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Additively Manufactured Coatings
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Additively Manufactured Coatings

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: closed (31 December 2020) | Viewed by 21814

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

Special Issue Editors

Dr. Pradeep Menezes

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Guest Editor
Department of Mechanical Engineering, University of Nevada, Reno, NV 89557, USA
Interests: manufacturing; material processing; surface engineering; electrochemical analysis; advanced material structures
Special Issues, Collections and Topics in MDPI journals
Dr. Pankaj Kumar

E-Mail Website
Guest Editor
Department of Mechanical Engineering, The University of New Mexico, MSC01 1150, Albuquerque, NM 87131, USA
Interests: advanced manufacturing; additive manufacturing; alloys and microstructure design; mechanical behavior of materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Functional coatings are of particular importance to protect the substrate from chemical and mechanical damage in aggressive environments. They are widely used as cost-effective methods to protect the substrate from wear, corrosion, erosion, tribocorrosion, high temperature and high pressure in extreme environmental conditions. These are primarily manufactured through metal/ceramic powder deposition in a subsequent layer by layer fashion on the substrate materials. In all cases, the functional coatings need to be reliable for the intended application. The emerging 3D printing/additive manufacturing techniques can be utilized to develop high-performance functional coatings. These methods provide geometrical precision, flexibility in geometrical complexity, customization of the coating layers, and reduce the raw materials waste, keeping the manufacturing cost low while addressing many of the technical barriers of conventional coating methods. With the rapid development of cutting-edge value-added technologies in aerospace, nuclear, military, space, and energy industry, 3D printing/additive manufacturing techniques will be major advantages. Novel functional coatings and 3D printing/additive manufacturing techniques will be critical to value-added components in the future development of technologies. The scope of this Special Issue covers technologies from solid-state coating methods to direct energy deposition that develops metal, ceramic, and composite coatings. This Special Issue is devoted to recent advances in functional coatings, including but not limited to metal, ceramic, and composite utilizing 3D printing/additive manufacturing techniques. Original research and review articles in relevant topics are welcomed.

Proposed topics of this Special Issue:

Cold spray and supersonic powder deposition techniques

Friction stir additive manufactured processes

Laser and electron beam-based additive manufacturing coating techniques, inkjet methods, and other 3D printing techniques

Case studies of functional coatings using advanced additive manufacturing techniques

Advanced functional coatings, including metallic, ceramics, and composites

Dr. Pradeep Menezes
Dr. Pankaj Kumar
Guest Editors

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. Coatings is an international peer-reviewed open access monthly 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.

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Published Papers (7 papers)

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Editorial

Jump to: Research

2 pages, 138 KiB  
Editorial
Additively Manufactured Coatings
by Pankaj Kumar and Pradeep L. Menezes
Coatings 2021, 11(5), 609; https://doi.org/10.3390/coatings11050609 - 20 May 2021
Cited by 1 | Viewed by 1927
Abstract
We are pleased to publish a Special Issue on “Additively Manufactured Coatings” that is intended to provide peer-reviewed articles in the fascinating field of coatings, particularly in the area of additive manufacturing technology [...] Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)

