Journal of Thermal Spray Technology

https://link.springer.com/journal/11666

List of Papers (Total 142)

Effect of Powder Preparation on the Microstructure and Wear of Plasma-Sprayed NiAl/CrB2 Composite Coatings

The properties of plasma-sprayed composite coatings depend to a large extent on the homogenization of the powders used for their deposition. In order to investigate this relation, mixtures of NiAl and CrB2 (15 and 30 wt.%) powders were prepared via an organic binder (a), hot pressing (b) or sintering (c). The obtained composite agglomerates were sprayed on cylindrical AISI 310S...

Beyond Traditional Coatings: A Review on Thermal-Sprayed Functional and Smart Coatings

Thermal spraying has been present for over a century, being greatly refined and optimized during this time. It has become nowadays a reliable and cost-efficient method to deposit thick coatings with a wide variety of feedstock materials and substrates. Thermal-sprayed coatings have been successfully applied in fields such as aerospace or electricity production, becoming an...

Modeling the Evolution of Residual Stresses in Thermally Sprayed YSZ Coating on Stainless Steel Substrate

This study is based on Eulerian method to model residual stresses for yttrium-stabilized zirconia coating applied to stainless steel substrate. A commercially available finite element software ABAQUS/Explicit is used to conduct this study. Single and multiple-particle impact analyses were carried out, and the residual stress data have been reported. The analysis is performed for...

Microstructure and Oxidation Performance of TiAl-(Cr, Nb, Ta) Coatings Fabricated by Warm Spray and High-Velocity Oxy-Fuel Spraying

To improve the oxidation resistance of near α-titanium alloy IMI834, TiAl-(Cr, Nb, Ta) coatings were deposited by applying high-velocity oxy-fuel (HVOF) and warm spray (WS). Comparison was made in terms of microstructure, surface morphology as well as isothermal and cyclic oxidation behaviors in the air at 750 °C up to 100 h and 100 cycles, respectively. The results show that...

Modeling of Dynamics and Thermal History of Fe40Al Intermetallic Powder Particles Under Gas Detonation Spraying Using Propane–Air Mixture

The dynamic properties and thermal history of Fe40Al at.% intermetallic particles have been estimated. The parameters of the gas detonation process for the investigated mixture have been calculated using thermochemical code, and the motion parameters as well as thermal history of the analyzed powder particles have been assessed using computational fluid dynamics software and self...

Effects of Combustion Model and Chemical Kinetics in Numerical Modeling of Hydrogen-Fueled Dual-Stage HVOF System

The present work examines the effect of utilizing different combustion models and chemical kinetics in predicting the properties of gas and particle phases in a hydrogen-fueled, dual-stage high-velocity oxy-fuel (HVOF) thermal spray system. For this purpose, effects of two combustion models, eddy dissipation concept (EDC) and eddy dissipation model (EDM), on the temperature and...

Effects and Interplays of Spray Angle and Stand-off Distance on the Sliding Wear Behavior of HVOF WC-17Co Coatings

The state of particle impact (velocity and temperature) significantly affects the coating’s microstructural, mechanical properties and wear performance. The spray stand-off distance and spray angle dictate particle velocity components and temperature at impact. This work aims in advancing the understanding of their effect and interplay in regard to the sliding wear performance as...

Preparation of MCrAlY–Al2O3 Composite Coatings with Enhanced Oxidation Resistance through a Novel Powder Manufacturing Process

MCrAlY–Al2O3 composite coatings were prepared by high-velocity oxygen fuel thermal spraying with bespoke composite powder feedstock for high-temperature applications. Powder processing via a suspension route was employed to achieve a fine dispersion of α-Al2O3 submicron particles on the MCrAlY powder surface. This was, however, compromised by ~ 50% less flowability of the...

Characterization of Powder-Precursor HVOF-Sprayed Al2O3-YSZ/ZrO2 Coatings

Thermal spraying using liquid feedstock can produce coatings with very fine microstructures either by utilizing submicron particles in the form of a suspension or through in situ synthesis leading, for example, to improved tribological properties. The focus of this work was to obtain a bimodal microstructure by using simultaneous hybrid powder-precursor HVOF spraying, where...

Medicine Meets Thermal Spray Technology: A Review of Patents

The patent literature concerning thermal spraying for biomedical applications is reviewed in this contribution. The patents were compiled from multiple databases search spanning the 2005-2018 period. For clarity and ease of reading, the results have been grouped into sections according to four individual material groups (apatites, titanium, oxide ceramics, other), with the...

