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Advances in Thermal Spray Technology
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Advances in Thermal Spray Technology

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (30 April 2020) | Viewed by 44931

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editor

Prof. Dr. Shrikant Joshi

E-Mail Website
Guest Editor
Department of Engineering Science, University West, Trollhättan, Sweden
Interests: suspension and solution plasma spraying; HVAF spraying; thermal barrier coatings; coatings for wear and corrosion; additive manufacturing; electron beam melting; laser metal deposition; post-treatment
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Thermal spray technology is already widely adopted industrially to deposit different kinds of coatings (metallic, intermetallic, ceramic, and their combinations) for combating diverse forms of surface degradation caused by wear, corrosion, oxidation, high thermal load, etc. Nonetheless, additional improvements in coating quality are incessantly sought in order to further enhance the durability and performance of components that routinely operate in increasingly aggressive environments. In recent years, this search for superior coating performance has led to wide-ranging technological advancements on various fronts, spanning feedstock materials, process variants, torch designs, coating architectures, etc. The above developments have also been complemented by the availability of significantly improved diagnostic tools and reliable control systems, as well as by a much improved process understanding through a blend of sophisticated coating characterization and modelling studies. The net result has been the realization of extremely robust and highly repeatable shop-floor thermal spray capabilities to consolidate the existing applications and spur new ones.

The proposed Special Issue of Material seeks to showcase some of the above developments. Contributions are particularly invited from, but not limited to, those of you who are actively involved in: (i) development and/or utilization of relatively new thermal spray processes such as SPS, SPPS, HVAF, Cold spray, etc; (ii) evolution of new torch designs; (iii) new concepts for feedstock, in terms of both material chemistry and delivery, including powder–liquid hybrids; (iv) advanced characterization of coatings; (v) novel approaches for in-flight diagnostics; (vi) modelling of gas–droplet and droplet–substrate interactions; (vii) assessment of coatings for new application domains.

Prof. Shrikant Joshi
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Suspension plasma spray (SPS)
  • Solution precursor plasma spray (SPPS)
  • Suspension High-velocity oxy-fuel (S-HVOF) spray
  • High-velocity air-fuel (HVAF) spray
  • Cold spray
  • Hybrid spray
  • Thermal spray modeling
  • Torch design
  • Liquid feedstock
  • Diagnostics
  • Applications

Published Papers (13 papers)

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Editorial

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3 pages, 162 KiB  
Editorial
Special Issue: Advances in Thermal Spray Technology
by Shrikant Joshi
Materials 2020, 13(16), 3521; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13163521 - 10 Aug 2020
Cited by 4 | Viewed by 2022
Abstract
Coatings deposited utilizing different thermal spray variants have been widely used for diverse industrial applications [...] Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)