Research

Jump to: Editorial

17 pages, 6097 KiB  
Article
Thermal Stress Cycle Simulation in Laser Cladding Process of Ni-Based Coating on H13 Steel
by Fangping Yao and Lijin Fang
Coatings 2021, 11(2), 203; https://doi.org/10.3390/coatings11020203 - 10 Feb 2021
Cited by 23 | Viewed by 3562
Abstract
In order to improve the work efficiency and save resources in the process of laser cladding on the H13 steel surface, based on COMSOL, by combining computer simulation and experiment, a plane continuous heat source model was used to simulate and analyze the [...] Read more.
In order to improve the work efficiency and save resources in the process of laser cladding on the H13 steel surface, based on COMSOL, by combining computer simulation and experiment, a plane continuous heat source model was used to simulate and analyze the temperature and stress field. The optimal power and scanning speed were obtained. It is found in the simulation process that the thermal sampling points stress increases with the increase of laser power and scanning speed. Because of the existence of solid–liquid phase variation in the laser cladding process, there are two peaks in the maximum thermal stress cycle curve of the sample points located in the molten pool, and the starting and ending time of each sample point’s peak value is basically the same. When the sample point is outside the molten pool, because the metal at the corresponding location is not melted, so there is no obvious peak value in the thermal stress cycle curve. With the increase of cladding layer depth corresponding to each sample point, the variation range of the two alternating thermal stress peaks increases first and then decreases, while the duration increases. According to the peak value of alternating thermal stress at the sampling point, the molten pool depth can be predicted. The residual stress analysis of the cladding layer is carried out according to the analysis results of temperature field and stress field. Through the actual cladding experiment, it is found that the depth of molten pool in the simulation results is basically consistent with the experimental results. All simulation results are verified through actual cladding experiments. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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9 pages, 1788 KiB  
Article
Tribocorrosion Behavior of Inconel 718 Fabricated by Laser Powder Bed Fusion-Based Additive Manufacturing
by Arpith Siddaiah, Ashish Kasar, Pankaj Kumar, Javed Akram, Manoranjan Misra and Pradeep L. Menezes
Coatings 2021, 11(2), 195; https://doi.org/10.3390/coatings11020195 - 8 Feb 2021
Cited by 11 | Viewed by 2954
Abstract
Additive manufacturing (AM) by laser powder bed fusion (LPBF) has gained significant research attention to fabricate complex 3D Inconel alloy components for jet engines. The strategic advantages of LPBF-based AM to fabricate jet components for aerospace applications are well reported. The jet components [...] Read more.
Additive manufacturing (AM) by laser powder bed fusion (LPBF) has gained significant research attention to fabricate complex 3D Inconel alloy components for jet engines. The strategic advantages of LPBF-based AM to fabricate jet components for aerospace applications are well reported. The jet components are exposed to a high degree of vibration during the jet operation in a variable aqueous environment. The combined vibration and the aqueous environment create a tribological condition that can accelerate the failure mechanism. Therefore, it is critical to understand the tribocorrosion behavior of the Inconel alloy. In the present work, tribocorrosion behavior of the LPBF fabricated standalone coating of Inconel 718 in the 3.5% NaCl aqueous solution is presented. The LPBF fabricated samples are analyzed to determine the impact of porosity, generated as a result of LPBF, on the triobocorrosion behavior of AM Inconel 718. The study includes potentiodynamic tests, cathodic polarization, along with OCP measurements. The corrosive environment is found to increase the wear by 29.24% and 49.5% without the initiation of corrosion in the case of AM and wrought Inconel 718, respectively. A corrosion accelerated wear form of tribocorrosion is observed for Inconel 718. Additionally, the corrosive environment has a significant effect on wear even when the Inconel 718 surface is in equilibrium potential with the corrosive environment and no corrosion potential scan is applied. This study provides an insight into a critical aspect of the AM Inconel components. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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20 pages, 30409 KiB  
Article
Improvement of Wear, Pitting Corrosion Resistance and Repassivation Ability of Mg-Based Alloys Using High Pressure Cold Sprayed (HPCS) Commercially Pure-Titanium Coatings
by Mohammadreza Daroonparvar, Ashish K. Kasar, Mohammad Umar Farooq Khan, Pradeep L. Menezes, Charles M. Kay, Manoranjan Misra and Rajeev K. Gupta
Coatings 2021, 11(1), 57; https://doi.org/10.3390/coatings11010057 - 6 Jan 2021
Cited by 16 | Viewed by 3522
Abstract
In this study, a compact cold sprayed (CS) Ti coating was deposited on Mg alloy using a high pressure cold spray (HPCS) system. The wear and corrosion behavior of the CS Ti coating was compared with that of CS Al coating and bare [...] Read more.
In this study, a compact cold sprayed (CS) Ti coating was deposited on Mg alloy using a high pressure cold spray (HPCS) system. The wear and corrosion behavior of the CS Ti coating was compared with that of CS Al coating and bare Mg alloy. The Ti coating yielded lower wear rate compared to Al coating and Mg alloy. Electrochemical impedance spectroscopy (EIS) and cyclic potentiodynamic polarization (CPP) tests revealed that CS Ti coating can substantially reduce corrosion rate of AZ31B in chloride containing solutions compared to CS Al coating. Interestingly, Ti-coated Mg alloy demonstrated negative hysteresis loop, depicting repassivation of pits, in contrast to AZ31B and Al-coated AZ31B with positive hysteresis loops where corrosion potential (Ecorr) > repassivation potential (Erp); indicating irreversible growth of pits. AZ31B and Al-coated AZ31B were most susceptible to pitting corrosion, while Ti-coated Mg alloy indicated noticeable resistance to pitting in 3.5 wt % NaCl solution. In comparison to Al coating, Ti coating considerably separated the AZ31BMg alloy surface from the corrosive electrolyte during long term immersion test for 11 days. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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18 pages, 4843 KiB  
