1
|
Idir A, Delloro F, Younes R, Bradai MA, Sadeddine A, Marginean G. Comparative Study of Corrosion Performance of LVOF-Sprayed Ni-Based Composite Coatings Produced Using Standard and Reducing Flame Spray Stoichiometry. Materials (Basel) 2024; 17:458. [PMID: 38255626 PMCID: PMC10820788 DOI: 10.3390/ma17020458] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/08/2023] [Revised: 01/11/2024] [Accepted: 01/13/2024] [Indexed: 01/24/2024]
Abstract
Coating efficiency and quality can be significantly improved by carefully optimizing the coating parameters. Particularly in the flame spray method, the oxygen/fuel ratio, which is classified as oxidizing flame stoichiometry (excess oxygen) and reduces flame stoichiometry (excess acetylene), and spray distance are the most critical factors, as they correlate significantly with coating porosity and corrosion performance. Hence, understanding the effects of these parameters is essential to further minimize the porosity, improving the corrosion performance of thermally sprayed coatings. In this work, a NiWCrBSi alloy coating was deposited via the oxyacetylene flame spray/Flexicord-wire (FS/FC) method. The effect of the flame oxygen/fuel ratio and spray distance on the microstructure properties and corrosion behavior of the coatings was investigated. Afterwards, the microstructure, phases' compositions, spray distance, and corrosion performance were studied. The equivalent circuit model was proposed, and the corrosion mechanism was discussed. The obtained results highlight that the oxygen-to-fuel ratio is a promising solution for the further application of flame spray/Flexicord-wire (FS/FC) cermet coatings in hostile environments. Depending on the flame's oxygen/fuel ratio, careful selection of the flame stoichiometry provides low porosity and high corrosion performance.
Collapse
Affiliation(s)
- Abdelhek Idir
- Laboratory of Mechanics, Materials and Energetic
(L2ME), Faculty of Technology, University of Bejaia, Bejaia 06000, Algeria (M.A.B.); (A.S.)
| | - Francesco Delloro
- MINES ParisTech, PSL Research University, MAT—Centre des Matériaux, CNRS UMR 7633, BP 87, 91003 Evry, France;
| | - Rassim Younes
- Laboratory of Mechanics, Materials and Energetic
(L2ME), Faculty of Technology, University of Bejaia, Bejaia 06000, Algeria (M.A.B.); (A.S.)
| | - Mohand Amokrane Bradai
- Laboratory of Mechanics, Materials and Energetic
(L2ME), Faculty of Technology, University of Bejaia, Bejaia 06000, Algeria (M.A.B.); (A.S.)
| | - Abdelhamid Sadeddine
- Laboratory of Mechanics, Materials and Energetic
(L2ME), Faculty of Technology, University of Bejaia, Bejaia 06000, Algeria (M.A.B.); (A.S.)
| | - Gabriela Marginean
- Institute for Mechanical Engineering, Westphalian University of Applied Sciences Gelsenkirchen Bocholt Recklinghausen, Neidenburger Str. 43, 45897 Gelsenkirchen, Germany
| |
Collapse
|
2
|
Singh S, Berndt CC, Singh Raman RK, Singh H, Ang ASM. Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry. Materials (Basel) 2023; 16:516. [PMID: 36676253 PMCID: PMC9866076 DOI: 10.3390/ma16020516] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/28/2022] [Revised: 12/23/2022] [Accepted: 12/30/2022] [Indexed: 06/17/2023]
Abstract
The steel making processes involves extreme and harsh operating conditions; hence, the production hardware is exposed to degradation mechanisms under high temperature oxidation, erosion, wear, impact, and corrosive environments. These adverse factors affect the product quality and efficiency of the steel making industry, which contributes to production downtime and maintenance costs. Thermal spray technologies that circumvent surface degradation mechanisms are also attractive for their environmental safety, effectiveness and ease of use. The need of thermal spray coatings and advancement in terms of materials and spray processes are reviewed in this article. Application and development of thermal spray coatings for steel making hardware from the molten metal processing stages such as electric arc and basic oxygen furnaces, through to continuous casting, annealing, and the galvanizing line; to the final shaping process such as cold and hot rolling of the steel strips are highlighted. Specifically, thermal spray feedstock materials and processes that have potential to replace hazardous hard chrome plating are discussed. It is projected that novel coating solutions will be incorporated as awareness and acceptance of thermal spray technology grows in the steel making sectors, which will improve the productivity of the industry.
