Current Status and Future Prospects of Warm Spray Technology

Katayama, Seiji; Watanabe, Makoto; Kim, KeeHyun; Katanoda, Hiroshi

doi:10.1007/s11666-011-9648-7

Cited by 86 publications

(26 citation statements)

References 49 publications

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“…Cold spraying, warm spraying or high-velocity air fuel (HVAF) spraying has potential to produce high-quality nanostructured coatings. Proper powder particle design and process development are needed for these processes (Ref 215,216,223). Moreover, plasma-sprayed nanostructured ceramic coatings can present better wear performance compared to conventional, microstructured counterparts (Ref 224).…”

Section: Current Challenges Performance Dependency On Wear Conditionmentioning

confidence: 99%

The 2016 Thermal Spray Roadmap

et al. 2016

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Considerable progress has been made over the last decades in thermal spray technologies, practices and applications. However, like other technologies, they have to continuously evolve to meet new problems and market requirements. This article aims to identify the current challenges limiting the evolution of these technologies and to propose research directions and priorities to meet these challenges. It was prepared on the basis of a collection of short articles written by experts in thermal spray who were asked to present a snapshot of the current state of their specific field, give their views on current challenges faced by the field and provide some guidance as to the R&D required to meet these challenges. The article is divided in three sections that deal with the emerging thermal spray processes, coating properties and function, and biomedical, electronic, aerospace and energy generation applications.

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Section: Current Challenges Performance Dependency On Wear Conditionmentioning

confidence: 99%

The 2016 Thermal Spray Roadmap

et al. 2016

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“…Recently, a novel spray process called warm spraying (WS) (Ref [8][9][10], which is a modification of high-velocity oxy-fuel (HVOF) spraying, has been used to produce Ti6Al-4V coatings. In this process, the temperature of a supersonic gas flow generated by combustion of kerosene and oxygen is controlled by diluting the combustion flame with an inert gas such as nitrogen.…”

Section: Introductionmentioning

confidence: 99%

Effects of Spray Parameters and Post-spray Heat Treatment on Microstructure and Mechanical Properties of Warm-Sprayed Ti-6Al-4V Coatings

et al. 2016

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Warm spray is a novel thermal spray technique that allows the formation of dense and relatively pure Ti-6Al-4V coatings due to its capability to control the temperature of the propellant gas by diluting the combustion flame with an inert gas such as nitrogen. Recently, its combustion pressure has been increased from 1 to 4 MPa aiming to further increase particle velocity to over 1000 m/ s. Two series of coatings with combustion pressure of 1 and 4 MPa and various nitrogen flow rates were prepared in this study. Effects of combustion pressure and nitrogen flow rate on the microstructure and mechanical properties of the Ti-6Al-4V coatings were systematically studied. Miniature tensile specimens with a total length of about 9 mm were used for static tensile tests. It was found that the spray parameters affect both the porosity and oxygen content of the coatings significantly and had remarkable effects on their mechanical properties. High level of porosity in the Ti-6Al-4V coatings reduced the effective cross-sectional area of the mini-specimens and caused a drop in their tensile strength and Young's modulus. Subsequent heat treatments were found effective in significantly recovering the mechanical properties of the as-sprayed coatings.

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“…The combination of higher gas pressures and particle injection outside the combustion zone results in lower particle thermal energies and higher velocities. In some embodiments, air is used in place of oxygen, HVAF, or via N 2 mixing into combustion gas (warm spray), 11 and it has further limited the thermal heating of feedstock material in an attempt to further limit phase decomposition or oxidation of feedstock material.…”

Section: Materials and Process Descriptions Process Hardware And Feedmentioning

confidence: 99%

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

Vackel

Dwivedi

Sampath

2015

JOM

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Thermal spray coatings are used extensively for the protection and life extension of engineering components exposed to harsh wear and/or corrosion during service in aerospace, energy, and heavy machinery sectors. Cermet coatings applied via high-velocity thermal spray are used in aggressive wear situations almost always coupled with corrosive environments. In several instances (e.g., landing gear), coatings are considered as part of the structure requiring system-level considerations. Despite their widespread use, the technology has lacked generalized scientific principles for robust coating design, manufacturing, and performance analysis. Advances in process and in situ diagnostics have provided significant insights into the process-structure-property-performance correlations providing a framework-enhanced design. In this overview, critical aspects of materials, process, parametrics, and performance are discussed through exemplary studies on relevant compositions. The underlying connective theme is understanding and controlling residual stresses generation, which not only addresses process dynamics but also provides linkage for process-property relationship for both the system (e.g., fatigue) and the surface (wear and corrosion). The anisotropic microstructure also invokes the need for damage-tolerant material design to meet future goals.

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Current Status and Future Prospects of Warm Spray Technology

Cited by 86 publications

References 49 publications

The 2016 Thermal Spray Roadmap

The 2016 Thermal Spray Roadmap

Effects of Spray Parameters and Post-spray Heat Treatment on Microstructure and Mechanical Properties of Warm-Sprayed Ti-6Al-4V Coatings

Structurally Integrated, Damage-Tolerant, Thermal Spray Coatings

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