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Advances in Thermal Spray Coatings: Technologies and Applications
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Advances in Thermal Spray Coatings: Technologies and Applications

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

Deadline for manuscript submissions: 30 June 2025 | Viewed by 4816

Special Issue Editors

Dr. Amit Roy

E-Mail Website
Guest Editor
Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, Montreal, QC, Canada
Interests: thermally spray coatings; CMAS behavior; tribology; binary and ternary oxides; advanced characterization
Dr. André C. Liberati

E-Mail Website
Guest Editor
Département de Physique, Université de Limoges, Limoges, France
Interests: thermal spray; cold spray; metallization of polymers; process development
Prof. Dr. Sergi Dosta

E-Mail Website
Guest Editor
Surfaces, Developments and Treatments (SDT), Department of Materials Sciences and Physical Chemistry, Universitat de Barcelona, Barcelona, Spain
Interests: thermal spray technologies; cold gas spray; microstructural characterization; mechanical properties; corrosion resistance
Special Issues, Collections and Topics in MDPI journals
Dr. Surinder Singh

E-Mail Website
Guest Editor
Australian Research Council (ARC) Industrial Transformation Training Centre in Surface Engineering for Advanced Materials (SEAM), Swinburne University of Technology, Hawthorn, VIC 3122, Australia
Interests: thermal spray coatings; cold Spray; high entropy alloys; Li-ion batteries; advanced manufacturing

Special Issue Information

Dear Colleagues,

This Special Issue of Coatings, entitled “Advances in Thermal Spray Coatings: Technologies and Applications”, is open for submissions. We would like to invite you to submit your research to this Issue.

Thermal spraying is an emerging coating development process that allows the use of a wide range of materials, including metals, cermets, ceramics and polymers, in the form of powders, suspension/liquid precursors, rods, or wire. The modification or variation of the feeding techniques, as well as the optimization of the spraying parameters, make the coatings applicable in different fields (i.e., wear, erosion, cavitation, corrosion, abrasion, or heat) depending on the desired conditions. Its application can be used to extend the life of new components or, using proven techniques, to repair and rebuild worn or damaged components.

In the Special Issue, we would like to hear about the latest developments and achievements in the field of thermal spraying.

Thus, we cordially invite scientists and academics from all over the world to submit original research papers and review articles on thermal spraying, its latest developments and applications, as well as coating properties and performance.

Topics of interest include, but are not limited to:

  • New processes in the development of new coatings
  • Coating properties and performance
  • Feedstock material developments
  • Friction, wear, and corrosion
  • New coating materials
  • Functional coatings

Dr. Amit Roy
Dr. André C. Liberati
Prof. Dr. Sergi Dosta
Dr. Surinder Singh
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.

Keywords

  • thermal spray coatings
  • coating properties
  • coating materials
  • tribology

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (4 papers)