Collapse
Affiliation(s)
- Surinder Singh
- Australian Research Council (ARC), Industrial Transformation Training Centre on Surface Engineering for Advanced Materials (SEAM), Swinburne University of Technology, Hawthorn, VIC 3122, Australia
| | - Christopher C. Berndt
- Australian Research Council (ARC), Industrial Transformation Training Centre on Surface Engineering for Advanced Materials (SEAM), Swinburne University of Technology, Hawthorn, VIC 3122, Australia
| | - R. K. Singh Raman
- Department of Mechanical and Aerospace Engineering, Monash University, Clayton, VIC 3800, Australia
- Department of Chemical Engineering, Monash University, Clayton, VIC 3800, Australia
| | - Harpreet Singh
- Australian Research Council (ARC), Industrial Transformation Training Centre on Surface Engineering for Advanced Materials (SEAM), Swinburne University of Technology, Hawthorn, VIC 3122, Australia
- Department of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar 140001, India
| | - Andrew S. M. Ang
- Australian Research Council (ARC), Industrial Transformation Training Centre on Surface Engineering for Advanced Materials (SEAM), Swinburne University of Technology, Hawthorn, VIC 3122, Australia
| |
Collapse
|
3
|
Bassam SN, Salimijazi H, Labbaf S, Amya M, Ehsani P, Mehrbod P. Antibacterial and Virucidal Evaluation of Ultrafine Wire Arc Sprayed German Silver Coatings. J Therm Spray Technol 2023; 32:959-969. [PMID: 37521527 PMCID: PMC9810382 DOI: 10.1007/s11666-022-01528-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 04/12/2022] [Revised: 12/01/2022] [Accepted: 12/12/2022] [Indexed: 08/01/2023]
Abstract
Copper and its alloys are known as antimicrobial agents that can be used in public places; however, pure copper has a low wear resistance and tends to lose its gloss relatively fast and stainless steel is still more desirable because of its mechanical properties and stable appearance. In this research, German silver coatings, a copper-nickel alloy, are studied as a superior alternative for pure copper coatings. German silver coating on mild steel substrates and stainless steel with two different surface roughnesses was prepared and placed into water bath up to 6 months to investigate the corrosion and exposure effects on the antibacterial behavior. A range of techniques was used to study the microstructure, surface morphology and mechanical properties such as microhardness, coating bonding adhesion, surface roughness and wettability of the coating. Colony count method was used to measure the antibacterial properties, and samples were tested against influenza A virus to evaluate the virucidal activity. The coating thickness was around 130 µm and contained 15% pores and oxides with splats forming inside the coating structure. Inside each splat, columnar grains could be seen with an average of 700 nm width and 4 µm length. The bonding strength of the coating was about 15 MPa, the hardness of coatings was about 180 HV, and the average surface roughness of the as-sprayed samples was about 10 µm. German silver coatings can destroy both Staphylococcus aureus and Escherichia coli by more than 90% after 6 h of exposure time, and it also has a high-level of virucidal activity against influenza A virus after 2 h exposure time. Antibacterial behavior did not show any significant changes after 6 months of immersing samples in water bath. Thus, thermally sprayed German silver coatings exhibited silvery color for a long period of time, while its antimicrobial efficiency was comparable to pure copper coatings. Supplementary Information The online version contains supplementary material available at 10.1007/s11666-022-01528-4.
Collapse
Affiliation(s)
- Seyed Navid Bassam
- Department of Materials Engineering, Isfahan University of Technology, Isfahan, 84156-83111 Iran
| | - Hamidreza Salimijazi
- Department of Materials Engineering, Isfahan University of Technology, Isfahan, 84156-83111 Iran
| | - Sheyda Labbaf
- Department of Materials Engineering, Isfahan University of Technology, Isfahan, 84156-83111 Iran
| | - Melika Amya
- Bacteriology Department, Molecular Biology Lab, Pasteur Institute of Iran, Tehran, Iran
| | - Parastoo Ehsani
- Bacteriology Department, Molecular Biology Lab, Pasteur Institute of Iran, Tehran, Iran
| | - Parvaneh Mehrbod
- Influenza and Respiratory Viruses Department, Pasteur Institute of Iran, Tehran, Iran
| |
Collapse
|
4
|
Černašėjus O, Škamat J, Čepukė Ž, Zhetessova G, Nikonova T, Zharkevich O, Višniakov N, Berg A. Oscillating Laser Post-Processing of NiCrCoFeCBSi/WC Thermally Sprayed Coatings. Materials (Basel) 2022; 15:8041. [PMID: 36431525 PMCID: PMC9696326 DOI: 10.3390/ma15228041] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 10/14/2022] [Revised: 11/06/2022] [Accepted: 11/07/2022] [Indexed: 06/16/2023]
Abstract
In the present experimental study, the transverse oscillating laser beam technique was applied for the post-melting of metal matrix composite coatings, thermally sprayed with nickel-based self-fluxing NiCrCoFeCBSi alloy and 40 wt.% WC, to improve their hardness and wear resistance. The study was conducted using the single module optical fiber laser at 300 W power, >9554 W/cm2 power density, 250−1000 mm/min laser speed, 1 mm and 2 mm transverse oscillation amplitude. Scanning electron microscopy, energy dispersive spectroscopy, Knop hardness measurements, and “Ball-on-disc” dry sliding tests were conducted to study the effect of the processing parameters on the molten pool geometry and microstructure, hardness, and tribology of the processed layers. Oscillating laser processing with an amplitude of 1 mm, 250−750 mm/min laser operating speed, and sample preheating to 400 °C gave a satisfactory result: wide and shallow molten pools of ~200−350 μm in depth, hardness between ~1100 and 1200 HV0.2 and minimum cracks obtained. The coatings obtained with laser beam oscillation and preheating, and ~1150 HV0.2 hardness showed an improvement in the wear resistance and friction coefficient (~0.33) of ~2.9 times and ~20%, respectively, compared with the respective values of the coatings remelted in furnace.
