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Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt de matériaux non métalliques, Nonmetallic coatings, Barrière thermique, Thermal barrier, Barrera térmica, Conductivité thermique, Thermal conductivity, Conductividad térmica, Waermeleitfaehigkeit, Dilatation thermique, Thermal expansion, Dilatación térmica, Thermische Ausdehnung, Dopage, Doping, Dopen, Expansion, Expansión, Oxyde d'yttrium, Yttrium oxide, Ytrio óxido, Yttriumoxid, Perovskite, Perovskita, Revêtement non métallique, Non metal coating, Revestimiento no metálico, Nichtmetallischer Ueberzug, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, TBC, perovskites, thermal conductivity, and thermal expansion

Y2O3 and Yb2O3 co-doped strontium hafnate powder with chemistry of Sr(Hf0.9Y0.05Yb0.05)O2.95 (SHYY) was synthesized by a solid-state reaction at 1450 °C. The SHYY showed good phase stability not only from 200 to 1400 °C but also at a high temperature of 1450 °C for a long period, analyzed by differential scanning calorimetry and x-ray diffraction, respectively. The coefficient of thermal expansion of the sintered bulk SHYY was recorded by a high-temperature dilatometer and revealed a positive influence on phase transitions of SrHfO3 by co-doping with Y2O3 and Yb2O3. The thermal conductivity of the bulk SHYY was approximately 16% lower in contrast to that of SrHfO3 at 1000 °C. Good chemical compatibility was observed for SHYY with 8YSZ or Al2O3 powders after a 24 h heat treatment at 1250 °C. The phase stability and the microstructure evolution of the as-sprayed SHYY coating during annealing at 1400 °C were also investigated.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Propriétés mécaniques. Rhéologie. Mécanique de la rupture. Tribologie, Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology, Frottement. Usure, Contact of materials. Friction. Wear, Propriété mécanique, Mechanical properties, Propiedad mecánica, Contrainte résiduelle, Residual stress, Tensión residual, Eigenspannung, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement, Coatings, Revestimiento, Ueberzug, Résistance usure, Wear resistance, Resistencia al desgaste, Verschleissfestigkeit, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Tribologie, Tribology, Tribología, Usure, Wear, Desgaste, Verschleiss, iron alloys, residual stress, robot, and wear resistance

Even though the application of thermal spray coatings on complex geometries gained a greater interest in the last decade, the effect of different geometrical features on the wear behavior is still ill-defined. In this study, the wear resistance of FTC-FeCSiMn coated 3D surfaces was investigated. The wear test was carried out by means of two innovative testing procedures. The first test is a Pin-on-Tubes test where the rotating motion is realized by a lathe chuck. The specimens in the second test were fixed on the table and a robot arm operated the pin. This wear test was applied on specimens with concave or convex surfaces. The residual stresses, which were determined by means of an incremental hole-drilling method, show a dependency on the substrate geometry. The obtained stresses were put in relation to the different radii. After the wear test, a 3D-profilometer determined the wear volume and the sections of the coatings were characterized by a scanning electron microscope. The results indicate that the wear resistance is strongly influenced by the geometry of the substrate.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Alliage base titane, Titanium base alloys, Aluminium alliage, Aluminium alloy, Aluminio aleación, Aluminiumlegierung, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Formage projection, Spray forming, Formación proyección, Formage à tiède, Warm forming, Modelado en tibio, Halbwarmumformen, Microstructure, Microestructura, Mikrogefuege, Porosité, Porosity, Porosidad, Porositaet, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Vanadium alliage, Vanadium alloy, Vanadio aleación, Vanadiumlegierung, microstructure, oxygen content, porosity, and warm spraying

