Fundamentals of adhesion of thermal spray coatings: Adhesion of single splats

Balić, Edin E.; Hadad, M.; Bandyopadhyay, P.P.; Michler, Johann

doi:10.1016/j.actamat.2009.08.042

Cited by 37 publications

(11 citation statements)

References 15 publications

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“…For example, spraying the 70S-6 or 410NiMo alloys, the best standoff distance is 160 mm, where the Kinetic energy is the highest possible, since mathematically this kind of energy has direct relation to the velocity, as seen in Equations (1), where K is the Kinetic energy, m is the particle mass, and V is the velocity of the particle. As higher is the energy of the droplets at the moment of impact, as higher is the adherence of the lamellae on the substrate surface and lower porosity [40][41][42].…”

Section: Study Of the Droplets Velocitymentioning

confidence: 99%

Study of Particle Properties of Different Steels Sprayed by Arc Spray Process

et al. 2020

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Thermally sprayed coatings are employed for many purposes, as corrosion protection, wear resistance improvement, resistance to high temperatures, and others. The coating performance depends on its morphology, which is composed by splats, pores, oxide inclusions, and entrapped unmelted or resolidified particles. In arc spray process (ASP), the heat source is the arc electric obtained from the contact of two consumable metallic wires with different electric potentials, and the carrier gas is the compressed air. The velocity, dimensions, and thermal characteristics of the droplets sprayed are related to the morphology and properties of the coating. The main goal of this research is to evaluate how the velocity, temperature, and particle size are modified by the chemical composition of different materials (carbon steel, stainless steels, and FeMnCrSiNi alloy). The intention is to predict how the modification of the process parameters will change the particles properties. The materials had similar behavior tendencies during the flight: the velocity increased to a peak value then decreased, but this maximum value was different for materials with different particle size. The particles’ size did not present significant differences during the flight; and the particles cooled down as they moved away from the gun, except the austenitic stainless steel and the FeMnCrSiNi alloy, which increased the droplets temperature during the travel. These alloys also presented more variation in chemical composition during flight.

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Section: Study Of the Droplets Velocitymentioning

confidence: 99%

Study of Particle Properties of Different Steels Sprayed by Arc Spray Process

et al. 2020

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“…Due to the intrinsic small dimensions of thermally sprayed single splats (∼ µm), few attempts have been made in research to measure adhesion in these systems, mainly focusing on the application of known techniques generally used for thin films analysis. Balic et al, [29] reported an average strain energy release rate of 80 J/m 2 measured on single splats of Vacuum Plasma Sprayed (VPS) Al 2 O 3 material. The value was measured after following the interfacial splat-substrate crack propagation, obtained by indenting the splat via a specifically designed experimental setup.…”

Section: Adhesionmentioning

confidence: 99%

Residual stress and adhesion of thermal spray coatings: Microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat

et al. 2018

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A new approach is proposed to achieve an in-depth understanding of crystallisation, residual stress and adhesion in epitaxial splats obtained by Combustion Flame Spray. Modelling of the fundamental process mechanisms is achieved with the help of experimental observations providing details with a sub-micrometre spatial resolution. At this scope, High Angular Resolution Electron Backscatter Diffraction and Transmission Electron Microscopy analysis are employed to provide insights into crystallisation and residual stress levels, while FIB-milled microcantilever beam bending is used for fracture strength measurements in the case of single splats. A comparison to fully-developed coatings is achieved by employing the X-ray Diffraction sin 2 ψ technique and pull-off methods for residual stress and fracture strength, respectively. The methodology is applied to metallic CoNiCrAlY material sprayed onto a Ni-based superalloy substrate. The establishment of different crystallisation regions: epitaxial and polycrystalline, is the result of variations in the heat flux direction at the solidification front. Significant dislocation density is also reported, indicating the relevance of impact dynamics and plastic deformation mechanisms. The comparison with fully-developed coatings suggests a reduction in inter-splat bonding at splat overlapping.

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“…The coating technology has the advantage of combining two dissimilar materials to improve, in a synergistic way, the performance of the whole. Plasma spray, one of the most common deposition techniques for thick coatings, is characterized by a set of unique features, such as the wide range of materials, homogeneous coatings, fine microstructures, high deposition rate and a process being performed in any conceivable environment [1,2].The purpose of this study is to study the fatigue properties of Cr2O3 (Chromia) and TiO2 (Titania) coatings. Chromium oxide (Cr2O3) based materials have been used to improve the scuff resistance [3,4] and enhance corrosion resistance [5].…”

Section: Introductionmentioning

confidence: 99%

Fatigue behaviour of Plasma Sprayed Titania and Chromia Coatings

et al. 2021

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Cr2O3 and TiO2 powders were deposited by atmospheric plasma spray (APS) on steel substrates. Microstructural analysis of the coatings showed typical lamellar structure with good coating quality. Fatigue strength was studied by using cyclic testing (measuring with an inhouse-built apparatus the strength of the coated systems under a wide range of impact cycles) and static loading tests (Vickers tests standards with 600N and 1500N) measuring the adhesion properties of the coatings. In low cycles (1x103) Titania coatings exhibited better strength, while at intermediate (4.5x105) and high (1x106) number of impact cycles, both Chromia and Titania coatings exhibited quite similar strength characteristics. At low impact force the thickness of the coatings plays critical role with better performance obtained by Chromia coatings. During static loading both coatings exhibited similar characteristics at the crater diameter but with larger crater depth for Titania. Chromia coatings exhibited higher strength resistance than Titania coatings with better mechanical properties and coating structure.

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Fundamentals of adhesion of thermal spray coatings: Adhesion of single splats

Cited by 37 publications

References 15 publications

Study of Particle Properties of Different Steels Sprayed by Arc Spray Process

Study of Particle Properties of Different Steels Sprayed by Arc Spray Process

Residual stress and adhesion of thermal spray coatings: Microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat

Fatigue behaviour of Plasma Sprayed Titania and Chromia Coatings

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