Collapse
Affiliation(s)
- Olegas Černašėjus
- Department of Mechanics and Materials Engineering, Faculty of Mechanics, Vilnius Gediminas Technical University, 03224 Vilnius, Lithuania
| | - Jelena Škamat
- Laboratory of Composite Materials, Faculty of Civil Engineering, Vilnius Gediminas Technical University, 08217 Vilnius, Lithuania
| | - Živilė Čepukė
- Department of Mechanics and Materials Engineering, Faculty of Mechanics, Vilnius Gediminas Technical University, 03224 Vilnius, Lithuania
| | - Gulnara Zhetessova
- Department of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, Karaganda 100000, Kazakhstan
| | - Tatyana Nikonova
- Department of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, Karaganda 100000, Kazakhstan
| | - Olga Zharkevich
- Department of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, Karaganda 100000, Kazakhstan
| | - Nikolaj Višniakov
- Materials Research Laboratory, Vilnius Gediminas Technical University, 03224 Vilnius, Lithuania
| | - Alexandra Berg
- Department of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, Karaganda 100000, Kazakhstan
| |
Collapse
|
5
|
Fan K, Jiang W, Luzin V, Gong T, Feng W, Ruiz-Hervias J, Yao P. Influence of WC Particle Size on the Mechanical Properties and Residual Stress of HVOF Thermally Sprayed WC-10Co-4Cr Coatings. Materials (Basel) 2022; 15:ma15165537. [PMID: 36013673 PMCID: PMC9414634 DOI: 10.3390/ma15165537] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/18/2022] [Revised: 08/05/2022] [Accepted: 08/10/2022] [Indexed: 06/02/2023]
Abstract
Cermet coatings deposited using high-velocity oxy-fuel (HVOF) are widely used due to their excellent wear and corrosion resistance. The new agglomeration-rapid sintering method is an excellent candidate for the preparation of WC-Co-Cr feedstock powders. In this study, four different WC-10Co-4Cr feedstock powders containing WC particles of different sizes were prepared by the new agglomeration-rapid sintering method and deposited on steel substrates using the HVOF technique. The microstructures and mechanical properties of the coatings were investigated using scanning electron microscopy, X-ray diffraction, nanoindentation, and Vickers indentation. The through-thickness residual stress profiles of the coatings and substrate materials were determined using neutron diffraction. We found that the microstructures and mechanical properties of the coatings were strongly dependent on the WC particle size. Decarburization and anisotropic mechanical behaviors were exhibited in the coatings, especially in the nanostructured coating. The coatings containing nano- and medium-sized WC particles were dense and uniform, with a high Young's modulus and hardness and the highest fracture toughness among the four coatings. As the WC particle size increased, the compressive stress in the coating increased considerably. Knowledge of these relationships enables the optimization of feedstock powder design to achieve superior mechanical performance of coatings in the future.
Collapse
Affiliation(s)
- Kunyang Fan
- School of Mechanical Engineering, Chengdu University, Chengdu 610106, China
- Sichuan Province Engineering Technology Research Center of Powder Metallurgy, Chengdu University, Chengdu 610106, China
| | - Wenhuang Jiang
- School of Mechanical Engineering, Chengdu University, Chengdu 610106, China
- Sichuan Province Engineering Technology Research Center of Powder Metallurgy, Chengdu University, Chengdu 610106, China
| | - Vladimir Luzin
- Australian Nuclear Science and Technology Organisation, Lucas Height, Sydney, NSW 2234, Australia
- School of Engineering, The University of Newcastle, Callaghan, NSW 2304, Australia
| | - Taimin Gong
- State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China
| | - Wei Feng
- School of Mechanical Engineering, Chengdu University, Chengdu 610106, China
- Sichuan Province Engineering Technology Research Center of Powder Metallurgy, Chengdu University, Chengdu 610106, China
| | - Jesus Ruiz-Hervias
- Materials Science Department, Universidad Politécnica de Madrid, Escuela Tecnica Superior de Ingenieros de Caminos, Canales y Puertos, C/Profesor Aranguren s/n, 28040 Madrid, Spain
| | - Pingping Yao
- State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410083, China
| |
Collapse
|
6
|
Dorfman MR, Dwivedi G, Dambra C, Wilson S. Perspective: Challenges in the Aerospace Marketplace and Growth Opportunities for Thermal Spray. J Therm Spray Technol 2022; 31:672-684. [PMID: 37520273 PMCID: PMC9014972 DOI: 10.1007/s11666-022-01351-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/18/2021] [Revised: 11/08/2021] [Accepted: 11/08/2021] [Indexed: 08/01/2023]
Abstract
The market needs for increased engine efficiency and environmentally friendly solutions remain the key drivers for the aerospace industry. These efficiency gains will be achieved by meeting the challenges of higher engine operating temperatures, weight reduction, and novel surface solutions for increased component longevity. A critical question to address is if the thermal spray (TS) industry can continue to meet the challenges and demands seen by the airlines and the engine manufacturers. In addition to non-aerospace influences, the COVID-19 pandemic has dramatically affected the landscape of industry growth, not only directly on airlines but also on the associated supply chain. This article reviews this market, its suppliers, and identifies the challenges and opportunities for future growth. Primary focus is on technology and what will be required to bring about reliable, robust, and cost-effective TS solutions into the marketplace. Several issues affecting the global landscape of the aerospace industry are discussed including (1) sustainability, (2) technology, (3) cost of ownership, (4) evolving marketplace, (5) workforce and behavior, and (6) supply chain vitality. An important question to address is if the TS industry can accelerate development with its supply chain and have the ability to commercialize technology more efficiently. Despite the market setbacks from the pandemic and previous issues with the Boeing 737 MAX fleet, the aerospace industry is poised to make significant advancements. These will create new opportunities for thermal spray technology in materials, equipment, and processes. To deliver on them, the implementation of Industry 4.0 along with the investment in human resources is more critical than ever. Based on the findings, the authors project a bright long-term future for both the aerospace and thermal spray industries.