Warm spray (WS) is a modification of high-velocity oxy-fuel spraying, in which the temperature of the supersonic gas flow generated by the combustion of kerosene and oxygen is controlled by diluting the combustion flame with an inert gas such as nitrogen. The inert gas is injected into the mixing chamber placed between the combustion chamber and the powder feed ports, thus the temperature of the propellant gas can be controlled from ∼700 to 2,000 K. Since WS allows for higher particle temperatures in comparison to cold spray, warm sprayed particles are more softened upon impact, thus resulting in greater deformation facilitating the formation of shear instability for bonding. Recently, the combustion pressure of WS has been increased from 1 (low-pressure warm spray) to 4 MPa (high-pressure warm spray) in order to increase the velocity of sprayed particles. Effects of spray parameters on microstructure, mechanical properties, and splats formation of Ti-6Al-4V were systematically studied. Obtained coatings were examined by analyzing the coating cross-section images, microhardness as well as oxygen content. In addition, flattening ratio of splats was calculated as a function of nitrogen flow rate. It was found that the increased particle velocity caused by the increased combustion pressure had significant beneficial effects in terms of improving density and controlling the oxygen level in the sprayed Ti-6Al-4V coatings.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt de métaux et d'alliages, Metallic coatings, Propriétés mécaniques. Rhéologie. Mécanique de la rupture. Tribologie, Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology, Frottement. Usure, Contact of materials. Friction. Wear, Propriété mécanique, Mechanical properties, Propiedad mecánica, Adhérence, Adhesion, Adherencia, Adhaesion, Application, Aplicación, Anwendung, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Erosion, Erosión, Force adhérence, Adhesive strength, Fuerza adherencia, Haftfestigkeit, Plasma, Projection plasma, Plasma spraying, Proyección plasma, Plasmaspritzen, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement métallique, Metal coating, Revestimiento metálico, Metallischer Ueberzug, Résistance mécanique, Strength, Resistencia mecánica, Festigkeit, Résistance usure, Wear resistance, Resistencia al desgaste, Verschleissfestigkeit, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Tribologie, Tribology, Tribología, Turbine gaz, Gas turbine, Turbina gas, Gasturbine, Usure, Wear, Desgaste, Verschleiss, MCrAlY, abradable coating, adhesive strength, atmospheric plasma spray (APS), erosion resistance, gas turbines, and rubbing wear

The processing conditions, microstructural and tribological characterizations of plasma-sprayed CoNiCrAlY-BN high temperature abradable coatings are reported in this manuscript. Plasma spray torch parameters were varied to produce a set of abradable coatings exhibiting a broad range of porosity levels (34-62%) and superficial Rockwell hardness values (0-78 HR15Y). Abradability tests have been performed using an abradable-seal test rig, capable of simulating operational wear at different rotor speeds and seal incursion rates (SIRs). These tests allowed determining the rubbing forces and quantifying the blade and seal wear characteristics for slow and fast SIRs. Erosion wear performance and ASTM C633 coating adhesion strength test results are also reported. For optimal abradability performance, it is shown that coating hardness needs to be lower than 70 and 50 HR15Y for slow and fast blade incursion rate conditions, respectively. It is shown that the erosion wear performance, as well as, the coating cohesive strength is a function of the coating hardness. The current results allow defining the coating specifications in terms of hardness and porosity for targeted applications.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Techniques de l'ingénieur appliqués à la métallurgie. Applications. Divers, Engineering techniques in metallurgy. Applications. Other aspects, Applications, Industrie automobile, Automotive engineering, Adhérence, Adhesion, Adherencia, Adhaesion, Application, Aplicación, Anwendung, Force adhérence, Adhesive strength, Fuerza adherencia, Haftfestigkeit, Industrie automobile, Automobile industry, Industria automóvil, Autoindustrie, Industrie aéronautique, Aeronautic industry, Industria aeronáutica, Luftfahrtindustrie, Morphologie, Morphology, Morfología, Plasma, Projection plasma, Plasma spraying, Proyección plasma, Plasmaspritzen, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement conducteur, Conductive coating, Revestimiento conductor, Résistance mécanique, Strength, Resistencia mecánica, Festigkeit, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Adhesion testing, aircraft, atmospheric plasma spray (APS), automotive, copper, and electrically conductive coatings