Research

Jump to: Editorial, Other

21 pages, 19767 KiB  
Article
A Study on the Microstructural Characterization and Phase Compositions of Thermally Sprayed Al2O3-TiO2 Coatings Obtained from Powders and Water-Based Suspensions
by Monika Michalak, Filofteia-Laura Toma, Leszek Latka, Pawel Sokolowski, Maria Barbosa and Andrzej Ambroziak
Materials 2020, 13(11), 2638; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13112638 - 09 Jun 2020
Cited by 14 | Viewed by 2712
Abstract
In this work, the alumina (Al2O3) and alumina-titania coatings with different contents of TiO2, i.e., Al2O3 + 13 wt.% TiO2 and Al2O3 + 40 wt.% TiO2, were studied. [...] Read more.
In this work, the alumina (Al2O3) and alumina-titania coatings with different contents of TiO2, i.e., Al2O3 + 13 wt.% TiO2 and Al2O3 + 40 wt.% TiO2, were studied. The coatings were produced by means of powder and liquid feedstock thermal spray processes, namely atmospheric plasma spraying (APS), suspension plasma spraying (SPS) and suspension high-velocity oxygen fuel spraying (S-HVOF). The aim of the study was to investigate the influence of spray feedstocks characteristics and spray processes on the coating morphology, microstructure and phase composition. The results revealed that the microstructural features were clearly related both to the spray processes and chemical composition of feedstocks. In terms of phase composition, in Al2O3 (AT0) and Al2O3 + 13 wt.% TiO2 (AT13) coatings, the decrease in α-Al2O3, which partially transformed into γ-Al2O3, was the dominant change. The increased content of TiO2 to 40 wt.% (AT40) involved also an increase in phases related to the binary system Al2O3-TiO2 (Al2TiO5 and Al2−xTi1+xO5). The obtained results confirmed that desired α-Al2O3 or α-Al2O3, together with rutile-TiO2 phases, may be preserved more easily in alumina-titania coatings sprayed by liquid feedstocks. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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11 pages, 4155 KiB  
Article
Impact Wear of the Protective Cr3C2-Based HVOF-Sprayed Coatings
by Josef Daniel, Jan Grossman, Šárka Houdková and Martin Bystrianský
Materials 2020, 13(9), 2132; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13092132 - 04 May 2020
Cited by 14 | Viewed by 2294
Abstract
High velocity oxygen-fuel (HVOF) prepared CrC-based hardmetal coatings are generally known for their superior wear, corrosion, and oxidation resistance. These properties make this coating attractive for application in industry. However, under some loading conditions and in aggressive environments, the most commonly used NiCr [...] Read more.
High velocity oxygen-fuel (HVOF) prepared CrC-based hardmetal coatings are generally known for their superior wear, corrosion, and oxidation resistance. These properties make this coating attractive for application in industry. However, under some loading conditions and in aggressive environments, the most commonly used NiCr matrix is not sufficient. The study is focused on the evaluation of dynamic impact wear of the HVOF-sprayed Cr3C2-25%NiCr and Cr3C2-50%NiCrMoNb coatings. Both coatings were tested by an impact tester with a wide range of impact loads. The Wohler-like dependence was determined for both coatings’ materials. It was shown that, due to the different microstructure and higher amount of tough matrix, the impact lifetime of the Cr3C2-50%NiCrMoNb coating was higher than the lifetime of the Cr3C2-25%NiCr coating. Differences in the behavior of the coatings were the most pronounced at high impact loads. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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10 pages, 3612 KiB  
Article
Tribocorrosion Properties of NiCrAlY Coating in Different Corrosive Environments
by Bo Li, Yimin Gao, Cong Li, Hongjian Guo, Qiaoling Zheng, Yefei Li, Yunchuan Kang and Siyong Zhao
Materials 2020, 13(8), 1864; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13081864 - 16 Apr 2020
Cited by 16 | Viewed by 2656
Abstract
Atmospheric plasma spraying (APS) was taken to fabricate the NiCrAlY coating. The corrosion-wear properties of NiCrAlY coating was measured respectively under deionized water, artificial seawater, NaOH solution and HCl solution. Experimental results presented that the as-sprayed NiCrAlY coating consisted of Ni3Al, [...] Read more.
Atmospheric plasma spraying (APS) was taken to fabricate the NiCrAlY coating. The corrosion-wear properties of NiCrAlY coating was measured respectively under deionized water, artificial seawater, NaOH solution and HCl solution. Experimental results presented that the as-sprayed NiCrAlY coating consisted of Ni3Al, nickel-based solid solution, NiAl and Y2O3. In deionized water, the coating with the lowest corrosion current density (icorr) of 7.865 × 10−8 A/cm2 was hard to erode. Meanwhile, it presented a lower friction coefficient and the lowest wear rate. In HCl solution, NiCrAlY coating gave the highest corrosion current density (icorr) of 3.356 × 10−6 A/cm2 and a higher wear rate of 6.36 × 10−6 mm3/Nm. Meanwhile, the emergence of Al(OH)3 on the coating surface could reduce the direct contact between the counter ball and sample effectively, which was conducive to the lowest friction coefficient of 0.24. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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15 pages, 4073 KiB  
Article
Thermally Sprayed Coatings: Novel Surface Engineering Strategy Towards Icephobic Solutions