Collapse
Affiliation(s)
| | | | - C. Dambra
- Oerlikon Metco US Inc, Westbury, USA
| | - S. Wilson
- Oerlikon Metco US Inc, Westbury, USA
| |
Collapse
|
7
|
Vinagre PA, Lindén JB, Mardaras E, Pinori E, Svenson J. Probing the correlation between corrosion resistance and biofouling of thermally sprayed metallic substrata in the field. Biofouling 2022; 38:147-161. [PMID: 35184621 DOI: 10.1080/08927014.2022.2033736] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/24/2021] [Revised: 01/19/2022] [Accepted: 01/19/2022] [Indexed: 06/14/2023]
Abstract
The correlation between inherent corrosion resistance and biofouling was investigated for five different metallic coatings. Steel panels thermally spray-coated with either aluminium, Monel, bronze or different aluminium alloys were tested in controlled salt mist conditions and electrochemical corrosion tests and subsequently employed at sea. The biofouling of the panels was monitored at different depths (5, 10 and 15 m) at periods ranging from 5 to 12 months. The main macrofouling organisms were quantified and analysed using permutational multivariate analysis. The results indicate a significant difference in fouling pressure between depths and the geographic sites used. No statistically significant link between high corrosion resistance and lower biofouling pressure was observed, indicating that the main marine macrofoulers settled equally well on corrosion resistant and corrosion prone metallic surfaces. This work sheds light on biofouling of thermally sprayed metallic substrata and it characterizes and compares biofouling assemblages from different biogeographical regions in Europe.
Collapse
Affiliation(s)
- Pedro A Vinagre
- Department of Marine Environment and Licensing, WavEC Offshore Renewables, Lisbon, Portugal
| | - Johan B Lindén
- Department of Corrosion, RISE Research Institutes of Sweden, Borås, Sweden
| | - Enara Mardaras
- AZTERLAN, Basque Research and Technology Alliance (BRTA), Durango, Spain
| | - Emiliano Pinori
- Department of Corrosion, RISE Research Institutes of Sweden, Borås, Sweden
| | | |
Collapse
|
8
|
Singh JK, Mandal S, Adnin RJ, Lee HS, Yang HM. Role of Coating Processes on the Corrosion Kinetics and Mechanism of Zinc in Artificial Seawater. Materials (Basel) 2021; 14:7464. [PMID: 34885619 PMCID: PMC8659072 DOI: 10.3390/ma14237464] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/20/2021] [Revised: 12/01/2021] [Accepted: 12/03/2021] [Indexed: 11/21/2022]
Abstract
Zinc (Zn) coating is being used to protect steel structures from corrosion. There are different processes to deposit the coating onto a steel substrate. Therefore, in the present study, a 100 µm thick Zn coating was deposited by arc and plasma arc thermal spray coating processes, and the corrosion resistance performance was evaluated in artificial seawater. Scanning electron microscopy (SEM) results showed that the arc thermal spray coating exhibited splats and inflight particles, whereas plasma arc spraying showed a uniform and dense morphology. When the exposure periods were extended up to 23 d, the corrosion resistance of the arc as well as the plasma arc thermal spray coating increased considerably. This is attributed to the blocking characteristics of the defects by the stable hydrozincite (Zn5(OH)6(CO3)2).
Collapse
Affiliation(s)
- Jitendra Kumar Singh
- Innovative Durable Building and Infrastructure Research Center, Hanyang University, 55 Hanyangdaehak-ro, Sangrok-gu, Ansan-si 15588, Korea;
| | - Soumen Mandal
- Intelligent Construction Automation Center, Kyungpook National University, 80, Daehak-ro, Buk-gu, Daegu 41566, Korea;
| | - Raihana Jannat Adnin
- Department of Architectural Engineering, Hanyang University, 55 Hanyangdaehak-ro, Sangrok-gu, Ansan-si 15588, Korea;
| | - Han-Seung Lee
- Department of Architectural Engineering, Hanyang University, 55 Hanyangdaehak-ro, Sangrok-gu, Ansan-si 15588, Korea;
| | - Hyun-Min Yang
- Innovative Durable Building and Infrastructure Research Center, Hanyang University, 55 Hanyangdaehak-ro, Sangrok-gu, Ansan-si 15588, Korea;
| |
Collapse
|
9
|
Škamat J, Černašėjus O, Zhetessova G, Nikonova T, Zharkevich O, Višniakov N. Effect of Laser Processing Parameters on Microstructure, Hardness and Tribology of NiCrCoFeCBSi/WC Coatings. Materials (Basel) 2021; 14:6034. [PMID: 34683639 DOI: 10.3390/ma14206034] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/06/2021] [Revised: 10/08/2021] [Accepted: 10/08/2021] [Indexed: 11/27/2022]
Abstract
In the present study, pulsed laser post-processing was applied to improve the properties of the thermally sprayed NiCrCoFeCBSi/40 wt.% WC coatings. The powder mix was deposited onto a mild steel substrate by flame spray method and then the as-sprayed coatings were processed by Nd:YAG laser. The peak power density applied was between 4.00 × 106 and 5.71 × 106 W/cm2, and the laser operating speed ranged between 100 and 400 mm/min, providing processing in a melting mode. Scanning electron microscopy, energy dispersive spectroscopy, Knop hardness measurements, and “ball-on-disc” dry friction tests were applied to study the effect of the processing parameters on the geometry of laser pass and microstructure, hardness, and tribology of the processed layers. The results obtained revealed that pulsed laser processing provides a monolithic remelted coating layer with the microstructure of ultrafine, W-rich dendrites in Ni-based matrix, where size and distribution of W-rich dendrites periodically vary across remelted layer depth. The composition of W-rich dendrites can be attributed to a carbide of type (W, Cr, Ni, Fe)C. The cracks sensitivity of coatings was visibly reduced with the reduction of power density applied. The hardness of coatings was between ~1070 and ~1140 HK0.2 and correlated with microstructure size, being dependent on the processing parameters. The friction coefficient and wear rate of coatings during dry sliding were reduced by up to ~30% and up to ~2.4 times, respectively, after laser processing.