Metallization of Carbon Fiber-Reinforced Polymer (CFRP) composites aggrandized their application to aircraft, automobile, and wind power industries. Recently, the metallization of CFRP surface using thermal spray technique, especially the cold spray, a solid state deposition technique, is a topic of research. However, a direct cold spray deposition on the CFRP substrate often imposes severe erosion on the surface owing to the high-impact energy of the sprayed particles. This urges the requirement of an interlayer on the CFRP surface. In the present study, the effect of surface treatment on the interlayer adhesion strength is evaluated. The CFRP samples were initially treated mechanically, chemically, and thermally and then an interlayer was developed by atmospheric plasma spray system. The quality of the coating is highly dependent on the splat taxonomy; therefore the present work also devoted to study the splat formation behavior using the splat-collection experiments, where the molten Cu particles impinged on the treated CFRP substrates. These results were correlated with the coating adhesion strength. The coating adhesion strength was measured by pull-out test. The results showed that the surface treatment, particularly the chemical treatment, was fairly successful in improving the adhesion strength.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Propriétés mécaniques. Rhéologie. Mécanique de la rupture. Tribologie, Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology, Adhérence, Adhesion, Adherencia, Adhaesion, Alumine, Alumina, Alúmina, Tonerde, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Haute résolution, High resolution, Alta resolucion, Microscopie électronique transmission, Transmission electron microscopy, Microscopía electrónica transmisión, Transmissionselektronenmikroskopie, Mécanisme formation, Formation mechanism, Mecanismo formacion, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Propriété mécanique, Mechanical properties, Propiedad mecánica, Propriété traction, Tensile property, Propiedad tracción, Zugeigenschaft, Revêtement, Coatings, Revestimiento, Ueberzug, Résistance mécanique, Strength, Resistencia mecánica, Festigkeit, Résistance traction, Tensile strength, Resistencia tracción, Zugfestigkeit, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, HRTEM, adhesion, alumina, aluminum, cold gas spraying (CGS), and tensile strength

The metallization of ceramics by means of cold gas spraying (CGS) has been in the focus of numerous publications in the recent past. However, the bonding mechanism of metallic coatings on non-ductile substrates is still not fully understood. Former investigations of titanium coatings deposited on corundum revealed that a combination of recrystallization induced by adiabatic shear processes and hetero-epitaxial growth might be responsible for the high adhesion strengths of coatings applied on smooth ceramic surfaces. In the present work, the interface formation between CGS aluminum and alumina substrates is examined for different particle sizes and substrate temperatures. Furthermore, the influence of subsequent heat treatment on tensile strength and hardness is investigated. The splat formation of single particles is examined by means of scanning electron microscopy, while a high resolution transmission electron microscope is used to study the Al/Al2O3 interface. First results suggest that mechanical interlocking is the primary adhesion mechanism on polycrystalline substrates having the roughness in sub-micrometer range, while the heteroepitaxy between Al and Al2O3 can be considered as the main bonding mechanism for single-crystalline sapphire (α-Al2O3) substrates with the surface roughness in nanometer range. The heteroepitaxial growth is facilitated by deformation-induced recrystallisation of CGS aluminum.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Carbure de tungstène, Tungsten carbide, Wolframio carburo, Wolframcarbid, Carbure fritté, Cemented carbides, Carburo sinterizado, Hartmetall, Cobalt, Cobalto, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Ecaillage, Scaling, Escamadura, Nanostructure, Nanoestructura, Poudre fine, Fine powder, Polvo fino, Projection HVOF, HVOF spraying, Proyeccion HVOF, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement, Coatings, Revestimiento, Ueberzug, Résistance usure, Wear resistance, Resistencia al desgaste, Verschleissfestigkeit, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Tribologie, Tribology, Tribología, Usure glissement, Sliding wear, Desgaste deslizamiento, Gleitverschleiss, Usure roulement, Rolling wear, Desgaste rodadura, Waelzverschleiss, Fine structured coatings, HVOF, Nanostructured coatings, Scaling effects, WC-Co, Wear effects, Wear resistant coatings, and Wear testing

