Journal articles: 'Spray-fused coatings'

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Kulu, P., T. Pihl, K. Tammjärv, and P. Vuoristo. "Formation of microstructure of spray-fused powder coatings." Proceedings of the Estonian Academy of Sciences. Engineering 8, no. 1 (2002): 38. http://dx.doi.org/10.3176/eng.2002.1.03.

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Kulu, P. A., and Ya A. Khalling. "Flame spray coatings on powder metallurgy materials. II. Fused powder coatings." Soviet Powder Metallurgy and Metal Ceramics 25, no. 9 (September 1986): 752–56. http://dx.doi.org/10.1007/bf00797308.

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Sarma, B. Y., and M. M. Mayuram. "Some Studies on Life Prediction of Thermal Sprayed Coatings Under Rolling Contact Conditions." Journal of Tribology 122, no. 3 (October 13, 1999): 503–10. http://dx.doi.org/10.1115/1.555393.

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Design of engineering components is concerned with their strength and durability characteristics. While design for strength is influenced by the bulk material characteristics, the design for durability is dependant on the surface characteristics. Majority of the component failures are surface originated. Surface engineering could play a vital role in minimizing such failures. Thermal sprayed coatings, one of the versatile surface coating techniques, can be applied to components of machinery surfaces to avoid such failures. The present paper presents a methodology for contact stress evaluation of surface coated elements, adopting a layered structure approach, and thereby analytically predict their spalling life. Further data on cycles to single pit formation, and spalling of spray fused coatings obtained from experimental testing are presented for assessing the applicability of life prediction models to layered structures such as sprayed coatings. Experimental investigations were conducted on spray fused coatings using a twin disk RCF test setup. The surface and subsurface contact stress distribution have been obtained analytically by Smith–Liu equations along with first order model perturbation method (FOMP), to account for the variation of elastic modulus constants of the layered structure. Applying Lundberg-Palmgren and Tallian life prediction models, the spalling life of these coatings has been predicted analytically and compared with experimental life values. [S0742-4787(00)02502-9]

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SAREMI, MOHSEN, AHMAD KEYVANI, and MAHMOUD HEYDARZADEH SOHI. "HOT CORROSION RESISTANCE AND MECHANICAL BEHAVIOR OF ATMOSPHERIC PLASMA SPRAYED CONVENTIONAL AND NANOSTRUCTURED ZIRCONIA COATINGS." International Journal of Modern Physics: Conference Series 05 (January 2012): 720–27. http://dx.doi.org/10.1142/s201019451200267x.

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Conventional and nanostructured zirconia coatings were deposited on In-738 Ni super alloy by atmospheric plasma spray technique. The hot corrosion resistance of the coatings was measured at 1050°C using an atmospheric electrical furnace and a fused mixture of vanadium pent oxide and sodium sulfate respectively. According to the experimental results nanostructured coatings showed a better hot corrosion resistance than conventional ones. The improved hot corrosion resistance could be explained by the change of structure to a dense and more packed structure in the nanocoating. The evaluation of mechanical properties by nano indentation method showed the hardness (H) and elastic modulus (E) of the YSZ coating increased substantially after hot corrosion.

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Heath, G. R., and P. A. Kammer. "Fabrication of Graded, Spray, and Fused Coatings and Their High Temperature Erosion Performance." Materials and Manufacturing Processes 11, no. 5 (September 1996): 847–54. http://dx.doi.org/10.1080/10426919608947531.

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Vardavoulias, Michail, Paraskevi Gkomoza, Michael Arkas, Dimitrios K. Niakolas, and Stylianos G. Neophytides. "Thermal Spray Multilayer Ceramic Structures with Potential for Solid Oxide Cell Applications." Coatings 11, no. 6 (June 5, 2021): 682. http://dx.doi.org/10.3390/coatings11060682.

