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Thermal Sprayed Coatings

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Dr. Daniela-Lucia Chicet

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Materials Science Department, Materials Science and Engineering Faculty, Gheorghe Asachi Technical University of Iasi, 700050 Iasi, Romania
Interests: thermal spray coating; microstructure; phase transformation; electronic microscopy; splat formation
Special Issues, Collections and Topics in MDPI journals

Dr. Ştefan-Lucian Toma

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Guest Editor

Faculty of Science and Materials Engineering, Technical University Gheorghe Asachi from Iasi, 700050 Iași, Romania
Interests: thermal spray coating; electric arc spray; CFD simulations; tribological characterisation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Thermal spraying has become one of the well-known processing technologies, now used in a wide range of industries, from automotive to medical, chemical and even aerospace, to provide wear and corrosion resistance, biocompatibility, and thermal insulation (TBC). Its versatility is due both to the multitude of methods and equipment developed since 1909 when Max Ulrich Schoop laid the foundations of this process, and to the variety of materials that can be deposited: ceramics, metals, cermets, and multi-component alloys, in single or multi-layer. The way coatings are formed is unique and is based on the superposition of individual particles that impact and adhere to the substrate, representing the 'bricks' that form the layers. The unique properties of these coatings thus depend on a multitude of working parameters that influence both how the coating adheres to the substrate and how the splats interact with each other. It becomes very clear that the study of splat morphology and particles phase transformations that occur during deposition and rapid solidification is crucial for the understanding of the coating’s formation and behaviour in operation.

For these reasons, I invite you all to contribute with your valuable studies on obtaining, properties and applications, to complete such a complex picture, which will help other researchers and industrial engineers who want to use thermal spray deposited coatings in various applications.

Dr. Daniela-Lucia Chicet
Dr. Ştefan-Lucian Toma
Guest Editors

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Research

16 pages, 13395 KiB

Open AccessArticle

Mechanical Properties and Thermal Shock Behavior of Al₂O₃-YSZ Ceramic Layers Obtained by Atmospheric Plasma Spraying

by Marian Luțcanu, Ramona Cimpoeșu, Mărioara Abrudeanu, Corneliu Munteanu, Sorin Georgian Moga, Margareta Coteata, Georgeta Zegan, Marcelin Benchea, Nicanor Cimpoeșu and Alice Mirela Murariu

Crystals 2023, 13(4), 614; https://doi.org/10.3390/cryst13040614 - 3 Apr 2023

Cited by 3 | Viewed by 1608

Abstract

Ceramic coatings have many advantages for industrial and medical applications due to their exceptional properties. Ceramic coatings with a thickness of approximately 45 μm, after grinding, were grown using a robotic arm that used the atmospheric plasma spraying procedure. The thermal shock stresses—a common situation in applications but difficult to reproduce under laboratory conditions—of the ceramic layers on top of the metal substrate was achieved using solar energy focused by a concentrating mirror, based on experiments conducted in the CNRS-PROMES laboratory, UPR 8521, belonging to the French National Centre for Scientific Research (CNRS). The ceramic layers showed excellent stability at 1000 °C, even at high heating or cooling rates. At high temperatures (above 1800 °C), the exfoliation of the complex ceramic layer was observed. No differences in the structural, phase, mechanical or adhesion properties of the ceramic layer were observed after the thermal shock cycles (in the literature, there have been quite few reports regarding the properties of the ceramic layers after the thermal shock application). Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), atomic force microscopy (AFM) and X-ray diffraction (XRD) techniques were used to characterize the complex ceramic coating and the effects of thermal shock cycling. The phases and chemical composition of the complex coatings remained similar, insensitive to thermal shock at 1000 °C, consisting of a mixture of crystalline yttrium zirconium oxide and α and γ alumina. For all cases, the main residual stress state was tensile. After 5 or 10 cycles of thermal shocks, a smoothing of the residual stress state was observed in the investigated area. A higher temperature (above 1800 °C), applied as thermal shock, led to higher residual stresses and resulted in large cracks and the spallation of the coating layer. Full article

(This article belongs to the Special Issue Thermal Sprayed Coatings)

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17 pages, 6504 KiB

Open AccessArticle

Tribocorrosion Performance of WC-12Co HVOF-Sprayed Coatings Reinforced with Carbon Nanotubes

by Mariana Henriette Staia, Alberto Mejias, Stephania Kossman and Eli Saul Puchi-Cabrera

Crystals 2023, 13(3), 457; https://doi.org/10.3390/cryst13030457 - 6 Mar 2023

Cited by 1 | Viewed by 1460

Abstract

WC-12Co HVOF-sprayed coatings (~400 µm in thickness) reinforced with multiwalled carbon nanotubes (MWCNTs), were deposited on a steel substrate. The aim of this work is to provide and analyze data from HVOF WC-12Co sprayed coatings, concerning the influence of the addition of MWCNTs on their tribocorrosion performance, in a 3.5% NaCl electrolyte. Electrochemical data (current density and corrosion potential from potentiodynamic polarization curves) and wear data (coefficients of friction, coating volume losses and wear constants) are reported for the coatings, with and without the addition of MWCNTs (labeled WC_CNT and WC_AS-RECEIVED, respectively), considering the synergistic effects of wear and corrosion coupling. Scanning electron microscopy (SEM) and profilometry are used to explain both the wear and corrosion mechanisms that account for each coating’s performance in this environment. During the tribocorrosion tests, similar wear constants, of the order of approximately 10⁻¹² m³/Nm, were found for all samples, with an increase of ~20% due to the MWCNTs presence. However, for the coatings reinforced with MWCNTs, a remarkable increase in

i_{corr}

, representing almost 3 times the

i_{corr}

of the WC_AS-RECEIVED coating, was determined. The above results illustrate the complex mechanisms that occur when these coatings are tested under tribocorrosion conditions, which give rise to concurrent interacting phenomena, involving both electrochemical and mechanical responses. Full article

(This article belongs to the Special Issue Thermal Sprayed Coatings)

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