Fine structured and nanostructured materials represent a promising class of feedstock for future applications, which has also attracted increasing interest in the thermal spray technology. Within the field of wear protection, the application of fine structured or nanostructured WC-Co powders in the High Velocity Oxy-Fuel flame spraying technique (HVOF) provides novel possibilities for the manufacturing of cermet coatings with improved mechanical and tribological characteristics. In this study the tribological behavior of HVOF sprayed coatings derived from conventional, fine and nanostructured WC-12Co powders under sliding and rolling wear are investigated and the results are compared to C45 steel (Mat.-No. 1.0503). In addition, sliding and rolling wear effects on a microscopic level are scrutinized. It has been shown that under optimized spray conditions the corresponding fine and nanostructured WC-12Co coatings are able to obtain higher wear resistances and lower friction coefficients than the conventional coatings. This can be attributed to several scaling effects of the microstructure and to the phase evolution of the coating, which are discussed.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Propriétés mécaniques. Rhéologie. Mécanique de la rupture. Tribologie, Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Condition opératoire, Operating conditions, Condición operatoria, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Grosseur grain, Grain size, Grosor grano, Korngroesse, Microstructure, Microestructura, Mikrogefuege, Nanocomposite, Nanocompuesto, Propriété mécanique, Mechanical properties, Propiedad mecánica, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, cold spray, mechanical properties, microstructural behavior, nanocomposites, and processing parameters

Cold spray is a coating technology based on aerodynamics and high-speed impact dynamics. In this process, spray particles (usually 1-50 μm in diameter) are accelerated to a high velocity (typically 300-1200 m/s) by a high-speed gas (pre-heated air, nitrogen, or helium) flow that is generated through a convergent-divergent de Laval-type nozzle. A coating is formed through the intensive plastic deformation of particles impacting on a substrate at a temperature below the melting point of the spray material. In the present paper the main processing parameters affecting the microstructural and mechanical behavior of metal-metal cold spray deposits are described. The effect of process parameters on grain refinement and mechanical properties were analyzed for composite particles of Al-Al2O3, Ni-BN, Cu-Al2O3, and Co-SiC. The properties of the formed nanocomposites were compared with those of the parent materials sprayed under the same conditions. The process conditions, leading to a strong grain refinement with an acceptable level of the deposit mechanical properties such as porosity and adhesion strength, are discussed.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Modélisation, Modeling, Modelización, Prédiction, Prediction, Predicción, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Transfert chaleur, Heat transfer, Transferencia térmica, Waermeuebertragung, Vitesse, Velocity, Velocidad, cold spray, heat transfer, numerical model, and particle velocity

In cold spraying (CS), critical velocity of particles is one of the most important parameters. The impacting particle and substrate inevitably undergo a strong thermomechanical coupling process at the contacting interface and serious plastic deformation in a very short time. In this paper, a coupled thermomechanical Eulerian (CTM-Eulerian) model was, for the first time, developed for CS particles to investigate plastic deformation and heat conduction within the bulk, and to predict the critical velocity. Results show that heat conduction has a significant effect on the temperature distribution within the particle which will influence the atom diffusion at the impacting interface, while a little influence on plastic deformation. Moreover, based on the deformed particle shapes and plastic strain analysis, a calculated critical velocity of about 300 m/s for copper is obtained. Finally, this CTM-Eulerian model is extended to other commonly sprayed materials and the predicted critical velocities of Fe, Ni, SS304, Al, In718, and TC4 are about 350, 380, 395, 410, 490, and 500 m/s, respectively.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Physique, Physics, Domaines interdisciplinaires: science des materiaux; rheologie, Cross-disciplinary physics: materials science; rheology, Science des matériaux, Materials science, Méthodes de dépôt de films et de revêtements; croissance de films et épitaxie, Methods of deposition of films and coatings; film growth and epitaxy, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Couche mince, Thin film, Capa fina, Duennschicht, Dépôt phase vapeur, Vapor deposition, Depósito fase vapor, Aufdampfen, Dépôt physique phase vapeur, Physical vapor deposition, Deposición física fase vapor, Physikalisches Aufdampfen, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Membrane, Membrana, Membran, Perovskite, Perovskita, Plasma, Projection plasma, Plasma spraying, Proyección plasma, Plasmaspritzen, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, oxygen transport membrane, perovskite La1-xSrxCoyFe1-yO3-δ, plasma spray physical vapor deposition, porous metallic support, and thin films

