Materials Literature
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Abstract This study aims to better understand stress fields in composite coatings produced by plasma spraying. To that end, Al2O3-TiO2 coatings are deposited under conditions that result in architectures differing in pore content, crack density, and crack orientation. SEM images of the coatings are divided into discre…
Abstract This work investigates some of the unique properties that can be achieved by combining materials with positive and negative thermal expansion coefficients. In the experiments, different mixtures of MCrAlY, WO3, and Y2O3 powders are deposited on stainless steel substrates by laser cladding and HVOF spraying. T…
Abstract Recently, an advanced technique was developed to fabricate sandwich structures for high temperature applications by depositing alloy 625 skins on Ni alloy foam core by thermal spraying. This study tries to utilize an analytical model to estimate the mechanical performance of these structures based on the mech…
Abstract This study compares the deposition behavior of kinetic sprayed bronze-diamond composite coatings produced using different mixtures of helium and nitrogen gas. To determine impact properties of the diamond particles, bare and nickel-coated diamonds are deposited on bronze layers and the effects of plastic defo…
Abstract This paper presents a way of processing cold-sprayed Ti-Al to produce titanium aluminum nitride coatings. These coatings are meant to serve as a durable protective layer on tools exposed to molten aluminum alloys. A Ti-Al powder mixture with a weight ratio of 70/30 was cold sprayed onto specially prepared sub…
Abstract This study evaluates the potential of functionally graded composite coatings fabricated with a novel spraying process. The hybrid process embeds varying amounts of ceramic particles in a metal matrix by combining HVOF and wire arc spray streams. In this case, ceramic nanoparticles (SiO2, Cr2O3, Al2O3) from li…
Abstract This paper presents a method, based on push-rod type thermomechanical analysis, for determining the thermal expansion behavior of thermal barrier coatings (TBCs). It shows that TMA measurements can provide accurate CTEs for yttria-stabilized zirconia layers as thin as 0.3 mm with good reproducibility and low…
Abstract Plasma-sprayed yttria-stabilized zirconia (YSZ) can be potentially employed as electrolyte coating in solid oxide fuel cells (SOFCs). The formation of a convex coating surface with semi-melted particles will increase the specific surface area and subsequently improve the output performance of SOFCs. However,…
Abstract Changes in phase composition of titania (TiO2) coatings were studied with respect to in-flight particle characteristics during atmospheric plasma spraying. A CCD camera was used to record the average temperature and velocity of TiO2 particles within the plasma jet for six combinations of spraying parameters s…
Abstract This paper discusses the double-arc phenomenon that occurs in plasma arc spraying and its prevention through the use of a bi-anode torch. It also presents the results of a study that compares voltage-current characteristics of the arc for different plasma gases and arc root attachment points. It is shown that…
Abstract This paper reviews some of the tools used to characterize the pore microstructure of thermally sprayed thermal barrier coatings. It describes the capabilities of optical and SEM analysis, intrusion porosimetry, high-flux X-ray and neutron imaging, small-angle scattering, and X-ray microtomography. It explains…
Abstract In this study, WC-12Co powders with multimodal-sized WC particles were prepared by ball milling and deposited onto stainless steel substrates by cold spraying. Microhardness and fracture toughness were measured on cross-sections by the indentation approach. Coatings produced from powders with small carbide pa…
Abstract In this study, molecular dynamic simulations are used to analyze the effect of dopant concentration on the performance and stability of zirconia-based solid electrolyte. Different amounts of Sc2O3 are diffused into the YSZ system to simulate various Sc-Y-SZ electrolyte compositions for analysis. The calculati…
Abstract A noncryogenic milling process was recently developed to produce equiaxed nanostructured NiCrAlY powders. In this study, the powders are used to deposit metal bond coats, with and without thermal barrier topcoats, via HVOF and low-pressure plasma spraying. TBCs with bond coats derived from non-cryogenically m…
Abstract This study shows that surface preheating is required to avoid delamination of flame sprayed coating glazes. In the experiments, preheating parameters are determined from heat flux measurements and potential substrate degradation is characterized and controlled by optimizing spray parameters. Coating adhesion…
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 efficien…
Abstract Thermal spray coatings have been applied on furnace rolls in continuous annealing lines to improve product quality and prolong roll service life. The most common defects formed on working furnace rolls are oxide pickups. In this study, HVOF sprayed cermet coatings are used to duplicate pickups by reacting wit…
Abstract In this investigation, carbon nanotube (CNT) aluminum composite coatings are produced by kinetic spraying. Electrical and mechanical properties are evaluated and compared with those of cold-sprayed pure aluminum coatings. The CNT aluminum composite coatings exhibited higher conductivity and hardness than the…
Abstract Aluminum-based composite coatings reinforced with different volume fractions of SiC particles were deposited on aluminum substrates by means of pulsed gas dynamic spraying using a mechanically mixed composite feedstock powder. Microstructural features of the coatings are examined and their hardness is reporte…
Abstract This paper describes the properties and behaviors of alumina and titania coatings that have recently been produced using suspension spraying techniques. It examines coating microstructures and phase compositions are shows how they are influenced by different operating parameters and interactions. A selection…