One of the promising thermal barrier coatings (TBC) options for use above 1250 °C has been La 2 Ce 2 O 7 (LC). This work explored the role of dual layered ceramic coatings in the top layer of the TBC system that has been prepared using atmospheric plasma spraying (APS). Above the NiCrAlY bond coat, 8 mol.% yttria stabilized zirconia (8YSZ) coating has been deposited with optimized APS parameters. Over the top layer (8YSZ), another layer that comprises composite with LC and 8 wt.% of 8YSZ (spray dried) has been deposited. Investigations into the hot-corrosion behavior of 8YSZ-LC based TBC subjected to Na 2 SO 4 +V 2 O 5 salt at 950 °C for 4 hours. A porous layer made mostly of LaVO 4 , CeO 2 , CeO 1.66 and YVO 4 was developed on the LC+8wt.% YSZ layer after being subjected to a hot corrosion test in Na 2 SO 4 +V 2 O 5 salt. Dissociation of LC and 8YSZ leads to the formation of new phases, such as CeO 1.66 , CeO 2 , LaVO 4 and YVO 4 as the corrosion by-products in the extreme environment. The findings indicated that delamination has occurred due to the phase transformation, cavities and cracks in the 8YSZ-LC based TBCs. The molten salt's hot corrosion mechanisms of the 8YSZ-LC based TBC are discussed in detail. Further, the potential use of 8YSZ-LC based dual coatings and scope for the future work have been derived from the current study.

Cavitation is a wear process in engineering systems caused by the energy release of collapsing bubbles leading to the failure of critical components such as valves, pumps, and propellers. Thermally sprayed coatings can be applied to improve the wear resistance of these components. This investigation considers a WC-NiCrBSi coating composition under cavitation wear, where the WC phase provides the strength and the NiCrBSi matrix offers corrosion resistance in seawater. Coatings were deposited on AISI 440C stainless steel discs of 32mm diameter and 8mm thickness using industrially optimized parameters for the HVOF JP5000 system. Indirect cavitation tests were conducted using a modified ASTM G32 testing procedure on coated test coupons in as-sprayed and Hot Isostatic Pressed (HIPed) conditions. Two tests were performed for each coating using natural seawater of pH 8.19 at room temperature, and averaged wear values are reported to compare the cavitation rate and cumulative mass loss of the coatings. Coating microstructural phases in the as-sprayed and HIPed conditions were identified using X-ray diffraction. The microstructure of the coating substrate system and post-cavitation test wear scars were investigated using Scanning Electron Microscopy (SEM) equipped with energy dispersive spectroscopy (EDS). This investigation provides an understanding of the corrosive-cavitation wear behavior and failure modes of coatings. The cavitation erosion rate and cumulative mass loss results showed that the as-sprayed WC-NiCrBSi coatings improve the cavitation wear resistance of the substrate.

Nowadays, Cr 3 C 2 -based cermet coatings by HVOF process are widely recognized for their corrosion and erosion resistance, particularly at high temperatures. These coatings also offer the advantage of being lightweight and exhibiting superior wear, corrosion and cavitation resistance in room-temperature applications. Their lightweight nature and high temperature capability make them an attractive alternative to WC-based alloy coatings and hard Cr plating coatings. The objective of this study is to develop optimal Cr 3 C 2 -NiCr coatings by comparing different feedstock materials, including feedstock with nanocrystalline and/or submicron sized Cr 3 C 2 phases. The focus of the investigation is on understanding the impact of feedstock features such as particle size, morphology, and carbide sizes, as well as sliding abrasive wear conditions (specifically SiC grit size and working load), on the coating properties and sliding wear performance. The results of the study indicate that the sliding wear resistance of the Cr 3 C 2 -NiCr coatings is highly influenced by the features of the Cr 3 C 2 carbides. The presence of nano, submicron and few microns sized carbides in the coatings improves their density and hardness, leading to a significant reduction in wear rates under test conditions. Furthermore, the size of the abrasive SiC grit on the counter surface plays a significant role in determining the sliding wear behavior of these coatings. Based on the analysis of the test data, the mechanisms behind the performance of the Cr3C2-NiCr coatings have been investigated and used to interpret their sliding wear behaviors. A high microhardness in the coating is considered a reliable indicator of high quality, full density, and satisfactory wear resistance. This study has identified and recommended optimized materials for improved coating properties based on the key findings. These findings contribute to the understanding of the relationship between feedstock features, sliding abrasive wear conditions, and the wear rates of HVOF-sprayed Cr 3 C 2 -NiCr coatings.