Collapse
|
10
|
Chiang PC, Chen CW, Tsai FT, Lin CK, Chen CC. Hard Anodization Film on Carbon Steel Surface by Thermal Spray and Anodization Methods. Materials (Basel) 2021; 14:ma14133580. [PMID: 34206939 PMCID: PMC8269702 DOI: 10.3390/ma14133580] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/12/2021] [Revised: 06/18/2021] [Accepted: 06/24/2021] [Indexed: 11/16/2022]
Abstract
In this paper, we used two mass-produced industrial technologies, namely, thermal spraying and anodization methods, to enhance the surface characteristics of AISI 1045 medium carbon steel for use in special environments or products. The anodic film can effectively improve the surface properties of carbon steel. A sequence of treatments of the carbon steel substrate surface that consist of sandblasting, spraying the aluminum film, annealing, hot rolling, cleaning, grinding, and polishing can increase the quality of the anodized film. This paper proposes an anodization process for the surface of carbon steel to increase the corrosion resistance, hardness, color diversification, and electrical resistance. The resulting surface improves the hardness (from 170 HV to 524 HV), surface roughness (from 1.26 to 0.15 μm), coloring (from metal color to various colors), and corrosion resistance (from rusty to corrosion resistant). The electrochemical corrosion studies showed that the AISI 1045 steel surface with a hard anodized film had a lower corrosion current density of 10-5.9 A/cm2 and a higher impedance of 9000 ohm than those of naked AISI 1045 steel (10-4.2 A/cm2 and 150 ohm) in HCl gas.
Collapse
Affiliation(s)
- Pao-Chang Chiang
- School of Dentistry, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan;
- Dental Department, Wan Fang Hospital, Taipei Medical University, Taipei 11696, Taiwan
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
| | - Chih-Wei Chen
- Division of Neurosurgery, Department of Surgery, Chi Mei Medical Center, Tainan 71004, Taiwan;
- Department of Occupational Safety and Health, Institute of Industrial Safety and Disaster Prevention, College of Sustainable Environment, Chia Nan University of Pharmacy and Science, Tainan 71710, Taiwan
| | - Fa-Ta Tsai
- Department of Mechanical Engineering, National United University, Miaoli 36003, Taiwan;
| | - Chung-Kwei Lin
- School of Dentistry, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan;
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
- Correspondence: (C.-K.L.); (C.-C.C.)
| | - Chien-Chon Chen
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
- Department of Energy Engineering, National United University, Miaoli 36003, Taiwan
- Correspondence: (C.-K.L.); (C.-C.C.)
| |
Collapse
|
11
|
Liu Y, Huang J, Feng X, Li H. Thermal-Sprayed Photocatalytic Coatings for Biocidal Applications: A Review. J Therm Spray Technol 2020; 30:1-24. [PMID: 38624582 PMCID: PMC7640575 DOI: 10.1007/s11666-020-01118-2] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/24/2020] [Revised: 10/05/2020] [Indexed: 05/03/2023]
Abstract
There have been ever-growing demands for disinfection of water and air in recent years. Efficient, eco-friendly, and cost-effective methods of disinfection for pathogens are vital to the health of human beings. The photocatalysis route has attracted worldwide attention due to its highly efficient oxidative capabilities and sustainable recycling, which can be used to realize the disinfection purposes without secondary pollution. Though many studies have comprehensively reviewed the work about photocatalytic disinfection, including design and fabrication of photocatalytic coatings, inactivation mechanisms, or practical applications, systematic reviews about the disinfection photocatalysis coatings from fabrication to effort for practical use are still rare. Among different ways of fabricating photocatalytic materials, thermal spray is a versatile surface coating technique and competitive in constructing large-scale functional coatings, which is a most promising way for the future environmental purification, biomedical and life health applications. In this review, we briefly introduced various photocatalytic materials and corresponding inactivation mechanisms for virus, bacteria and fungus. We summarized the thermal-sprayed photocatalysts and their antimicrobial performances. Finally, we discussed the future perspectives of the photocatalytic disinfection coatings for potential applications. This review would shed light on the development and implementation of sustainable disinfection strategies that is applicable for extensive use for controlling pathogens in the near future.
Collapse
Affiliation(s)
- Yi Liu
- Key Laboratory of Marine Materials and Related Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
- Zhejiang Engineering Research Center for Biomedical Materials, Cixi Institute of Biomedical Engineering, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
| | - Jing Huang
- Key Laboratory of Marine Materials and Related Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
- Zhejiang Engineering Research Center for Biomedical Materials, Cixi Institute of Biomedical Engineering, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
| | - Xiaohua Feng
- Key Laboratory of Marine Materials and Related Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
- Zhejiang Engineering Research Center for Biomedical Materials, Cixi Institute of Biomedical Engineering, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
| | - Hua Li
- Key Laboratory of Marine Materials and Related Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
- Zhejiang Engineering Research Center for Biomedical Materials, Cixi Institute of Biomedical Engineering, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201 China
| |
Collapse
|
12
|
Ogawa A, Takakura K, Hirai N, Kanematsu H, Kuroda D, Kougo T, Sano K, Terada S. Biofilm Formation Plays a Crucial Rule in the Initial Step of Carbon Steel Corrosion in Air and Water Environments. Materials (Basel) 2020; 13:E923. [PMID: 32092999 PMCID: PMC7079648 DOI: 10.3390/ma13040923] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/28/2019] [Revised: 02/13/2020] [Accepted: 02/14/2020] [Indexed: 12/15/2022]
Abstract
In this study, we examined the relationship between the effect of a zinc coating on protecting carbon steel against biofilm formation in both air and water environments. SS400 carbon steel coupons were covered with a zinc thermal spray coating or copper thermal spray coating. Coated coupons were exposed to either air or water conditions. Following exposure, the surface conditions of each coupon were observed using optical microscopy, and quantitatively analyzed using an x-ray fluorescence analyzer. Debris on the surface of the coupons was used for biofilm analysis including crystal violet staining for quantification, Raman spectroscopic analysis for qualification, and microbiome analysis. The results showed that the zinc thermal spray coating significantly inhibited iron corrosion as well as biofilm formation in both air and water environments. The copper thermal spray coating, however, accelerated iron corrosion in both air and water environments, but accelerated biofilm formation only in a water environment. microbially-influenced-corrosion-related bacteria were barely detected on any coupons, whereas biofilms were detected on all coupons. To summarize these results, electrochemical corrosion is dominant in an air environment and microbially influenced corrosion is strongly involved in water corrosion. Additionally, biofilm formation plays a crucial rule in carbon steel corrosion in both air and water, even though microbially-influenced-corrosion-related bacteria are barely involved in this corrosion.
