally sprayed alumina coatings. There is controversial information about the possibility of stabilization of α-alumina by additions of chromia in the literature. In this work the stabilization using different spray processes (water stabilized plasma WSP, gas stabilized plasma APS and HVOF) was studied. Mechanical mixtures of alumina and chromia were used, as well as pre-alloyed powders consisting of solid solutions. The coatings were studied by X-ray diffraction and metallographic cross-sections. It was shown that in the case of the mechanically mixed powders the stabilization predominantly depends on the applied spray process. The stabilization by use of the WSP process was confirmed.
Processing and Properties of Advanced Ceramic Abradable Coatings
Authors: Sporer D. , Dorfman M. , Xie L. , Refke A. , Giovannetti I. , Giannozzi M. 
Published: September 2022

Abstract
Abradable seals have been used in jet engines since the late 1960's. Today abradable seals are seeing applications not only in low pressure and high pressure sections of the compressor but also in the high pressure turbine module of jet engines and are gaining ever more attention in industrial gas turbines. Thermal spraying is a relative simple and cost effective means to apply abradable seals. These work by minimizing gaps between rotating and stationary components by allowing the rotating parts to cut into the stationary ones. The types of coatings employed are zirconia based abradable material systems with polymer and, in some cases, hexagonal boron nitride additions. The coatings are designed to work at service temperatures of up to 1200 °C. The objective of this paper is to review various types of commercial and experimental ceramic abradable systems and to assess their performance profiles. The paper will review yttria stabilized zirconia based systems with modified polymer additions and with variable particle sizes of the ceramic phase. Alternative stabilizers and their influence on key coating properties such as thermal shock resistance and abradability will be studied. The paper will also review the influence of plasma spray parameters on coating properties and study the general influence of coating porosity on coating erosion properties and abradability.
Characterization of Adhesion Strength and Residual Stresses of HVOF Sprayed Inconel 718 for Aerospace Repair Applications
Authors: Lyphout C. , Nylén P. , Wigren J. 
Published: September 2022

Abstract
Thermally sprayed Inconel 718 coatings have been deposited by high velocity oxy-fuel (HVOF) spraying on Inconel 718 substrates. The aim of the on-going study is to understand and control the adhesion mechanisms and the residual stress state of the deposit/substrate system, in order to build up thick coatings for maintenance purposes. The coating adhesion strength was evaluated by the standard ASTM C633 tensile test. Coating shear strength was evaluated by the recently developed prEN15340 Shear Test. A modified Layer Removal Method (MLRM) test was carried out to measure residual stresses. The work is a part of an ongoing study for evaluation of relationships between process parameters, residual stress distribution and adhesion strength.
Nanostructured Plasma Sprayed Anodes for Solid Oxide Fuel Cells
Authors: Syed A.A. , Ilhan Z. 
Published: September 2022

Abstract
Nanostructured YSZ+NiO functional layers for SOFC anodes were developed by air plasma spraying. Spray processing was controlled to conserve finely porous and nanostructure of the feedstock in the deposit. The optimized deposits exhibiting high gas permeability, suitable high temperature electronic conductivity, enhanced triple phase boundaries and catalytic activity. The results were compared with conventional NiO+YSZ and Ni-C+YSZ anodes. YSZ electrolyte layer was deposited onto the anodes for electrochemical testing at 800°C in static conditions. Impedance spectroscopy measurements were performed to collect data on the polarization resistance and catalytic behavior of these anode layers. It was established that enlarged reaction zone, provided by high specific surface area of the nanostructured anodes, and finely porous microstructure, led to lower polarizations and enhanced cell performance by more than 60% compared to conventional cells.