by Heli Koivuluoto, Enni Hartikainen and Henna Niemelä-Anttonen
Materials 2020, 13(6), 1434; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13061434 - 21 Mar 2020
Cited by 19 | Viewed by 3707
Abstract
Surface engineering promotes possibilities to develop sustainable solutions to icing challenges. Durable icephobic solutions are under high interest because the functionality of many surfaces can be limited both over time and in icing conditions. To solve this, one potential approach is to use [...] Read more.
Surface engineering promotes possibilities to develop sustainable solutions to icing challenges. Durable icephobic solutions are under high interest because the functionality of many surfaces can be limited both over time and in icing conditions. To solve this, one potential approach is to use thermally sprayed polymer or composite coatings with multifunctional properties as a novel surface design method. In thermal spraying, coating materials and structures can be tailored in order to achieve different surface properties, e.g., wetting performance, roughness and protection against several weathering and wearing conditions. These, in turn, are beneficial for excellent icephobic performance and surface durability. The icephobicity of several different surfaces are tested in our icing wind tunnel (IWiT). Here, mixed-glaze ice is accreted from supercooled water droplets and the ice adhesion is measured using a centrifugal adhesion tester (CAT). The present study focuses on the icephobicity of thermally sprayed coatings. In addition, surface-related properties are evaluated in order to illustrate the correlation between the icephobic performance and the surface properties of differently tailored thermally sprayed coatings as well as compared those to other coatings and surfaces. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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17 pages, 22697 KiB  
Article
High Velocity Suspension Flame Spraying (HVSFS) of Metal Suspensions
by Matthias Blum, Peter Krieg, Andreas Killinger, Rainer Gadow, Jan Luth and Fabian Trenkle
Materials 2020, 13(3), 621; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13030621 - 30 Jan 2020
Cited by 8 | Viewed by 2495
Abstract
Thermal spraying of metal materials is one of the key applications of this technology in industry for over a hundred years. The variety of metal-based feedstocks (powders and wires) used for thermal spray is incredibly large and utilization covers abrasion and corrosion protection, [...] Read more.
Thermal spraying of metal materials is one of the key applications of this technology in industry for over a hundred years. The variety of metal-based feedstocks (powders and wires) used for thermal spray is incredibly large and utilization covers abrasion and corrosion protection, as well as tribological and electrical applications. Spraying metals using suspension- or precursor-based thermal spray methods is a relatively new and unusual approach. This publication deals with three metal types, a NiCr 80/20, copper (Cu), and silver (Ag), sprayed as fine-grained powders dispersed in aqueous solvent. Suspensions were sprayed by means of high-velocity suspension spraying (HVSFS) employing a modified TopGun system. The aim was to prepare thin and dense metal coatings (10–70 µm) and to evaluate the process limits regarding the oxygen content of the coatings. In case of Cu and Ag, possible applications demand high purity with low oxidation of the coating to achieve for instance a high electrical conductivity or catalytic activity. For NiCr however, it was found that coatings with a fine dispersion of oxides can be usable for applications where a tunable resistivity is in demand. The paper describes the suspension preparation and presents results of spray experiments performed on metal substrates. Results are evaluated with respect to the phase composition and the achieved coating morphology. It turns out that the oxidation content and spray efficiency is strongly controlled by the oxygen fuel ratio and spray distance. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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16 pages, 39443 KiB  
Article
Improvement of Mechanical Properties of Plasma Sprayed Al2O3–ZrO2–SiO2 Amorphous Coatings by Surface Crystallization
by Jan Medricky, Frantisek Lukac, Stefan Csaki, Sarka Houdkova, Maria Barbosa, Tomas Tesar, Jan Cizek, Radek Musalek, Ondrej Kovarik and Tomas Chraska
Materials 2019, 12(19), 3232; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12193232 - 02 Oct 2019
Cited by 8 | Viewed by 2238
Abstract
Ceramic Al2O3−ZrO2−SiO2 coatings with near eutectic composition were plasma sprayed using hybrid water stabilized plasma torch (WSP-H). The as-sprayed coatings possessed fully amorphous microstructure which can be transformed to nanocrystalline by further heat treatment. The amorphous/crystalline [...] Read more.