Plasma spray physical vapor deposition (PS-PVD) is a very promising route to manufacture ceramic coatings, combining the efficiency of thermal spray processes and characteristic features of thin PVD coatings. Recently, this technique has been investigated to effectively deposit dense thin films of perovskites particularly with the composition of La0.58Sr0.4Co0.2Fe0.8O3-δ (LSCF) for application in gas separation membranes. Furthermore, asymmetric type of membranes with porous metallic supports has also attracted research attention due to the advantage of good mechanical properties suitable for use at high temperatures and high permeation rates. In this work, both approaches are combined to manufacture oxygen transport membranes made of gastight LSCF thin film by PS-PVD on porous NiCoCrAlY metallic supports. The deposition of homogenous dense thin film is challenged by the tendency of LSCF to decompose during thermal spray processes, irregular surface profile of the porous metallic substrate and crack and pore-formation in typical ceramic thermal spray coatings. Microstructure formation and coating build-up during PS-PVD as well as the annealing behavior at different temperatures of LSCF thin films were investigated. Finally, measurements of leak rates and oxygen permeation rates at elevated temperatures show promising results for the optimized membranes.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Activité catalytique, Catalyst activity, Actividad catalítica, Anatase, Anatasa, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Eau usée, Waste water, Agua residual, Abwasser, Nanostructure, Nanoestructura, Oxyde de titane, Titanium oxide, Titanio óxido, Titanoxid, Revêtement, Coatings, Revestimiento, Ueberzug, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, cold gas spray, nanostructured TiO2 powder, photocatalysis, and wastewater

This article describes a photocatalytic nanostructured anatase coating deposited by cold gas spray (CGS) supported on titanium sub-oxide (TiO2-x) coatings obtained by atmospheric plasma spray (APS) onto stainless steel cylinders. The photocatalytic coating was homogeneous and preserved the composition and nanostructure of the starting powder. The inner titanium sub-oxide coating favored the deposition of anatase particles in the solid state. Agglomerated nano-TiO2 particles fragmented when impacting onto the hard surface of the APS TiO2-x bond coat. The rough surface provided by APS provided an ideal scenario for entrapping the nanostructured particles, which may be adhered onto the bond coat due to chemical bonding; a possible bonding mechanism is described. Photocatalytic experiments showed that CGS nano-TiO2 coating was active for photodegrading phenol and formic acid under aqueous conditions. The results were similar to the performance obtained by competitor technologies and materials such as dip-coating P25® photocatalysts. Disparity in the final performance of the photoactive materials may have been caused by differences in grain size and the crystalline composition of titanium dioxide.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Activité catalytique, Catalyst activity, Actividad catalítica, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Nanocomposite, Nanocompuesto, Oxyde de titane, Titanium oxide, Titanio óxido, Titanoxid, Projection HVOF, HVOF spraying, Proyeccion HVOF, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement, Coatings, Revestimiento, Ueberzug, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, HVOF, TiO2, nanocomposite structure, photocatalysis, photocatalytic activity, rhodamine B, and suspension

Photocatalytic properties of titania have been studied very intensively for a variety of applications, including air and water purification. In order to clarify the influence of the phase composition and other parameters, thermal spraying with suspensions was applied to produce photocatalytically active titania coatings starting from two commercially available anatase and rutile submicron powders. Aqueous suspensions containing 40% solids by weight were sprayed with an HVOF process using ethylene as the fuel gas. The spray parameters were chosen in order to produce mechanically stable coatings and to preserve a high content of the initial crystalline phases of the powders. The coating microstructures, phase compositions, and surface properties were characterized. The photocatalytic performance was evaluated by degradation of the pink dye Rhodamine B (RB) using two techniques: degradation of an aqueous solution of RB and discoloration of impregnated RB. All the coatings exhibited photocatalytic activity to varying degrees, depending on the phase composition as well as other factors, namely, the coating microstructure, surface morphology, surface hydroxylation, light absorption, and interaction with the pollutant.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Fabrication, Manufacturing, Fabricación, Fertigung, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, cold spray, diagnostic, energetic materials, and nano composites