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The objective of this paper is to manufacture free-standing solid oxide cells (SOCs) through the atmospheric plasma spray process (APS), without the aid of a metallic support nor the need for a post-process heating treatment. A five-layered cell was fabricated. Fused and crushed yttria-stabilized zirconia (YSZ) powder in the 5–22 μm particle size range was used in order to achieve a dense electrolyte layer, yet still permitting satisfactory ionic diffusivity. Nickel oxide (NiO) powder that was obtained by in-house flame spray (FS) oxidation of pure nickel (Ni) powder was mixed and sprayed with the original Ni-YSZ feedstock, so as to increase the porosity content in the supporting electrode. Two transition layers were sprayed, the first between the support electrode and the electrolyte (25% (Ni/NiO)–75% YSZ) and the second at the electrolyte and the end electrode interface (50% YSZ–50% lanthanum strontium manganite (LSM)). The purpose of intercalation of these transition layers was to facilitate the ionic motion and also to eliminate thermal expansion mismatches. All the as-sprayed layers were separately tested by an in-house developed acetone permeability comparative test (APCT). Electrodes with adequate porosity (25–30%) were obtained. Concerning electrolytes, relatively thick (150–200 µm) layers derived from fused and crushed YSZ were found to be impermeable to acetone, while thinner YSZ counterparts of less than 100 µm showed a low degree of permeability, which was attributed mostly to existent microcracks and insufficient interparticle cohesion, rather than to interconnected porosity.

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Zhang, Wenmin, Cheng Peng, Defang Liu, Yangfang Cheng, and Jianqing Wu. "Preparation of fused silica membrane with high performance for high temperature gas filtration by sealing and spray coating." Ceramics International 45, no. 9 (June 2019): 11607–14. http://dx.doi.org/10.1016/j.ceramint.2019.03.032.

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Ayouchi, R., F. Mart�n, J. R. Ramos-Barrado, and D. Leinen. "Compositional, structural and electrical characterization of barium titanate thin films prepared on fused silica and Si(111) by spray pyrolysis." Surface and Interface Analysis 30, no. 1 (2000): 565–69. http://dx.doi.org/10.1002/1096-9918(200008)30:1<565::aid-sia867>3.0.co;2-p.

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Faisal, Nadimul Haque, John A. Steel, Rehan Ahmed, R. L. Reuben, G. Heaton, and Bryan Allcock. "Application of Acoustic Emission for Monitoring the HVOF Thermal Spraying Process." Advanced Materials Research 13-14 (February 2006): 291–98. http://dx.doi.org/10.4028/www.scientific.net/amr.13-14.291.

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This research aims to characterise and quantify the acoustic emission (AE) generated during the high velocity oxy-fuel (HVOF) thermal spraying process, recorded using piezoelectric AE sensors. The HVOF process is very complex involving high temperature turbulent flow through a nozzle with entrained particles, the projection of these particles, and their interaction with the target surface. Process parameters such as gun speed, oxy-fuel pressure and powder specification affect various characteristics of the coating, including thermal residual stresses; the lamellar microstructure and the topology and geometry of pores, all formed when the fused powder hits the surface, forming “splats”. It is widely acknowledged in the thermal spray industry that existing quality control techniques and testing techniques need to be improved. New techniques which help to understand the effects of coating process parameters on the characteristics of the coating are therefore of value, and it was anticipated that recording the AE produced when the fused particles contact the surface would aid this understanding. As a first stage, we demonstrated here that AE associated with particle impact can, in fact, be discerned in the face of the considerable airborne and structure-borne noise. In order to do this, a new test method using a masking sheet with slits of varying size was developed. Thermal spraying was carried out for a range of spray gun speeds and process parameters. The AE was measured using a broad band AE sensor positioned on the back of the sample as the spot was traversed across it. The results show that the amplitude and energy of the AE signals is related to the spray gun speed, powder used and the oxy-fuel pressure. Using a simple geometrical model for particle impact, the measured AE was found to vary with the energy and number of particles impacting on the sample in a predictable way.

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OH, J., J. KOMOTORI, and J. SONG. "Fatigue strength and fracture mechanism of different post-fused thermal spray-coated steels with a Co-based self-fluxing alloy coating." International Journal of Fatigue 30, no. 8 (August 2008): 1441–47. http://dx.doi.org/10.1016/j.ijfatigue.2007.10.004.

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Sauerbier, Philipp, James Anderson, and Douglas Gardner. "Surface Preparation and Treatment for Large-Scale 3D-Printed Composite Tooling Coating Adhesion." Coatings 8, no. 12 (December 11, 2018): 457. http://dx.doi.org/10.3390/coatings8120457.