Ceramic Al2O3−ZrO2−SiO2 coatings with near eutectic composition were plasma sprayed using hybrid water stabilized plasma torch (WSP-H). The as-sprayed coatings possessed fully amorphous microstructure which can be transformed to nanocrystalline by further heat treatment. The amorphous/crystalline content ratio and the crystallite sizes can be controlled by a specific choice of heat treatment conditions, subsequently leading to significant changes in the microstructure and mechanical properties of the coatings, such as hardness or wear resistance. In this study, two advanced methods of surface heat treatment were realized by plasma jet or by high energy laser heating. As opposed to the traditional furnace treatments, inducing homogeneous changes throughout the material, both approaches lead to a formation of gradient microstructure within the coatings; from dominantly amorphous at the substrate–coating interface vicinity to fully nanocrystalline near its surface. The processes can also be applied for large-scale applications and do not induce detrimental changes to the underlying substrate materials. The respective mechanical response was evaluated by measuring coating hardness profile and wear resistance. For some of the heat treatment conditions, an increase in the coating microhardness by factor up to 1.8 was observed, as well as improvement of wear resistance behaviour up to 6.5 times. The phase composition changes were analysed by X-ray diffraction and the microstructure was investigated by scanning electron microscopy. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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12 pages, 1584 KiB  
Article
Neural Network Modelling of Track Profile in Cold Spray Additive Manufacturing
by Daiki Ikeuchi, Alejandro Vargas-Uscategui, Xiaofeng Wu and Peter C. King
Materials 2019, 12(17), 2827; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12172827 - 02 Sep 2019
Cited by 32 | Viewed by 6631
Abstract
Cold spray additive manufacturing is an emerging technology that offers the ability to deposit oxygen-sensitive materials and to manufacture large components in the solid state. For further development of the technology, the geometric control of cold sprayed components is fundamental but not yet [...] Read more.
Cold spray additive manufacturing is an emerging technology that offers the ability to deposit oxygen-sensitive materials and to manufacture large components in the solid state. For further development of the technology, the geometric control of cold sprayed components is fundamental but not yet fully matured. This study presents a neural network predictive modelling of a single-track profile in cold spray additive manufacturing to address the problem. In contrast to previous studies focusing only on key geometric feature predictions, the neural network model was employed to demonstrate its capability of predicting complete track profiles at both normal and off-normal spray angles, resulting in a mean absolute error of 8.3%. We also compared the track profile modelling results against the previously proposed Gaussian model and showed that the neural network model provided comparable predictive accuracy, even outperforming in the predictions at cold spray profile edges. The results indicate that a neural network modelling approach is well suited to cold spray profile prediction and may be used to improve geometric control during additive manufacturing with an appropriate process planning algorithm. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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14 pages, 5049 KiB  
Article
Durability of Gadolinium Zirconate/YSZ Double-Layered Thermal Barrier Coatings under Different Thermal Cyclic Test Conditions
by Satyapal Mahade, Nicholas Curry, Stefan Björklund, Nicolaie Markocsan and Shrikant Joshi
Materials 2019, 12(14), 2238; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12142238 - 11 Jul 2019
Cited by 24 | Viewed by 3269
Abstract
Higher durability in thermal barrier coatings (TBCs) is constantly sought to enhance the service life of gas turbine engine components such as blades and vanes. In this study, three double layered gadolinium zirconate (GZ)-on-yttria stabilized zirconia (YSZ) TBC variants with varying individual layer [...] Read more.
Higher durability in thermal barrier coatings (TBCs) is constantly sought to enhance the service life of gas turbine engine components such as blades and vanes. In this study, three double layered gadolinium zirconate (GZ)-on-yttria stabilized zirconia (YSZ) TBC variants with varying individual layer thickness but identical total thickness produced by suspension plasma spray (SPS) process were evaluated. The objective was to investigate the role of YSZ layer thickness on the durability of GZ/YSZ double-layered TBCs under different thermal cyclic test conditions i.e., thermal cyclic fatigue (TCF) at 1100 °C and a burner rig test (BRT) at a surface temperature of 1400 °C, respectively. Microstructural characterization was performed using SEM (Scanning Electron Microscopy) and porosity content was measured using image analysis technique. Results reveal that the durability of double-layered TBCs decreased with YSZ thickness under both TCF and BRT test conditions. The TBCs were analyzed by SEM to investigate microstructural evolution as well as failure modes during TCF and BRT test conditions. It was observed that the failure modes varied with test conditions, with all the three double-layered TBC variants showing failure in the TGO (thermally grown oxide) during the TCF test and in the ceramic GZ top coat close to the GZ/YSZ interface during BRT. Furthermore, porosity analysis of the as-sprayed and TCF failed TBCs revealed differences in sintering behavior for GZ and YSZ. The findings from this work provide new insights into the mechanisms responsible for failure of SPS processed double-layered TBCs under different thermal cyclic test conditions. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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18 pages, 8364 KiB  