It has been shown that the cold-gas dynamic spraying process, or simply cold spray, is a suitable technique to manufacture nanoscale energetic materials with high reactivity and low porosity. The current study focuses on the Ni-Al system, for which the reactivity has been increased by an initial mechanical activation achieved by the ball-milling technique, leading to lamellar nanostructured composite particles. The consolidation of this nanoscale energetic material using the cold-gas dynamic spray technique permits to retain the feedstock powder nanoscale structure in the coatings, which in turn retain the high reactivity features of the powder. However, it has been noticed that the stagnation temperature during the spray can lead to partial reaction of the highly reactive feedstock powder, which directly influences the reactivity of the coatings. In this study, different stages of the spray process were investigated: (i) the in-flight behavior of the nanoscale energetic material (powder) at different stagnation temperatures (from 300 to 800 °C); (ii) the substrate-temperature evolution as the function of gas temperature; and (iii) the impact of the powder on the substrate, related to particle's velocity and its influence on the nanostructure of the particles.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt de matériaux non métalliques, Nonmetallic coatings, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Apatite hydroxylée, Hydroxyapatite, Hidroxiapatito, Application médicale, Medical application, Aplicación medical, Medizinische Technik, Biomatériau, Biomaterial, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Microstructure, Microestructura, Mikrogefuege, Nanocomposite, Nanocompuesto, Nanostructure, Nanoestructura, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement composite, Composite coating, Revestimiento compuesto, Revêtement non métallique, Non metal coating, Revestimiento no metálico, Nichtmetallischer Ueberzug, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, graphene-nanosheet, hydroxyapatite, microstructure, nanocomposite coatings, and vacuum cold spray

Development of novel biocompatible nanomaterials has provided insights into their potential biomedical applications. Bulk fabrication of the nanomaterials in the form of coatings remains challenging. Here, we report hydroxyapatite (HA)/graphene-nanosheet (GN) composite coatings deposited by vacuum cold spray (VCS). Significant shape changes of HA nanograins during the coating deposition were revealed. The nanostructural features of HA together with curvature alternation of GN gave rise to dense structures. Based on the microstructural characterization, a structure model was proposed to elucidate the nanostructural characteristics of the HA-GN nanocomposites. Results also showed that addition of GN significantly enhanced fracture toughness and elastic modulus of the HA-based coatings, which is presumably accounted for by crack bridging offered by GN in the composites. The VCS HA-GN coatings show potential for biomedical applications for the repair or replacement of hard tissues.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Dépôt de matériaux non métalliques, Nonmetallic coatings, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Barrière thermique, Thermal barrier, Barrera térmica, Lanthanide, Lantánido, Nanocomposite, Nanocompuesto, Plasma, Projection plasma, Plasma spraying, Proyección plasma, Plasmaspritzen, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement composite, Composite coating, Revestimiento compuesto, Revêtement non métallique, Non metal coating, Revestimiento no metálico, Nichtmetallischer Ueberzug, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Zirconate, Zirconates, Zirconato, lanthanum zirconate, suspension plasma spray, and thermal barrier coating

This work seeks to develop an innovative nanocomposite thermal barrier coating (TBC) exhibiting low thermal conductivity and high durability compared with that of current TBCs. To achieve this objective, nanosized lanthanum zirconate particles were selected for the topcoat of the TBC system, and a new process—suspension plasma spray—was employed to produce desirable microstructural features: the nanocomposite lanthanum zirconate TBC contains ultrafine splats and high volume porosity, for lower thermal conductivity, and better durability. The parameters of plasma spray experiment included two main variables: (i) spray distance varying from 40 to 80 mm and (ii) the concentration of suspension 20, 25, and 30 wt.%, respectively. The microstructure of obtained coatings was characterized with scanning electron microscope and x-ray diffraction. The porosity of coatings is in the range of 6-10%, and the single phase in the as-sprayed coatings was pyrochlore lanthanum zirconate.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Composé intermétallique, Intermetallic compound, Compuesto intermetálico, Intermetallische Verbindung, Nanocomposite, Nanocompuesto, Nanocristal, Nanocrystal, Projection détonation, Detonation spraying, Proyección detonación, Flammschockspritzen, Revêtement composite, Composite coating, Revestimiento compuesto, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Gas detonation spraying, multiphase nanocomposite coating (based on FeAl), and nanocrystalline self-decomposing powder