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Recent advances in large-scale thermoplastic additive manufacturing (AM), using fused deposition modelling (FDM), have shown that the technology can effectively produce large aerospace tools with common feed stocks, costing 2.3 $/kg, such as a 20% carbon-filled acrylonitrile butadiene styrene (ABS). Large-scale additive manufacturing machines have build-volumes in the range of cubic meters and use commercially available pellet feedstock thermoplastics, which are significantly cheaper (5–10 $/kg) than the filament feedstocks for desktop 3D printers (20–50 $/kg). Additionally, large-scale AM machines have a higher material throughput on the order of 50 kg/h. This enables the cost-efficient tool production for several industries. Large-scale 3D-printed tooling will be computerized numerical control (CNC)-machined and -coated, to provide a surface suitable for demolding the composite parts. This paper outlines research undertaken to review and improve the adhesion of the coating systems to large, low-cost AM composite tooling, for marine or infrastructure composite applications. Lower cost tooling systems typically have a lower dimensional accuracy and thermal operating requirements than might be required for aerospace tooling. As such, they can use lower cost commodity grade thermoplastics. The polymer systems explored in the study included polypropylene (PP), styrene-maleic anhydride (SMA), and polylactic acid (PLA). Bio-based filler materials were used to reduce cost and increase the strength and stiffness of the material. Fillers used in the study included wood flour, at 30% by weight and spray-dried cellulose nano-fibrils, at 20% by weight. Applicable adhesion of the coating was achieved with PP, after surface treatment, and untreated SMA and PLA showed desirable coating adhesion results. PLA wood-filled composites offered the best properties for the desired application and, furthermore, they have environment-friendly advantages.

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Stier, Simon P., and Holger Böse. "Ablative Laser Structuring for Stretchable Multilayer and Multi-Material Electronics and Sensor Systems." Proceedings 56, no. 1 (December 17, 2020): 21. http://dx.doi.org/10.3390/proceedings2020056021.

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Conventional machining and shaping processes for polymers and elastomers such as injection molding exhibit significant disadvantages, as specific tools have to be manufactured, the method of machining is highly dependent on the material properties, and the cost of automation is usually high. Therefore, additive manufacturing processes (3D printing) have established themselves as an alternative. This eliminates the expensive production of tools and the production is individualized. However, the specific (additive) manufacturing process remains highly dependent on the properties of the material. These processes include selective laser sintering (SLS) for powdered thermoplastic polymers and metals, extrusion such as fused deposition modeling (FDM) for thermoplastic polymers in wire form, or optical curing such as digital light processing (DLP) for liquid resins. Especially for elastomer sensors or circuit boards (structure of several alternately constituted approx. 100 µm-thick elastomer films made with different types of liquid silicone rubber), there is no suitable additive manufacturing process that combines liquid, partly non-transparent source materials, multi-component printing, and very fine layer thicknesses. In order to enable a largely automated, computer-aided manufacturing process, we have developed the concept of ablative multilayer and multi-material laser-assisted manufacturing. Here, the layers (conductive and non-conductive elastomers, as well as metal layers for contacting) are first coated over the entire surface (e.g., spray, dip, or doctor blade coating, as well as galvanic coating) and then selectively removed with a CO2 or fiber laser. These steps are repeated several times to achieve a multi-layer structured design. Is it not only possible to adjust and improve the work previously carried out manually, but also to introduce completely new concepts, such as fine through-plating between the layers to enable much more compact structures to be possible. As an exemplary application, we have used the process for manufacturing a thin and surface solderable pressure sensor and a stretchable circuit board.

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Govindaswamy, Pradeep Dyavappanakoppalu, Venkatesh Channarayapattana Venkataramaiah, Nithin Hiriyuru Shivegowda, and Subba Rao Medabalimi. "Evaluation of High Temperature Dry Sliding Wear Behaviour of Thermal Sprayed and Microwave Fused WC12Co and CeO2 Modified WC12Co Composite Coatings." Applied Science and Engineering Progress, March 29, 2022. http://dx.doi.org/10.14416/j.asep.2022.03.007.