Collapse
Affiliation(s)
- Akiko Ogawa
- Department of Chemistry and Biochemistry, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (K.T.); (N.H.)
| | - Keito Takakura
- Department of Chemistry and Biochemistry, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (K.T.); (N.H.)
| | - Nobumitsu Hirai
- Department of Chemistry and Biochemistry, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (K.T.); (N.H.)
| | - Hideyuki Kanematsu
- Department of Material Science and Engineering, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (H.K.); (D.K.); (T.K.)
| | - Daisuke Kuroda
- Department of Material Science and Engineering, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (H.K.); (D.K.); (T.K.)
| | - Takeshi Kougo
- Department of Material Science and Engineering, National Institute of Technology (KOSEN), Suzuka College, Suzuka 510-0294, Japan; (H.K.); (D.K.); (T.K.)
| | | | - Satoshi Terada
- Department of Materials Science and Biotechnology, University of Fukui, Fukui 910-8507, Japan;
| |
Collapse
|
13
|
Gateman SM, Page K, Halimi I, Nascimento ARC, Savoie S, Schulz R, Moreau C, Parkin IP, Mauzeroll J. Corrosion of One-Step Superhydrophobic Stainless-Steel Thermal Spray Coatings. ACS Appl Mater Interfaces 2020; 12:1523-1532. [PMID: 31820910 DOI: 10.1021/acsami.9b17836] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/10/2023]
Abstract
As most superhydrophobic coatings are made of soft materials, the need for harder, more robust films is evident in applications where erosional degradation is of concern. The work herein describes a methodology to produce superhydrophobic stainless-steel thermal spray coatings using the high-velocity oxygen fuel technique. Due to the use of a kerosene fuel source, a carbon-rich film is formed on the surface of the thermal spray coatings, lowering the surface energy of the high-energy metallic substrates. The thermal spray process generates a hierarchical micro-/sub-micro-structure that is needed to sustain superhydrophobicity. The effect of spray parameters such as particle velocity and temperature on the coating's hydrophobicity state was explored, and a high particle velocity was shown to cause superhydrophobic characteristics. The coatings were characterized using scanning electron microscopy, profilometry, X-ray photoelectron spectroscopy, static water contact angle measurements, water droplet roll-off measurements, and water droplet bouncing tests. The corrosion behavior of the coatings was studied using potentiodynamic polarization measurements in order to correlate water repellency with corrosion resistance; however, all coatings demonstrated active corrosion without passivation. This study describes an interesting phenomenon where superhydrophobicity does not guarantee corrosion resistance and discusses alternative applications for such materials.
Collapse
Affiliation(s)
- Samantha Michelle Gateman
- Laboratory for Electrochemical Reactive Imaging and Detection of Biological Systems , McGill University , Montreal , Quebec H3A 0B8 , Canada
| | - Kristopher Page
- Materials Chemistry Department , University College London , London WC1E 6BT , United Kingdom
| | - Ilias Halimi
- Laboratory for Electrochemical Reactive Imaging and Detection of Biological Systems , McGill University , Montreal , Quebec H3A 0B8 , Canada
| | | | - Sylvio Savoie
- Institut de recherche d'Hydro-Québec , Varennes , Quebec J3X 1S1 , Canada
| | - Robert Schulz
- Institut de recherche d'Hydro-Québec , Varennes , Quebec J3X 1S1 , Canada
| | - Christian Moreau
- Thermal Spray and Multiphase Flow Laboratory , Concordia University , Montreal , Quebec H3G 1M8 , Canada
| | - Ivan P Parkin
- Materials Chemistry Department , University College London , London WC1E 6BT , United Kingdom
| | - Janine Mauzeroll
- Laboratory for Electrochemical Reactive Imaging and Detection of Biological Systems , McGill University , Montreal , Quebec H3A 0B8 , Canada
| |
Collapse
|
14
|
Piola R, Ang ASM, Leigh M, Wade SA. A comparison of the antifouling performance of air plasma spray (APS) ceramic and high velocity oxygen fuel (HVOF) coatings for use in marine hydraulic applications. Biofouling 2018; 34:479-491. [PMID: 29772915 DOI: 10.1080/08927014.2018.1465052] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/28/2017] [Accepted: 04/10/2018] [Indexed: 06/08/2023]
Abstract
Maritime hydraulic components are often exposed to harsh environmental conditions which can lead to accelerated deterioration, reduced function, equipment failure and costly repair. Two leading causes of maritime hydraulic failure are biofouling accumulation and corrosion. This study examined the antifouling performance of three candidate replacement high velocity oxygen fuel (HVOF) coatings relative to the performance of the current baseline air plasma spray (APS) ceramic coating for protection of hydraulic actuators. Following 20 weeks immersion at tropical and temperate field exposure sites, the control APS ceramic accumulated significantly greater levels of biofouling compared to the HVOF coatings. More specifically, the magnitude of growth of real-world nuisance hard fouling observed on in-service hydraulic components (eg calcareous tubeworms and encrusting bryozoans) was significantly greater on the APS ceramic relative to HVOF coatings. Possible explanations for the observed patterns include differences in surface topography and roughness, the electrochemical potential of the surfaces and the colour/brightness of the coatings.