Article
Performance of Hybrid Powder-Suspension Axial Plasma Sprayed Al2O3—YSZ Coatings in Bovine Serum Solution
by Vasanth Gopal, Sneha Goel, Geetha Manivasagam and Shrikant Joshi
Materials 2019, 12(12), 1922; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12121922 - 14 Jun 2019
Cited by 12 | Viewed by 2880
Abstract
Ceramic coatings on metallic implants are a promising alternative to conventional implants due to their ability to offer superior wear resistance. The present work investigates the sliding wear behavior under bovine serum solution and indentation crack growth resistance of four coatings, namely (1) [...] Read more.
Ceramic coatings on metallic implants are a promising alternative to conventional implants due to their ability to offer superior wear resistance. The present work investigates the sliding wear behavior under bovine serum solution and indentation crack growth resistance of four coatings, namely (1) conventional powder-derived alumina coating (Ap), (2) suspension-derived alumina coating (As), (3) composite Al2O3—20wt % Yittria stabilized Zirconia (YSZ) coating (AsYs) deposited using a mixed suspension, and (4) powder Al2O3—suspension YSZ hybrid composite coating ApYs developed by axial feeding plasma spraying, respectively. The indentation crack growth resistance of the hybrid coating was superior due to the inclusion of distributed fine YSZ particles along with coarser alumina splats. Enhanced wear resistance was observed for the powder derived Ap and the hybrid ApYs coatings, whereas the suspension sprayed As and AsYs coatings significantly deteriorated due to extensive pitting. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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9 pages, 4351 KiB  
Article
Effect of Adjusted Gas Nitriding Parameters on Microstructure and Wear Resistance of HVOF-Sprayed AISI 316L Coatings
by Pia Kutschmann, Thomas Lindner, Kristian Börner, Ulrich Reese and Thomas Lampke
Materials 2019, 12(11), 1760; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12111760 - 30 May 2019
Cited by 16 | Viewed by 3119
Abstract
Gas nitriding is known as a convenient process to improve the wear resistance of steel components. A precipitation-free hardening by low-temperature processes is established to retain the good corrosion resistance of stainless steel. In cases of thermal spray coatings, the interstitial solvation is [...] Read more.
Gas nitriding is known as a convenient process to improve the wear resistance of steel components. A precipitation-free hardening by low-temperature processes is established to retain the good corrosion resistance of stainless steel. In cases of thermal spray coatings, the interstitial solvation is achieved without an additional surface activation step. The open porosity permits the penetration of the donator media and leads to a structural diffusion. An inhomogeneous diffusion enrichment occurs at the single spray particle edges within the coating’s microstructure. A decreasing diffusion depth is found with increasing surface distance. The present study investigates an adjusted process management for low-temperature gas nitriding of high velocity oxy-fuel-sprayed AISI 316L coatings. To maintain a homogeneous diffusion depth within the coating, a pressure modulation during the process is studied. Additionally, the use of cracked gas as donator is examined. The process management is designed without an additional surface activation step. Regardless of surface distance, microstructural investigations reveal a homogeneous diffusion depth by a reduced processing time. The constant hardening depth allows a reliable prediction of the coatings’ properties. An enhanced hardness and improved wear resistance is found in comparison with the as-sprayed coating condition. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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15 pages, 13420 KiB  
Article
Characteristics of ZrC Barrier Coating on SiC-Coated Carbon/Carbon Composite Developed by Thermal Spray Process
by Bo Ram Kang, Ho Seok Kim, Phil Yong Oh, Jung Min Lee, Hyung Ik Lee and Seong Min Hong
Materials 2019, 12(5), 747; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12050747 - 05 Mar 2019
Cited by 16 | Viewed by 3804
Abstract
A thick ZrC layer was successfully coated on top of a SiC buffer layer on carbon/carbon (C/C) composites by vacuum plasma spray (VPS) technology to improve the ablation resistance of the C/C composites. An optimal ZrC coating condition was determined by controlling the [...] Read more.
A thick ZrC layer was successfully coated on top of a SiC buffer layer on carbon/carbon (C/C) composites by vacuum plasma spray (VPS) technology to improve the ablation resistance of the C/C composites. An optimal ZrC coating condition was determined by controlling the discharge current. The ZrC layers were more than 70 µm thick and were rapidly coated under all spraying conditions. The ablation resistance and the oxidation resistance of the coated layer were evaluated in supersonic flames at a temperature exceeding 2000 °C. The mass and linear ablation rate of the ZrC-coated C/C composites increased by 2.7% and 0.4%, respectively. During flame exposure, no recession was observed in the C/C composite. It was demonstrated that the ZrC coating layer can fully protect the C/C composites from oxidation and ablation. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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Other