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Thermal spray methods are used to increase the wear resistance of working surfaces. Microwave post-treatment is the advanced approach for enhancing the properties of thermal spray coatings. The current investigation focuses on the wear behavior of HVOF-sprayed and microwave-treated coatings. The WC12Co and CeO2 modified WC12Co composite coatings were successfully deposited on AISI4140 steel using the HVOF thermal spray technique. The coatings were tested in both as-sprayed and microwave post-treatment conditions. The dry sliding wear tests were carried out at temperatures of RT, 200, 400, and 600 ℃ with various loads. Vickers hardness tester, Scanning Electron Microscopy (SEM), and X-ray diffraction (XRD) equipments were used to investigate the microhardness, microstructure, and phases of coatings, respectively. In both compositions, the microwave-fused coating had a fine homogeneous structure and higher hardness than the as-sprayed depositions. For typical loads of 20 N and 40 N for both compositions, the friction coefficient decreased with increasing temperature in the as-sprayed and fused coatings. At all conditions, the microwave fused coating outperforms the as-sprayed coating in terms of wear resistance. During sliding action, the fused coatings exhibit tribo-oxide layers, which provide the best wear resistance of the microwave fused composite coatings. The wear resistance of the WC12Co coatings is improved as compared to CeO2 modified WC12Co coatings.

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Perna, Alessia Serena, Antonello Astarita, Domenico Borrelli, Antonio Caraviello, Francesco Delloro, Roberta Della Gatta, Patrizio Lomonaco, Ilaria Papa, Raffaele Sansone, and Antonio Viscusi. "Fused Filament Fabrication of ONYX-Based Composites Coated with Aluminum Powders: a Preliminary Analysis on Feasibility and Characterization." ESAFORM 2021, March 30, 2021. http://dx.doi.org/10.25518/esaform21.4017.

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Polymer-based AM methods are the most mature additive technologies for their versatility and variety of products obtainable. The addition of fibre reinforcement can also confer to the manufactures produced good mechanical properties. Unfortunately, several applications are still precluded because polymers cannot guarantee appropriate electrical conductivity, erosion resistance and operating temperature. Aiming to overcome these issues, the metallization of the surfaces emerges as a possible solution. Unfortunately, thermoplastic polymers exhibit thermosensitive behaviour and run the risk of being damaged when traditional metallization techniques, which require the melting of metal powders which will act as a protective coating. For this reason, studies have focused on Cold Gas Dynamic Spray, an additive manufacturing technology, which exploits kinetic energy to favour the adhesion of metal particles rather than the increase in temperature. In this work, a first attempt is made to verify the feasibility of cold spray coatings on 3D printed composite substrates, produced by means of Fused Filament Fabrication (FFF) technique. FFF technology allows the deposition of two different types of filaments by using a double extruder. These composite fibres within 3D printed parts manage to give the object a resistance comparable to that of a metal part with lower production cost and a high degree of automation. These structures, made of ONYX, a Nylon matrix in which short carbon fibres are dispersed, and reinforced with long carbon fibres, are designed to better fit the CS deposition. Aluminium coatings have been produced and a characterization campaign has been carried on.

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Della Gatta, Roberta, Antonello Astarita, Domenico Borrelli, Antonio Caraviello, Francesco Delloro, Patrizio Lomonaco, Ilaria Papa, Alessia Serena Perna, Raffaele Sansone, and Antonio Viscusi. "Manufacturing Of Aluminum Coating On 3D-Printed Onyx With Cold Spray Technology." ESAFORM 2021, March 29, 2021. http://dx.doi.org/10.25518/esaform21.858.

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Composite materials are widely used as main parts and structural components in different fields, especially for automotive and military applications. Although these materials supply different advantages comparing to the metals, their implementation in engineering applications is limited due to low electrical and thermal properties and low resistance to erosion. To enhance these above-mentioned properties, the metallization of composite materials by creating a thin metal film on their surface can be achieved. Among different coating deposition techniques, Cold Spray appears to be the most suitable one for the metallization of temperature-sensitive materials such as polymers and composites with a thermoplastic matrix. This process relies on kinetic energy for the formation of the coating rather than on thermal energy and consequent erosion and degradation of the polymer-based composite can be avoided. In the last years, a new method to produce composite materials, as known as Fused Filament Fabrication (FFF), has been developed for industrial applications. This technique consists of a 3D printing process that involves the thermal extrusion of thermoplastic polymer and fibers in the form of filaments from a heated mobile nozzle. The implementation of this new technique is leading to the manufacturing of customized composite materials for the cold spray application. In the presented experimental campaign, Onyx material is used as a substrate. This material is made of Nylon, a thermoplastic matrix, and chopped carbon fibers randomly dispersed in it. Aluminum powders were cold sprayed on the Onyx substrate with a low-pressure cold spray (LPCS) system. This study aims to investigate the possibility of the metalizing 3D-printed composite material by cold spray technology. For this purpose, optical and microscopical analyses are carried out. Based on the results, the feasibility of the process and the influence of the morphology of the substrate are discussed, and optimal spraying conditions are proposed.