Collapse
Affiliation(s)
- Richard Piola
- a Maritime Division , Defence Science and Technology , Melbourne , Australia
- d Defence Materials Technology Centre , Melbourne , Australia
| | - Andrew S M Ang
- b Faculty of Science, Engineering and Technology , Swinburne University of Technology , Hawthorn , Australia
- d Defence Materials Technology Centre , Melbourne , Australia
| | - Matthew Leigh
- c MacTaggart Scott Australia , Adelaide , Australia
- d Defence Materials Technology Centre , Melbourne , Australia
| | - Scott A Wade
- b Faculty of Science, Engineering and Technology , Swinburne University of Technology , Hawthorn , Australia
- d Defence Materials Technology Centre , Melbourne , Australia
| |
Collapse
|
15
|
Li S, An Y, Zhao X, Zhou H, Chen J, Hou G. Bioinspired Smart Coating with Superior Tribological Performance. ACS Appl Mater Interfaces 2017; 9:16745-16749. [PMID: 28481509 DOI: 10.1021/acsami.7b03986] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/07/2023]
Abstract
Inspired by the structure of cancellous bone and the nutrition metabolism of articular cartilage, we present a novel concept for a synthetic articular-cartilage-like material. The bioinspired material possesses a low coefficient of friction even under ultrahigh loads and has an extremely long lifetime. Furthermore, the composite shows zero-wear behavior and causes negligible wear damage to the friction pair. The superior tribological performance is attributed to the spontaneously generated articular-cartilage-like layer, which is constantly replenished by frictional heat and pressure. Our findings open a new area for industrial scale engineering applications to improve the friction and wear properties of moving components.
Collapse
Affiliation(s)
- Shuangjian Li
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
- University of Chinese Academy of Sciences , Beijing 100049, People's Republic of China
| | - Yulong An
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
| | - Xiaoqin Zhao
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
| | - Huidi Zhou
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
| | - Jianmin Chen
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
| | - Guoliang Hou
- State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences , Lanzhou 730000, People's Republic of China
| |
Collapse
|
16
|
Xiong HB, Zhang CY, Zhang K, Shao XM. Effects of Atomization Injection on Nanoparticle Processing in Suspension Plasma Spray. Nanomaterials (Basel) 2016; 6:nano6050094. [PMID: 28335222 PMCID: PMC5302494 DOI: 10.3390/nano6050094] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/04/2016] [Revised: 03/30/2016] [Accepted: 05/11/2016] [Indexed: 11/16/2022]
Abstract
Liquid atomization is applied in nanostructure dense coating technology to inject suspended nano-size powder materials into a suspension plasma spray (SPS) torch. This paper presents the effects of the atomization parameters on the nanoparticle processing. A numerical model was developed to simulate the dynamic behaviors of the suspension droplets, the solid nanoparticles or agglomerates, as well as the interactions between them and the plasma gas. The plasma gas was calculated as compressible, multi-component, turbulent jet flow in Eulerian scheme. The droplets and the solid particles were calculated as discrete Lagrangian entities, being tracked through the spray process. The motion and thermal histories of the particles were given in this paper and their release and melting status were observed. The key parameters of atomization, including droplet size, injection angle and velocity were also analyzed. The study revealed that the nanoparticle processing in SPS preferred small droplets with better atomization and less aggregation from suspension preparation. The injection angle and velocity influenced the nanoparticle release percentage. Small angle and low initial velocity might have more nanoparticles released. Besides, the melting percentage of nanoparticles and agglomerates were studied, and the critical droplet diameter to ensure solid melting was drawn. Results showed that most released nanoparticles were well melted, but the agglomerates might be totally melted, partially melted, or even not melted at all, mainly depending on the agglomerate size. For better coating quality, the suspension droplet size should be limited to a critical droplet diameter, which was inversely proportional to the cubic root of weight content, for given critical agglomerate diameter of being totally melted.
Collapse
Affiliation(s)
- Hong-Bing Xiong
- Key Laboratory of Soft Machines and Smart Devices of Zhejiang Province, Zhejiang University, Hangzhou 310027, China.
| | - Cheng-Yu Zhang
- Key Laboratory of Soft Machines and Smart Devices of Zhejiang Province, Zhejiang University, Hangzhou 310027, China.
| | - Kai Zhang
- Key Laboratory of Soft Machines and Smart Devices of Zhejiang Province, Zhejiang University, Hangzhou 310027, China.