Microstructural Evolution and Sintering of Suspension Plasma-Sprayed Columnar Thermal Barrier Coatings

Suspension plasma spray (SPS) is capable of producing coatings with porous columnar structure, and it is also a much cheaper process compared to the conventionally used electron beam physical vapor deposition (EB-PVD). Although TBCs with a columnar microstructure that are fabricated using SPS have typically lower thermal conductivity than EB-PVD, they are used sparingly in the...

Thermal Spray Coatings on Orthopedic Devices: When and How the FDA Reviews Your Coatings

Thermal spray coatings have been commonly applied on medical devices for various reasons, e.g., surface roughening, biological fixation, and similarity of chemical composition to bone minerals. Generally, to introduce a thermal spray-coated device to the US market, a premarket review of the coated device is necessary by the US Food and Drug Administration (FDA). This article aims...

Fabrication and Oxidation Resistance of TiAl Matrix Coatings Reinforced with Silicide Precipitates Produced by Heat Treatment of Warm Sprayed Coatings

Ti-Al-based intermetallics are promising candidates as coating materials for thermal protection systems in aerospace vehicles; they can operate just below the temperatures where ceramics are commonly used, and their main advantage is the fact that they are lighter than most other alloys, such as MCrAlY. Therefore, Ti-Al-Si alloy coatings with five compositions were manufactured...

Prediction of Coating Properties of Thermally Sprayed WC–Co on Complex Geometries

This work outlines the development of an analytical software tool that enables the prediction of various coating properties on any given sprayable geometry. The prediction is achieved by analyzing the input computer-aided design geometry and by correlating the resulting kinematic conditions with experimental measurements. The results of the developed tool have been validated...

Plasma-Sprayed Hydroxylapatite Coatings as Biocompatible Intermediaries Between Inorganic Implant Surfaces and Living Tissue

The present contribution discusses critical aspects of the thermal alteration that HAp particles undergo when passing along the extremely hot plasma jet. This heat treatment leads to dehydroxylated phases such as oxyhydroxylapatite/oxyapatite as well as thermal decomposition products such as tri- and tetracalcium phosphates, and quenched phases in the form of amorphous calcium...

FIB-SEM Sectioning Study of Decarburization Products in the Microstructure of HVOF-Sprayed WC-Co Coatings

The thermal dissolution and decarburization of WC-based powders that occur in various spray processes are a widely studied phenomenon, and mechanisms that describe its development have been proposed. However, the exact formation mechanism of decarburization products such as metallic W is not yet established. A WC-17Co coating is sprayed intentionally at an exceedingly long spray...

The Influence of Heat Treatments on the Porosity of Suspension Plasma-Sprayed Yttria-Stabilized Zirconia Coatings

Suspension plasma-sprayed coatings are produced using fine-grained feedstock. This allows to control the porosity and to achieve low thermal conductivity which makes the coatings attractive as topcoats in thermal barrier coatings (TBCs). Used in gas turbine applications, TBCs are exposed to high temperature exhaust gases which lead to microstructure alterations. In order to...

Failure Analysis of Multilayered Suspension Plasma-Sprayed Thermal Barrier Coatings for Gas Turbine Applications

Improvement in the performance of thermal barrier coatings (TBCs) is one of the key objectives for further development of gas turbine applications. The material most commonly used as TBC topcoat is yttria-stabilized zirconia (YSZ). However, the usage of YSZ is limited by the operating temperature range which in turn restricts the engine efficiency. Materials such as pyrochlores...

KCl-Induced High-Temperature Corrosion Behavior of HVAF-Sprayed Ni-Based Coatings in Ambient Air

KCl-induced high-temperature corrosion behavior of four HVAF-sprayed Ni-based coatings (Ni21Cr, Ni5Al, Ni21Cr7Al1Y and Ni21Cr9Mo) under KCl deposit has been investigated in ambient air at 600 °C up to 168 h. The coatings were deposited onto 16Mo3 steel—a widely used boiler tube material. Uncoated substrate, 304L and Sanicro 25 were used as reference materials in the test...

Correction to: Optimization of Cold Spray Deposition of High-Density Polyethylene Powders

We regret that the original article contained an incorrect initial for the first listed author. The name should have been published to read: Trenton P. Bush.