The nanocomposite structure of Fe-Al intermetallic coating, created in situ during gas detonation spraying (GDS) of as-milled self-decomposing powder and containing disordered 8 nm FeAl nanocrystals, was analyzed using scanning electron microscopy (SEM) with energy-dispersive x-ray (EDX) spectroscopy, transmission electron microscopy (TEM), selected-area electron diffraction (SAED), and x-ray diffraction methods. It is found that the Fe-Al coating is characterized by a sublayer morphology consisting of flattened and partially melted splats containing a wide Al range from about 26 to 52 at.%, as well as Al2O3 oxides, created in situ at the internal interfaces of splats during the GDS process. The complex oxide films, identified as amorphous Al2O3, which are formed in the nanocrystalline Fe-Al matrix of the GDS coating behave like a composite reinforcement in the intermetallic Fe-Al coating. The combined presence of nanosized subgrains in the Fe-Al matrix and the Al2O3 nanoceramic dispersoids significantly increases the microhardness of the coating.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Métallurgie des poudres. Matériaux composites, Powder metallurgy. Composite materials, Métaux renforcés par dispersion, Dispersion hardening metals, Traitements de surface, Surface treatment, Acier inoxydable 304, Stainless steel-304, Acier inoxydable austénitique, Austenitic stainless steel, Acero inoxidable austenítico, Austenitischer nichtrostender Stahl, Acier inoxydable, Stainless steel, Acero inoxidable, Nichtrostender Stahl, Borure, Borides, Boruro, Borid, Dépôt laser, Laser deposition, Depósito laser, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Fusion laser, Laser fusion, Fusión láser, Laser, Láser, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Microdureté, Microhardness, Microdureza, Mikrohaerte, Microstructure, Microestructura, Mikrogefuege, Métal renforcé dispersion, Dispersion strengthened metal, Metal reforzado dispersión, Dispersionsgehaertetes Metall, Projection HVOF, HVOF spraying, Proyeccion HVOF, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement composite, Composite coating, Revestimiento compuesto, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, laser melting, microhardness, microstructure, nano-boride, and nano-silicide

The study concerned a detailed microstructural investigation of nano-borides (Cr2B and Ni3B) and nano-silicide (Ni2Si) dispersed γ-nickel composite coating on AISI 304 stainless steel by HVOF spray deposition of the NiCrBSi precursor powder and subsequent laser surface melting. A continuous wave diode laser with an applied power of 3 kW and scan speed of 20 mm/s in argon shroud was employed. The characterization of the surface in terms of microstructure, microtexture, phases, and composition were carried out and compared with the as-coated (high-velocity oxy-fuel sprayed) surface. Laser surface melting led to homogenization and refinement of microstructures with the formation of few nanosilicides of nickel along with nano-borides of nickel and chromium (Ni3B, Cr2B, and Cr2B3). A detailed microtexture analysis showed the presence of no specific texture in the as-sprayed and laser-melted surface of Cr2B and Ni3B phases. The average microhardness was improved to 750-900 VHN as compared to 250 VHN of the as-received substrate. Laser surface melting improved the microhardness further to as high as 1400 VHN due to refinement of microstructure and the presence of silicides.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, A froid, Cold process, En frío, Basse pression, Low pressure, Baja presión, Niederdruck, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Epaisseur, Thickness, Espesor, Dicke, Formage à froid, Cold forming, Modelado en frio, Kaltformgeben, Procédé dépôt, Deposition process, Procedimiento revestimiento, Beschichtungsverfahren, Projection à chaud, Hot spraying, Proyección en caliente, Spritzen, Revêtement conducteur, Conductive coating, Revestimiento conductor, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, cold spray, copper, electrically conductive coatings, and thickness

Most of the existing multi-response optimization approaches focus on the subjective and practical know-how of the process. As a result, some confusion and uncertainty are introduced in the overall decision-making process. In this work, an approach based on a Utility theory and Taguchi quality loss function has been applied to the process parameters for low-pressure cold spray process deposition of copper coatings, for simultaneous optimization of more than one response characteristics. In the present paper, two potential response parameters, i.e., coating thickness and coating density, have been selected. Utility values based on these response parameters have been analyzed for optimization using the Taguchi approach. The selected input parameters of powder feeding arrangement, substrate material, air stagnation pressure, air stagnation temperature, and stand-off distance significantly improve the Utility function (raw data) comprising quality characteristics (coating thickness and coating density). The percentage contribution of the parameters to achieve a higher value of Utility function is substrate material (50.03%), stand-off distance (28.87%), air stagnation pressure (6.41%), powder feeding arrangement (4.68%), and air stagnation temperature (2.64%).