- Research Institute of Petroleum Engineering, Shengli Oilfield, Sinopec, Dongying 257000, China.
| | - Xue-Ming Shao
- Key Laboratory of Soft Machines and Smart Devices of Zhejiang Province, Zhejiang University, Hangzhou 310027, China.
| |
Collapse
|
17
|
Dwivedi G, Flynn K, Resnick M, Sampath S, Gouldstone A. Bioinspired hybrid materials from spray-formed ceramic templates. Adv Mater 2015; 27:3073-3078. [PMID: 25855576 DOI: 10.1002/adma.201500303] [Citation(s) in RCA: 24] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/19/2015] [Revised: 02/19/2015] [Indexed: 06/04/2023]
Abstract
Thermally sprayed ceramics, when infiltrated with polymer, exhibit synergistic increases in strength and toughness. The structure of such composites-a dense, brick-mortar arrangement-is strikingly similar to that of nacre, as are the mechanisms underlying the robust mechanical behavior. This industrial-scale process thus presents an exciting tool for bio-mimetic exploration.
Collapse
Affiliation(s)
- Gopal Dwivedi
- Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, 130 Heavy Engineering Building, Stony Brook, NY, 11794, USA
| | - Katherine Flynn
- Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, 130 Heavy Engineering Building, Stony Brook, NY, 11794, USA
| | - Michael Resnick
- Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, 130 Heavy Engineering Building, Stony Brook, NY, 11794, USA
| | - Sanjay Sampath
- Center for Thermal Spray Research, Department of Materials Science and Engineering, Stony Brook University, 130 Heavy Engineering Building, Stony Brook, NY, 11794, USA
| | - Andrew Gouldstone
- Department of Mechanical and Industrial Engineering, Northeastern University, 343 Holmes Hall, Boston, MA, 02115, USA
| |
Collapse
|
18
|
Melero H, Garcia-Giralt N, Fernández J, Díez-Pérez A, Guilemany JM. In vitro performance of ceramic coatings obtained by high velocity oxy-fuel spray. Biomed Mater Eng 2015; 24:1781-91. [PMID: 25201392 DOI: 10.3233/bme-140989] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Hydroxyapatite coatings obtained by plasma-spraying have been used for many years to improve biological performance of bone implants, but several studies have drawn attention to the problems arising from high temperatures and the lack of mechanical properties. In this study, plasma-spraying is substituted by high velocity oxy-fuel (HVOF) spray, with lower temperatures reached, and TiO2 is added in low amounts to hydroxyapatite in order to improve the mechanical properties. Four conditions have been tested to evaluate which are those with better biological properties. Viability and proliferation tests, as well as differentiation assays and morphology observation, are performed with human osteoblast cultures onto the studied coatings. The hydroxyapatite-TiO2 coatings maintain good cell viability and proliferation, especially the cases with higher amorphous phase amount and specific surface, and promote excellent differentiation, with a higher ALP amount for these cases than for polystyrene controls. Observation by SEM corroborates this excellent behaviour. In conclusion, these coatings are a good alternative to those used industrially, and an interesting issue would be improving biological behaviour of the worst cases, which in turn show the better mechanical properties.
Collapse
Affiliation(s)
- H Melero
- Thermal Spray Centre, Universitat de Barcelona, Barcelona, Spain
| | - N Garcia-Giralt
- URFOA, Institut Hospital del Mar d'Investigacions Mèdiques, RETICEF, Barcelona, Spain
| | - J Fernández
- Thermal Spray Centre, Universitat de Barcelona, Barcelona, Spain
| | - A Díez-Pérez
- URFOA, Institut Hospital del Mar d'Investigacions Mèdiques, RETICEF, Barcelona, Spain Servei de Medicina Interna, Hospital del Mar, Barcelona, Spain
| | - J M Guilemany
- Thermal Spray Centre, Universitat de Barcelona, Barcelona, Spain
| |
Collapse
|
19
|
Kuroda S, Kawakita J, Watanabe M, Katanoda H. Warm spraying-a novel coating process based on high-velocity impact of solid particles. Sci Technol Adv Mater 2008; 9:033002. [PMID: 27877996 PMCID: PMC5099653 DOI: 10.1088/1468-6996/9/3/033002] [Citation(s) in RCA: 10] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/28/2008] [Revised: 09/10/2008] [Accepted: 05/01/2008] [Indexed: 06/01/2023]
Abstract
In recent years, coating processes based on the impact of high-velocity solid particles such as cold spraying and aerosol deposition have been developed and attracting much industrial attention. A novel coating process called 'warm spraying' has been developed, in which coatings are formed by the high-velocity impact of solid powder particles heated to appropriate temperatures below the melting point of the powder material. The advantages of such process are as follows: (1) the critical velocity needed to form a coating can be significantly lowered by heating, (2) the degradation of feedstock powder such as oxidation can be significantly controlled compared with conventional thermal spraying where powder is molten, and (3) various coating structures can be realized from porous to dense ones by controlling the temperature and velocity of the particles. The principles and characteristics of this new process are discussed in light of other existing spray processes such as high-velocity oxy-fuel spraying and cold spraying. The gas dynamics of particle heating and acceleration by the spraying apparatus as well as the high-velocity impact phenomena of powder particles are discussed in detail. Several examples of depositing heat sensitive materials such as titanium, metallic glass, WC-Co cermet and polymers are described with potential industrial applications.
Collapse
Affiliation(s)
- Seiji Kuroda
- Composites and Coatings Center, National Institute for Materials Science, 1-2-1 Sengen, Tsukuba, Ibaraki, 305-0047, Japan
| | - Jin Kawakita
- Composites and Coatings Center, National Institute for Materials Science, 1-2-1 Sengen, Tsukuba, Ibaraki, 305-0047, Japan
| | - Makoto Watanabe
- Composites and Coatings Center, National Institute for Materials Science, 1-2-1 Sengen, Tsukuba, Ibaraki, 305-0047, Japan
| | - Hiroshi Katanoda
- Department of Mechanical Engineering, Kagoshima University, Kagoshima 890-0065, Japan
| |
Collapse
|