Carbide-based thermal spray coatings: A review on performance characteristics and post-treatment

Govande, Akshay R.; Chandak, Aayush; Sunil, B. Ratna; Dumpala, Ravikumar

doi:10.1016/j.ijrmhm.2021.105772

Cited by 70 publications

(16 citation statements)

References 213 publications

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“…Considering that post-processing of thermally sprayed layers is known to lead to changes in microstructure, phase constitution, etc., [141][142][143] some of which could be relevant for enhancing the attributes of a few of the coatings discussed above, not much work has been reported on this aspect in the context of coatings for electrolysers. Most commonly, thermal post-treatment (including laser irradiation) of coatings to refine microstructure and potentially enhance properties has been explored.…”

Section: Raney Nickelmentioning

confidence: 99%

Application of Thermal Spray Coatings in Electrolysers for Hydrogen Production: Advances, Challenges, and Opportunities

et al. 2022

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Thermal spray coatings have the advantage of providing thick and functional coatings from a range of engineering materials. The associated coating processes provide good control of coating thickness, morphology, microstructure, pore size and porosity, and residual strain in the coatings through selection of suitable process parameters for any coating material of interest. This review consolidates scarce literature on thermally sprayed components which are critical and vital constituents (e.g., catalysts (anode/cathode), solid electrolyte, and transport layer, including corrosion-prone parts such as bipolar plates) of the water splitting electrolysis process for hydrogen production. The research shows that there is a gap in thermally sprayed feedstock material selection strategy as well as in addressing modelling needs that can be crucial to advancing applications exploiting their catalytic and corrosion-resistant properties to split water for hydrogen production. Due to readily scalable production enabled by thermal spray techniques, this manufacturing route bears potential to dominate the sustainable electrolyser technologies in the future. While the well-established thermal spray coating variants may have certain limitations in the manner they are currently practiced, deployment of both conventional and novel thermal spray approaches (suspension, solution, hybrid) is clearly promising for targeted development of electrolysers.

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Section: Raney Nickelmentioning

confidence: 99%

Application of Thermal Spray Coatings in Electrolysers for Hydrogen Production: Advances, Challenges, and Opportunities

et al. 2022

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“…Protective coatings can increase the lifespan of equipment parts and structures, since the coating protects the substrates from damaging mechanisms, such as corrosion, fatigue, high-temperature oxidation, and wear [ 1 , 2 , 3 , 4 , 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of Pre-Milling of Cr3C2-25 NiCr Spray Powder on the Fatigue Life of HVOF-Sprayed Coating on ASTM A516 Steel Substrate

Oliveira

Cogo²,

Nascimento

et al. 2023

Materials

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The aim of the present investigation is to evaluate the influence of the powder size of Cr3C2-25NiCr spraying powder on the fatigue behavior of HVOF-sprayed coating on the ASTM A516 steel substrate. Conventional commercial Cr3C2-25NiCr spraying powder was previously treated through high-energy milling. The crystallite sizes of milled powders were measured by X-ray diffraction and transmission electronic microscopy. Three different powder formats of the same Cr3C2-25NiCr composite were subjected to HVOF spraying to produce (i) a Milled-Coating (from high-energy milled spray powder), (ii) an Original-Coating (from conventional commercial spray powder), and (iii) a 50%–50% mixture of both (Milled + Original-Coating). The same spraying conditions were adopted for all the assessed cases. The sprayed coatings were investigated through the Knoop hardness test and SEM-EDS analysis. In addition, 3-point bending fatigue tests were conducted at different stress levels up to 107 cycles. The coating morphology and roughness effects on fatigue behavior were analyzed. The Cr3C2-25NiCr milled coating presented a lower fatigue life above the fatigue limit and a higher fatigue limit than other coatings; this outcome could be attributed to its lower surface roughness and finer grain size microstructure.

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“…The High-Velocity Oxygen Flame (HVOF) method, High-Velocity Air Flame (HVAF) method, cold spray (CS) method, and aerosol deposition (AD) method have been developed as devices for spraying with compressed gas [ 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 ]. Much research and development have been conducted on HVOF and HVAF spraying equipment [ 1 , 2 , 3 , 4 , 5 ]. HVOF spraying equipment has the powder material sprayed onto the substrate at high speed and high temperature with high-pressure oxygen [ 1 ].…”

Section: Introductionmentioning

confidence: 99%

Characteristics of Vibrating Fluidization and Transportation for Al2O3 Powder

et al. 2022

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This study focused on the vibrating fluidized-bed-type powder feeder used in HVAF thermal spraying equipment. This feeder has been used in thermal spraying equipment and industrial applications. However, particulate materials’ flow mechanism and stable transport characteristics have not been fully understood. This study experimentally investigated the fluidization characteristics, powder dispersion state, and powder transportation characteristics of Al2O3 particles during vertical vibration fluidization. The material used was Al2O3 particles of 2.9 μm and 3808 kg/m3, classified as the group C particles in the Geldart diagram. As experimental conditions, the fluidized air velocity to the bottom of the powder bed and the vibration intensity in the vertical direction changed. The critical fluidization air velocity was defined to evaluate the generating powder flow by vertical vibrating fluidization. As a result, good fluidization of the powder bed of Al2O3 was obtained by the vertical vibration, as well as an airflow that was higher than the critical fluidization air velocity. Regarding powder transportation characteristics, it was clarified that the fluidized air velocity at the bottom of the powder dispersion vessel and the pressure difference from the powder dispersion vessel to the transportation part significantly affect the mass flow rate.

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Carbide-based thermal spray coatings: A review on performance characteristics and post-treatment

Cited by 70 publications

References 213 publications

Application of Thermal Spray Coatings in Electrolysers for Hydrogen Production: Advances, Challenges, and Opportunities

Application of Thermal Spray Coatings in Electrolysers for Hydrogen Production: Advances, Challenges, and Opportunities

Influence of Pre-Milling of Cr3C2-25 NiCr Spray Powder on the Fatigue Life of HVOF-Sprayed Coating on ASTM A516 Steel Substrate

Characteristics of Vibrating Fluidization and Transportation for Al2O3 Powder

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