Jump to: Editorial, Research

9 pages, 4558 KiB  
Letter
Exploiting Suspension Plasma Spraying to Deposit Wear-Resistant Carbide Coatings
by Satyapal Mahade, Karthik Narayan, Sivakumar Govindarajan, Stefan Björklund, Nicholas Curry and Shrikant Joshi
Materials 2019, 12(15), 2344; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12152344 - 24 Jul 2019
Cited by 29 | Viewed by 5494
Abstract
Titanium- and chromium-based carbides are attractive coating materials to impart wear resistance. Suspension plasma spraying (SPS) is a relatively new thermal spray process which has shown a facile ability to use sub-micron and nano-sized feedstock to deposit high-performance coatings. The specific novelty of [...] Read more.
Titanium- and chromium-based carbides are attractive coating materials to impart wear resistance. Suspension plasma spraying (SPS) is a relatively new thermal spray process which has shown a facile ability to use sub-micron and nano-sized feedstock to deposit high-performance coatings. The specific novelty of this work lies in the processing of fine-sized titanium and chromium carbides (TiC and Cr3C2) in the form of aqueous suspensions to fabricate wear-resistant coatings by SPS. The resulting coatings were characterized by surface morphology, microstructure, phase constitution, and micro-hardness. The abrasive, erosive, and sliding wear performance of the SPS-processed TiC and Cr3C2 coatings was also evaluated. The results amply demonstrate that SPS is a promising route to manufacture superior wear-resistant carbide-based coatings with minimal in situ oxidation during their processing. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Technology)
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