New Advances in High and Low Temperature Spray Processes for Functional Metallic Coatings

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Plasma Coatings, Surfaces & Interfaces".

Deadline for manuscript submissions: closed (20 September 2021) | Viewed by 3523

Special Issue Editors


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Guest Editor
Department of Mechanical and Manufacturing Engineering, Trinity College of Dublin, The University of Dublin, Parsons Building, Dublin 2, Ireland
Interests: cold spray; laser cladding; additive manufacturing; selective laser melting
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Department of Mechanical, Manufacturing and Biomedical Engineering, Trinity College Dublin, D02 PN40 Dublin, Ireland
Interests: additive manufacturing; 3D printing; cold spraying; digital light processing; selective laser melting; high velocity imaging; numerical simulation
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Guest Editor
State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi'an Jiaotong University, Xi'an, Shaanxi, China
Interests: thermal spray; energy; solar cell
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Special Issue Information

Dear Colleagues,

Spray processes for metallic materials have been successfully used for many years to solve and address problems in industry. The vast majority of methods are based on the melting temperature of the feedstock material in order to form a coating layer (such as in the plasma spray of HVOF). Much has been achieved using this strategy academically, as well as industrially with applications in several key sectors (aerospace, automotive, oil, and gas are tangible examples). Other methodologies (such as cold spray) are, by definition, not crossing the melting point of materials. On paper, these are younger methods, which have attracted a relatively large academic population for their development, and are in progress for large scale industrial application. Overall, we have witnessed research work on this topic in several key areas, such as material development, process development, equipment design, and fundamental studies. However, some key issues remain. For example, in high temperature spray thermal distortion, coating oxidation and phases control are not comprehensively solved; while in lower temperature spray, the substrate bond-strength, coating density, and deposition efficiency (related to process cost) have so far been difficult hurdles to overcome.

The interest of this Special Issue is to collect new advances that are promising for solving the major key issues of the past and the present. These could be material, equipment, or process related. We are looking to receive ground-breaking contributions in order to gather compelling evidence of how metallic spray processes are likely to be re-shaped within the next 10–15 years.

Prof. Dr. Rocco Lupoi
Prof. Dr. Shuo Yin
Prof. Dr. Guanjun Yang
Guest Editors

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Keywords

  • Cold spray
  • Plasma spray
  • Thermal spray
  • PS-PVD
  • PS-CVD
  • Nozzle design
  • Microstructure 
  • New materials
  • Equipment development
  • Parameters development
  • Material characterization
  • Coating performance
  • Coating properties
  • Coating bond strength

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Published Papers (1 paper)

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Research

15 pages, 2808 KiB  
Article
Tailoring Periodic Vertical Cracks in Thermal Barrier Coatings Enabling High Strain Tolerance
by Ghazanfar Mehboob, Tong Xu, Guang-Rong Li, Guan-Jun Yang, Adnan Tahir, Mohamed Ragab and Shahnwaz Hussain
Coatings 2021, 11(6), 720; https://doi.org/10.3390/coatings11060720 - 16 Jun 2021
Cited by 8 | Viewed by 2853
Abstract
Lifetime is a basic support for the thermal insulation function of thermal barrier coatings (TBCs). Therefore, extending the life span is essential to develop next-generation TBCs. For this objective, the columnar structure formed by vertical cracks appears to make sense. However, the underlying [...] Read more.
Lifetime is a basic support for the thermal insulation function of thermal barrier coatings (TBCs). Therefore, extending the life span is essential to develop next-generation TBCs. For this objective, the columnar structure formed by vertical cracks appears to make sense. However, the underlying mechanism is still unclear. This work scrutinizes the influence of periodic vertical cracks on cracking behavior in order to tailor high strain tolerant TBCs. A finite element model was evolved to explore the crack behavior influenced by thermal mismatch strain between substrate and coating. The virtual crack closure technique (VCCT) was used to describe the propagation of crack under load. It is found clearly that the space between two vertical cracks (short for SVC) along the in-plane direction has a noteworthy influence on the strain tolerance of TBCs. Results indicate that the strain energy release rate (SERR) and stresses at the pre-crack tip increase continuously with the increase of the SVC, suggesting that the driving force for cracks is increasing. The crack is not propagated when the SVC is very small, whereas the crack grows continuously with the increase of the SVC. The growth of a crack can be prevented by reducing the SVC. A critical value for the SVC was found. When the SVC is less than the critical value, the SERR can be dramatically reduced. Thus, the SVC of periodic cracks can be tailored to obtain TBCs with high strain tolerance. Full article
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