Article
Molecular Dynamics Simulation of Dislocation Plasticity Mechanism of Nanoscale Ductile Materials in the Cold Gas Dynamic Spray Process
by Sunday Temitope Oyinbo and Tien-Chien Jen
Coatings 2020, 10(11), 1079; https://doi.org/10.3390/coatings10111079 - 10 Nov 2020
Cited by 12 | Viewed by 3328
Abstract
The dislocation plasticity of ductile materials in a dynamic process of cold gas spraying is a relatively new research topic. This paper offers an insight into the microstructure and dislocation mechanism of the coating using simulations of molecular dynamics (MD) because of the [...] Read more.
The dislocation plasticity of ductile materials in a dynamic process of cold gas spraying is a relatively new research topic. This paper offers an insight into the microstructure and dislocation mechanism of the coating using simulations of molecular dynamics (MD) because of the short MD simulation time scales. The nano-scale deposition of ductile materials onto a deformable copper substrate has been investigated in accordance with the material combination and impact velocities in the particle/substrate interfacial region. To examine the jetting mechanisms in a range of process parameters, rigorous analyses of the developments in pressure, temperature, dislocation plasticity, and microstructure are investigated. The pressure wave propagation’s critical function was identified by the molecular dynamics’ simulations in particle jet initiation, i.e., exterior material flow to the periphery of the particle and substrate interface. The initiation of jet occurs at the point of shock waves interact with the particle/substrate periphery and leads to localization of the metal softening in this region. In particular, our findings indicate that the initial particle velocity significantly influences the interactions between the material particles and the substrate surface, yielding various atomic strain and temperature distribution, processes of microstructure evolution, and the development of dislocation density in the particle/substrate interfacial zone for particles with various impact velocities. The dislocation density in the particle/substrate interface area is observed to grow much more quickly during the impact phase of Ni and Cu particles and the evolution of the microstructure for particles at varying initial impact velocities is very different. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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15 pages, 10100 KiB  
Article
Microstructure Control and Friction Behavior Prediction of Laser Cladding Ni35A+TiC Composite Coatings
by Xu Huang, Chang Liu, Hao Zhang, Changrong Chen, Guofu Lian, Jibin Jiang, Meiyan Feng and Mengning Zhou
Coatings 2020, 10(8), 774; https://doi.org/10.3390/coatings10080774 - 9 Aug 2020
Cited by 5 | Viewed by 2711
Abstract
The premise of surface strengthening and repair of high valued components is to identify the relationship between coating formulation, structure, and properties. Based on the full factorial design, the effects of process parameters (laser power, scanning speed, gas-powder flow rate, and weight fraction [...] Read more.
The premise of surface strengthening and repair of high valued components is to identify the relationship between coating formulation, structure, and properties. Based on the full factorial design, the effects of process parameters (laser power, scanning speed, gas-powder flow rate, and weight fraction of TiC) on the phase composition, microstructure, and element distribution of Ni35A/TiC cladding layer were investigated, followed by the cause identification of wear behavior. Through ANOVA, the correlation was established with good prediction accuracy (R2 = 0.9719). The most important factors affecting the wear rate of the cladding layer were recognized as laser power and particle ratio with a p-value < 0.001. The cladding layer was mainly comprised of Ni3Fe and TiC0.957. The excessive laser power would enhance the process of convection-diffusion of the melt pool, increase dilution, and improve wear volume. High laser power facilitates renucleation and growth of the hard phase, especially the complete growth of secondary axis dendrite for the top region. Increased TiC significantly changes the microstructure of the hard phase into a non-direction preferable structure, which prevents stress concentration at tips and further improves the mechanical properties. The research results are a valuable support for the manipulation of microstructure and prediction of wear behavior of composite cladding layer. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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12 pages, 7056 KiB  
Article
Effect of Interlayer Cooling on the Preparation of Ni-Based Coatings on Ductile Iron
by Yuyu He, Yijian Liu, Jiquan Yang, Fei Xie, Wuyun Huang, Zhaowei Zhu, Jihong Cheng and Jianping Shi
Coatings 2020, 10(6), 544; https://doi.org/10.3390/coatings10060544 - 4 Jun 2020
Cited by 5 | Viewed by 2133
Abstract
In metal additive manufacturing without interlayer cooling, the macro-size of the layer itself is difficult to control due to the thermal storage effect. The effect of interlayer cooling was studied by cladding Ni-based coatings on the substrate of ductile iron. The results show [...] Read more.
In metal additive manufacturing without interlayer cooling, the macro-size of the layer itself is difficult to control due to the thermal storage effect. The effect of interlayer cooling was studied by cladding Ni-based coatings on the substrate of ductile iron. The results show that under the same process parameters, compared with non-interlayer cooling deposition, the dilution rate is better, and the thickness increase of interlayer cooling deposition is more uniform, which is conducive to controlling the macro-size of the interlayer cooling deposition. Furthermore, interlayer cooling deposition has fewer impurities and more uniform microstructures. Moreover, the average grain size is refined and the dendrite growth is inhibited, which improves the mechanical properties of the coating. Therefore, the hardness of the interlayer cooling specimens is greater than that of the non-interlayer-cooled specimens. Full article
(This article belongs to the Special Issue Additively Manufactured Coatings)
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