Current status and future directions of thermal spray coatings and techniques

Fauchais, Pierre

doi:10.1016/b978-0-85709-769-9.00002-6

Cited by 18 publications

(10 citation statements)

References 124 publications

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“…As invented a century ago, thermal spray (TS) has been continuously developed based on inherited flexibility, which has led to the expansion of its variants for coating surfaces and applications in a variety of fields. In TS processes, coating precursors, in different physical states (i.e., molten, or semi-molten), are accelerated onto the surface of the substrate producing dense/thick coatings [122][123][124]. The schematic shown in Figure 6 represents a general thermal spraying process and coating produced.…”

Section: Thermal-spraying Processesmentioning

confidence: 99%

High-Entropy Coatings (HEC) for High-Temperature Applications: Materials, Processing, and Properties

et al. 2022

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High-entropy materials (HEM), including alloys, ceramics, and composites, are a novel class of materials that have gained enormous attention over the past two decades. These multi-component novel materials with unique structures always have exceptionally good mechanical properties and phase stability at all temperatures. Of particular interest for high-temperature applications, e.g., in the aerospace and nuclear sectors, is the new concept of high-entropy coatings (HEC) on low-cost metallic substrates, which has just emerged during the last few years. This exciting new virgin field awaits exploration by materials scientists and surface engineers who are often equipped with high-performance computational modelling tools, high-throughput coating deposition technologies and advanced materials testing/characterisation methods, all of which have greatly shortened the development cycle of a new coating from years to months/days. This review article reflects on research progress in the development and application of HEC focusing on high-temperature applications in the context of materials/composition type, coating process selection and desired functional properties. The importance of alloying addition is highlighted, resulting in suppressing oxidation as well as improving corrosion and diffusion resistance in a variety of coating types deposited via common deposition processes. This review provides an overview of this hot topic, highlighting the research challenges, identifying gaps, and suggesting future research activity for high temperature applications.

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Section: Thermal-spraying Processesmentioning

confidence: 99%

High-Entropy Coatings (HEC) for High-Temperature Applications: Materials, Processing, and Properties

et al. 2022

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“…For the scenario described above, a equals 4.271×10 -5 , b is 4.292×10 -7 , and c is 3.743×10 -3 . (̇, ̅ , ) is a function relevant to the powder feed rate (̇) and the deposition efficiency ( ) [46]. Their estimations will be introduced in the following subsection.…”

Section: Single Coating Profile Construction 331 Initial Single Coating Profile Calculationmentioning

confidence: 99%

A parametric simulation model for HVOF coating thickness control

Ren

Rong

2021

Int J Adv Manuf Technol

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“…Subsequently, for using particles smaller than 1 µm, the use of a solvent carrier is necessary for injecting the powder into the plasma. This solvent is evaporated when reaching the core of the plasma, while the solid particles melt, accelerate and impact on a substrate to form a coating [54]. Lee et al [55] used a colloidal spray deposition of Pd particles in the range of 100-300 nm (using water with dispersing agent Darvan C as solvent) with additional heating during spraying at 110 • C. Their efforts resulted in porous Yttria-stabilized Zirconia (YSZ)supported Pd films after subsequent sintering (at 1160 • C for 3 h) with a controllable homogeneous thickness of about 5-11 µm and pores in the range of 3-7 µm.…”

Section: Introductionmentioning

confidence: 99%

Palladium Membrane with High Density of Large-Angle Grain Boundaries to Promote Hydrogen Diffusivity

et al. 2022

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A higher density of large-angle grain boundaries in palladium membranes promotes hydrogen diffusion whereas small-angle grain boundaries suppress it. In this paper, the microstructure formation in 10 µm thick palladium membranes is tuned to achieve a submicronic grain size above 100 nm with a high density of large-angle grain boundaries. Moreover, changes in the grain boundaries’ structure is investigated after exposure to hydrogen at 300 and 500 °C. To attain large-angle grain boundaries in Pd, the coating was performed on yttria-stabilized zirconia/porous Crofer 22 APU substrates (intended for use later in an ultracompact membrane reactor). Two techniques of plasma sprayings were used: suspension plasma spraying using liquid nano-sized powder suspension and vacuum plasma spraying using microsized powder as feedstock. By controlling the process parameters in these two techniques, membranes with a comparable density of large-angle grain boundaries could be developed despite the differences in the fabrication methods and feedstocks. Analyses showed that a randomly oriented submicronic structure could be attained with a very similar grain sizes between 100 and 500 nm which could enhance hydrogen permeation. Exposure to hydrogen for 72 h at high temperatures revealed that the samples maintained their large-angle grain boundaries despite the increase in average grain size to around 536 and 720 nm for vacuum plasma spraying and suspension plasma spraying, respectively.

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Current status and future directions of thermal spray coatings and techniques

Cited by 18 publications

References 124 publications

High-Entropy Coatings (HEC) for High-Temperature Applications: Materials, Processing, and Properties

High-Entropy Coatings (HEC) for High-Temperature Applications: Materials, Processing, and Properties

A parametric simulation model for HVOF coating thickness control

Palladium Membrane with High Density of Large-Angle Grain Boundaries to Promote Hydrogen Diffusivity

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