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Viscusi, Antonio, Antonello Astarita, Domenico Borrelli, Antonio Caraviello, Luigi Carrino, Roberta Della Gatta, Valentina Lopresto, et al. "On the Influence of Manufacturing Strategy of 3D-Printed Polymer Substrates on Cold Spray Deposition." ESAFORM 2021, April 2, 2021. http://dx.doi.org/10.25518/esaform21.3003.

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PMCs are anisotropic and heterogeneous structures with excellent performances in terms of mechanical strength and stiffness, coupled with reduced weight, widely used in engineering sectors. The use of PMCs can be further extended by improving their surface properties such as electrical conductivity, erosion, radiation and lightning protection. In this context, the surface metallization seems to be best solution. In particular, the cold spray (CS) technique candidates as a potential method for the manufacturing of a metal coating on PMCs’ surface. However, the design and the manufacturing methods of PMCs can play a crucial role for an effective metallization through CS. The additive manufacturing technologies for composite materials can be used to manufacture customized reinforced polymer-based panels, like PMCs; the most common method for printing them is the Fused Filament Fabrication (FFF) technique which relies on the thermal extrusion of a thermoplastic feedstock from a mobile heated nozzle. Therefore, this research activity aims to manufacture customized PMCs panels by using FFF technology for the substrate and the cold spray technique for the metallization in order to study the influence of the substrate manufacturing strategy on CS deposition process. For this purpose, three kind of 3D-printed PMCs were manufactured through the FFF technology by varying the percentage fill of the Onyx polymeric matrix and aluminum powders were sprayed on the substrates with a low-pressure cold spray (LPCS) system; both FFF and CS process parameters were varied to study the process in its wholeness. Microscope analyses were carried out to analyze the influence of the manufacturing strategy on the coating quality.

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"Study of Surface Properties of Fused Deposition Modelling Parts." International Journal for Research in Engineering Application & Management, May 30, 2020, 61–64. http://dx.doi.org/10.35291/2454-9150.2020.0363.

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Fused Deposition Modeling (FDM) is one of the most commonly used Additive Manufacturing (AM) methods for converting 3D designs into physical models. The printing head melts the thermoplastic material and then extrudes the melted material through the extrusion nozzle layer by layer until the final 3D object is obtained. The build material used here is acrylonitrile butadiene styrene (ABS). The layer by layer addition of the material results in an uneven surface finish of the final product. Studies have shown that the post processing techniques like coating will have a positive impact on the surface finish as well as hardness. In this study, the specimen for the coating processes were printed as per the ASTM standards (ASTM D2240, ASTM D256) needed for mechanical tests. Different post processing techniques involving sputtering, spray painting and acetone dipping were carried out with a negligible change in specimen thickness. The samples were either coated with Copper, or dipped in acetone to smoothen the surface. These coated specimens were then tested for roughness & hardness and the results showed significant improvements. A comparison has been made between the results of different post processing techniques in order to determine the most suitable process.

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Hussain, Rohanah, Tamás Jávorfi, and Giuliano Siligardi. "CD Imaging at High Spatial Resolution at Diamond B23 Beamline: Evolution and Applications." Frontiers in Chemistry 9 (April 8, 2021). http://dx.doi.org/10.3389/fchem.2021.616928.

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Circular Dichroism imaging in the 190–650 nm spectral region pionered at Diamond Light Source B23 beamline, has been made possible by the highly collimated microbeam generated at the beamline and has been used to study the homogeneity of the supramolecular structures of thin films of chiral materials deposited on fused quartz substrates. This facility has been expanded with the installation of a Mueller Matrix Polarimeter, MMP, coupled to the beamlight, of which a preliminary data will be discussed. In the solid state, the measurement of CD related to the supramolecular structure is hampered by the presence of circular birefringence, linear dichroism, and linear birefringence that can only be evaluated using the MMP technique. The ability to characterize the chiroptical property of thin chiral films prepared under a variety of conditions and protocols such as drop cast, spin coating, spray at different temperatures and concentrations will enable the determination of the critical parameters for reproducible, uniform and homogeneous specimen preparation, which is the sine qua non for any commercial application. This is of particular importance for optoelectronic materials, but it can also be extended to a broad variety of materials with applications from biosensors to biological tissues.

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Journal articles on the topic 'Spray-fused coatings'

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