Microstructure and Flight Behaviors of Droplet and its Solidification in Twin-Wire Arc Sprayed Ni-Al Composite Coatings

Wang, Jixiao; Wang, Yongdong; Liu, Jingshun; Zhang, Lunyong; Gao, Lizhen; Zheng, Guanghai; Shen, Hongxian; Sun, Jianfei

doi:10.1590/1980-5373-mr-2017-0394

Cited by 5 publications

(3 citation statements)

References 18 publications

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“…However, because this alone cannot be the only reason for the remaining coating porosity, the particle formation itself was investigated. Particle formation upon atomisation is also dependent on the environmental conditions and can be described with the Weber number [35][36][37][38]:…”

Section: Coating Morphology Depending On the Setted Process Atmospherementioning

confidence: 99%

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Oxide Free Wire Arc Sprayed Coatings—An Avenue to Enhanced Adhesive Tensile Strength

Díaz

Szafarska

Gustus

et al. 2022

Metals

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Conventionally, thermal spraying processes are almost exclusively carried out in an air atmosphere. This results in oxidation of the particles upon thermal spraying, and thus, the interfaces of the splats within the coating are oxidized as well. Hence, a full material bond strength cannot be established. To overcome this issue, a mixture of monosilane and nitrogen was employed in the present study as the atomising and environment gas. With this approach, an oxygen partial pressure corresponding to an extreme-high vacuum was established in the environment and oxide-free coatings could be realized. It is shown that the oxide-free particles have an improved substrate wetting behaviour, which drastically increases the adhesive tensile strength of the wire arc sprayed copper coatings. Moreover, the altered deposition conditions also led to a significant reduction of the coating porosity.

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Section: Coating Morphology Depending On the Setted Process Atmospherementioning

confidence: 99%

“…Metals 2022, 12, x FOR PEER REVIEW 12 of 20 is also dependent on the environmental conditions and can be described with the Weber number [35][36][37][38]:…”

Section: Coating Morphology Depending On the Setted Process Atmospherementioning

confidence: 99%

Oxide Free Wire Arc Sprayed Coatings—An Avenue to Enhanced Adhesive Tensile Strength

Díaz

Szafarska

Gustus

et al. 2022

Metals

View full text Add to dashboard Cite

show abstract

“…In contrast to other coating processes such as atmospheric plasma spraying or cold gas spraying, where the size of the impacting particles is predetermined by the powder fractionation used, particle formation in the arc spraying method is a complex process. According to [38][39][40], the breakup behaviour of a molten droplet in a free jet during arc spraying can be described by the dimensionless Weber number:…”

Section: Particle Formationmentioning

confidence: 99%

Young’s Modulus and Residual Stresses of Oxide-Free Wire Arc Sprayed Copper Coatings

et al. 2022

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Conventional thermal spraying processes are almost exclusively carried out in an air atmosphere, resulting in the oxidation of the particle surfaces and interfaces within the coating and between the substrate and coating. Furthermore, the initial process of surface activation conventionally takes place in an air atmosphere, preventing an oxide-free interfacial transition. Consequently, the application of spraying materials with high oxygen affinity represents a major challenge. To overcome these issues, the present study utilized silane-doped inert gases to create an environment in which the oxygen concentration was equivalent to the residual oxygen content in an extreme high vacuum. By transferring the corundum blasting and coating process (wire arc spraying) to this environment, materials with a high oxygen affinity can be applied without oxidation occurring. For industrial use, this is an interesting prospect, e.g., for repair coatings, as the homogeneity of the composite is improved by a non-oxidized coating. Using the example of arc-sprayed copper coatings, the microstructure and mechanical properties of the coatings were analysed. The results showed that the oxide-free, wire arc sprayed copper coatings exhibited an improved wetting behaviour resulting in a significant reduction of the coating porosity. Moreover, the improved wetting behaviour and led to an increase in the bonding rate and apparent Young’s modulus. Contrary to expectations, the residual stresses decrease although relaxation mechanisms should be inhibited, and possible reasons for this are discussed in the paper.

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Oxynitrided Ti-6Al-4V Coatings Deposited by Twin Wire Arc Spray for Protection of Aluminum Die-Casting Molds

Nango-Blanco,

Brizuela-Colmenares,

Pérez

et al. 2024

J Therm Spray Tech

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Steel molds used for aluminum die-casting often fail due to excessive wear or cracking phenomena associated with the soldering effect in contact with molten aluminum, which leads to the formation of iron-based intermetallic compounds and causes problems in the cast components. One solution is to apply protective coatings whose composition is less reactive with the molten aluminum and improve its hardness, toughness, wear, and corrosion resistance, thus prolonging its service life. This work evaluates the effectiveness of Ti-6Al-4V coatings deposited by twin wire arc spraying in an air or nitrogen atmosphere. Nitrogen was used as the carrier and shielding gas for the in-flight molten particles. Coatings were deposited by varying the stand-off distance, the nitrogen gas pressures, and the substrate temperature. The microstructure of the coatings is interlayered, one porous layer of dendrites and one highly densified layer. The presence of TiN, TiO2, α-Ti, and β-Ti phases was confirmed by different characterization methods. For instance, x-ray photoelectron spectroscopy measurements confirmed the presence of N-Ti, O-Ti, and N-O bonds, with the oxygen/nitrogen/titanium percentage associated with the formation of a non-stoichiometric (Ti, Al, V)NxOy phase. Finally, the reactivity of selected oxynitrided Ti-6Al-4V coating in contact with molten aluminum showed a low reaction rate compared to the coarse reaction layer suffered by the uncoated steel substrates.

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Microstructure and Flight Behaviors of Droplet and its Solidification in Twin-Wire Arc Sprayed Ni-Al Composite Coatings

Cited by 5 publications

References 18 publications

Oxide Free Wire Arc Sprayed Coatings—An Avenue to Enhanced Adhesive Tensile Strength

Oxide Free Wire Arc Sprayed Coatings—An Avenue to Enhanced Adhesive Tensile Strength

Young’s Modulus and Residual Stresses of Oxide-Free Wire Arc Sprayed Copper Coatings

Oxynitrided Ti-6Al-4V Coatings Deposited by Twin Wire Arc Spray for Protection of Aluminum Die-Casting Molds

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