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Basse température, Low temperature, Baja temperatura, Tieftemperatur, Ecoulement, Flow(fluid), Flujo, Fluide Stroemung, Modélisation, Modeling, Modelización, Simulation, Simulación, Température, Temperature, Temperatura, Temperatur, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Transfert chaleur, Heat transfer, Transferencia térmica, Waermeuebertragung, fluid flow and heat transfer, low-temperature oxygen-fuel spray, particles behavior, and simulation

The low-temperature oxygen-fuel (LTOF) spray is a modification of high velocity oxygen fuel spray. In this process, the high-temperature gas is accelerated to supersonic speed through a Laval nozzle followed by a straight barrel. By injecting room temperature gas into the mixing chamber, the temperature of the gas can be controlled in a range of about 1000-2500 K, so that some oxygen and temperature-sensitive materials, such as titanium and copper, can avoid oxidation or decomposition during the spraying process. The purpose of this paper is to establish a 2-D mathematical model to simulate the supersonic gas dynamics and particles behavior in LTOF process. The temperature and velocity of the flow fields, and the trajectory and heating of in-flight particles are predicted for different operating parameters. The model is validated by experimental data in the literature. Effects of the mixing gas flow rates, particle sizes, and injection conditions on this process were investigated as well.

Metallurgy, welding, Métallurgie, soudage, Sciences exactes et technologie, Exact sciences and technology, Sciences appliquees, Applied sciences, Metaux. Metallurgie, Metals. Metallurgy, Transformation de matériaux métalliques, Production techniques, Traitements de surface, Surface treatment, Propriétés mécaniques. Rhéologie. Mécanique de la rupture. Tribologie, Mechanical properties and methods of testing. Rheology. Fracture mechanics. Tribology, Matériau composite, Composite material, Material compuesto, Verbundwerkstoff, Abrasif, Abrasives, Abrasivo, Schleifmittel, Alliage base nickel, Nickel base alloys, Dépôt projection, Spray coating, Depósito proyección, Spritzbeschichten, Microstructure, Microestructura, Mikrogefuege, Nanocomposite, Nanocompuesto, Propriété mécanique, Mechanical properties, Propiedad mecánica, Revêtement composite, Composite coating, Revestimiento compuesto, Traitement surface, Surface treatment, Tratamiento superficie, Oberflaechenbehandlung, Tribologie, Tribology, Tribología, Usure abrasive, Abrasive wear, Desgaste abrasivo, Abrasivverschleiss, abrasive wear behavior, cBN-NiCrAl, cold spray, mechanical properties, microstructure, and nanocomposite

20 vol.% cubic boron nitride (cBN) dispersoid reinforced NiCrAl matrix nanocomposite coating was prepared by cold spray using mechanically alloyed nanostructured composite powders. The as-sprayed nanocomposite coating was annealed at a temperature of 750 °C to enhance the inter-particle bonding. Microstructure of spray powders and coatings was characterized. Vickers microhardness of the coatings was measured. Two-body abrasive wear behavior of the coatings was examined on a pin-on-disk test. It was found that, in mechanically alloyed composite powders, nano-sized and submicro-sized cBN particles are uniformly distributed in nanocrystalline NiCrAl matrix. Dense coating was deposited by cold spray at a gas temperature of 650 °C with the same phases and grain size as those of the starting powder. Vickers hardness test yielded a hardness of 1063 HV for the as-sprayed 20 vol.% cBN-NiCrAl coating. After annealed at 750 °C for 5 h, unbonded inter-particle boundaries were partially healed and evident grain growth of nanocrystalline NiCrAl was avoided. Wear resistance of the as-sprayed 20 vol.% cBN-NiCrAl nanocomposite coating was comparable to the HVOF-sprayed WC-12Co coating. Annealing of the nanocomposite coating resulted in the improvement of wear resistance by a factor of ∼33% owing to the enhanced inter-particle bonding. Main material removal mechanisms during the abrasive wear are also discussed.