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Research

23 pages, 16310 KiB  
Article
Coupling APS/SPS Techniques for Cu-TiO2 Antibacterial Coating Deposition: Application to Water Treatment
by Laurène Youssef, Audrey Prorot, Laurène Gnodé, Pierre Th’Madiou Verdieu, Armelle Vardelle, Vincent Rat and Alain Denoirjean
Coatings 2024, 14(11), 1426; https://doi.org/10.3390/coatings14111426 - 9 Nov 2024
Viewed by 779
Abstract
Since the COVID-19 pandemic, efforts in the field of surface decontamination have been redoubled. Finding innovative self-cleaning devices has become a challenge, and several solutions have been proposed in the market in recent years. In this work, an optimized powder/suspension plasma spray process [...] Read more.
Since the COVID-19 pandemic, efforts in the field of surface decontamination have been redoubled. Finding innovative self-cleaning devices has become a challenge, and several solutions have been proposed in the market in recent years. In this work, an optimized powder/suspension plasma spray process at atmospheric pressure, using a Triplex Pro 210TM torch, is implemented to produce Cu-TiO2 surface coatings on stainless steel. The purpose is to investigate the potential improvement of antibacterial efficacy by the reactive surface species generated from TiO2 photoactivity under irradiation. A water-based suspension, prepared with AnalaR NORMAPURTM TiO2, is used as a precursor to incorporate the photocatalyst into an antibacterial copper matrix. Surface antibacterial tests according to ASTM 2180 standards were performed, and experiments were performed in treated contaminated water. Sub-stoichiometric blue TiO2 coatings showed complete bacterial elimination after 90 min of visible light irradiation, and Cu-TiO2 surface coatings were even able to disinfect the surfaces under white light, making the application interesting for bacterial destruction under natural illumination. These materials are also intended for application in water treatment, including both pathogens and chemical micropollutants, which is a pressing issue facing many countries today. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Coatings: Technologies and Applications)
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18 pages, 8817 KiB  
Article
Shrouding Gas Plasma Deposition Technique for Developing Low-Friction, Wear-Resistant WS2-Zn Thin Films on Unfilled PEEK: The Relationship Between Process and Coating Properties
by Dietmar Kopp, Christine Bandl, Reinhard Kaindl, Thomas Prethaler, Anna Maria Coclite and Wolfgang Waldhauser
Coatings 2024, 14(11), 1365; https://doi.org/10.3390/coatings14111365 - 27 Oct 2024
Viewed by 842
Abstract
In this study, tungsten disulfide–zinc (WS2-Zn) composite films were generated on polyether ether ketone (PEEK) disks by an atmospheric pressure plasma jet (APPJ) equipped with a shrouding attachment. The friction and wear properties of the WS2-Zn coatings were intensively [...] Read more.
In this study, tungsten disulfide–zinc (WS2-Zn) composite films were generated on polyether ether ketone (PEEK) disks by an atmospheric pressure plasma jet (APPJ) equipped with a shrouding attachment. The friction and wear properties of the WS2-Zn coatings were intensively investigated by using a rotational ball-on-disk setup under dry sliding and ambient room conditions. In order to gain more information about the lubrication mechanism, the coating areas as deposited and the worn areas (i.e., in the wear track) were analyzed with a scanning electron microscope (SEM) with regard to their chemical composition in depth by energy-dispersive X-ray spectroscopy (EDS). X-ray photoelectron spectroscopy (XPS) was conducted to obtain precise chemical information from the surface. The results indicated that WS2-Zn coatings significantly improved the tribological properties, exhibiting a coefficient of friction (COF) of <0.2. However, the tribological performance of the coatings is strongly dependent on the plasma process settings (i.e., plasma current, dwell time of the powder particles in the plasma jet), which were tuned to reduce the oxidation by-products of WS2 to a minimum. The COF values achieved of the dry lubricant films were significantly reduced in contrast to the uncoated PEEK by a factor of four. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Coatings: Technologies and Applications)
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15 pages, 9333 KiB  
Article
Investigation of the Influence of the Oxygen Flow Rate on the Mechanical, Structural and Operational Properties of 86WC-10Co-4Cr Coatings, as Determined Using the High-Velocity Oxyfuel Spraying Method
by Bauyrzhan Rakhadilov, Nazerke Muktanova, Ainur Seitkhanova, Dauir Kakimzhanov and Merkhat Dautbekov
Coatings 2024, 14(10), 1275; https://doi.org/10.3390/coatings14101275 - 6 Oct 2024
Viewed by 1012
Abstract
The structural-phase composition and tribological and performance properties of coatings based on an 86WC-10Co-4Cr composition obtained by the HVOF method at varying (150 L/min, 170 L/min, 190 L/min) oxygen flow rates were studied. The results showed that the coefficient of friction of coatings [...] Read more.
The structural-phase composition and tribological and performance properties of coatings based on an 86WC-10Co-4Cr composition obtained by the HVOF method at varying (150 L/min, 170 L/min, 190 L/min) oxygen flow rates were studied. The results showed that the coefficient of friction of coatings in gear oil remained almost unchanged with the variation in oxygen flow rate. However, microhardness increased significantly with an increasing oxygen flow rate, reaching a maximum at 190 L/min. An increasing oxygen flow rate was also accompanied by an increase in roughness and coating thickness, with a decrease in porosity, particularly notable at 190 L/min. Adhesion strength reached the maximum values for the A2 and A3 coatings under high loads. The phase composition of the coatings included WC, W2C and CoO phases irrespective of the oxygen flow rate, and their microstructure was characterized by a more homogeneous and dense structure. Thus, this study confirmed that the optimal oxygen flow rate for achieving an improved performance and tribological characteristics of 86WC-10Co-4Cr coatings is 190 L/min. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Coatings: Technologies and Applications)
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17 pages, 5180 KiB  
Article
Performance of Atmospheric Plasma-Sprayed Thermal Barrier Coatings on Additively Manufactured Super Alloy Substrates
by Madhura Bellippady, Stefan Björklund, Xin-Hai Li, Robert Frykholm, Bjorn Kjellman, Shrikant Joshi and Nicolaie Markocsan
Coatings 2024, 14(5), 626; https://doi.org/10.3390/coatings14050626 - 15 May 2024
Viewed by 1207
Abstract
This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES®282® (H282) superalloy substrates. The effect of different feedstock morphologies and spray gun designs with radial [...] Read more.
This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES®282® (H282) superalloy substrates. The effect of different feedstock morphologies and spray gun designs with radial and axial injection on APS-deposited YSZ layer characteristics such as microstructure, porosity content, roughness, etc., has been investigated. The performance of TBCs in terms of thermal cycling fatigue (TCF) lifetime and erosion behaviour were also comprehensively investigated. In view of the high surface roughness of as-built AM surfaces compared to forged substrates, two different types of NiCoCrAlY bond coats were examined: one involved high-velocity air fuel (HVAF) spraying of a finer powder, and the other involved APS deposition of a coarser feedstock. Despite the process and feedstock differences, the above two routes yielded comparable bond coat surface roughness on both types of substrates. Variation in porosity level in the APS topcoat was observed when deposited using different YSZ feedstock powders employing axial or radial injection. However, the resultant TBCs on AM-derived substrates were observed to possess similar microstructures and functional properties as TBCs deposited on reference (forged) substrates for any given YSZ deposition process and feedstock. Full article
(This article belongs to the Special Issue Advances in Thermal Spray Coatings: Technologies and Applications)
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