Thermally sprayed wear resistant coatings have proven their effectiveness in many applications. Their benefit is unquestionable in the case of mutual sliding contact or abrasive stress caused by hard particles. However, for the case of dynamic impact loading, either single or cyclic, the lifetime of different types of coatings is rarely described, probably due to the complex influence of many parameters. The paper deals with the evaluation of resistance to dynamic impact loading of two types of HVOF-sprayed Cr3C2-rich binary hardmetal coatings (Cr3C2-42%WC-16%Ni and Cr3C2-37%WC-18%NiCoCr) with respect to the variation of their deposition parameters and compares them to a well established Cr3C2-25%NiCr coating. For each coating, a Wohler-like curve was constructed based on a failure criterion of sudden increase in impact crater volume. Besides, coatings deposition rate, residual stress, microstructure and hardness were evaluated. Differences in the coatings dynamic impact wear resistance was found, related to their residual stress. The failure mechanism and crack propagation mode are analyzed using SEM of impact surface and cross-sections. Deformation and related stress changes in coated systems during dynamic impact loading are described using FEA analyzes.

Thermally sprayed abradable coatings are essential for improving the performance of gas turbine engines. They act as a protective barrier between the stationary casing and rotating blades. Though a lot of research has been done on abradable coatings, little attention has been paid to comprehending wear mechanisms in the abradable-blade tip interaction. The goal of this project is to create a cost-effective test rig that can evaluate different thermally sprayed abradable coatings and understand how they interact with titanium blade tips under application-relevant conditions. Blade tip velocity, incursion rates, incursion depths, reaction forces, and interfacial temperatures are some of the inputs and outputs that the testing rig can provide. Aiming to validate the rig, this study examined the wear behavior of aluminum, thermally sprayed polyester, and AlSi-40Polyester abradable coating. The reaction forces for aluminum and polyester were overall higher when compared to AlSi-40Polyester. However, thermally sprayed polyester showed the highest interfacial temperatures of all materials tested. The difference in the reaction forces and interfacial temperature correlates well with the different wear mechanisms and thermal conductivities. Overall, the equipment showed to be a promising pre-screening methodology to evaluate and develop novel thermal spray abradable coatings.

Composite coatings using mixed alloy matrices reinforced with carbon-based solid lubricants as feedstock materials were prepared by atmospheric plasma spraying. The aim of the present study was to investigate the tribological characteristics of such coatings exploring potential benefits of CNTs as nano-additive to reduce friction and wear, improving lubrication conditions during operation in tribosystems, such as piston ring – cylinder liner systems. The chemical composition of feedstock materials and the thermal spray parameters during coatings deposition are correlated to friction coefficient and wear rate using pin-on-disk measurements. The developed coatings hybrid behaviour is studied. Co-based cermet as well as metal alloy anti-wear performance along with the promoted lubrication conditions during operation is revealed. The dependence of the developed coatings quality and performance on the characteristics of the feedstock powder is thoroughly discussed.

Thermal barrier coatings have provided a revolution in the industry as they allow a higher operating temperature of equipment, improving the efficiency of gas turbines. However, one of the biggest challenges in terms of increasing the lifespan of TBC systems is the attack of fused silicates or simply CMAS (Calcium-Magnesium-Alumina-Silicate). CMAS are particles from the environment that can penetrate the TBC structure and cause delamination of the coating when exposed to high temperatures during thermal cycling. In this study, a plasma sprayed YSZ coating in the as coated and surface treated condition were given CMAS depositions from various preparation methods, and then subjected to thermal cycles at different evaluation temperatures and exposure times. The permeability of the ceramic layer and the penetration path of CMAS at different temperature levels were evaluated, as well as the penetration characteristics in relation to the microstructure of the ceramic layer. X-Ray diffraction and Scanning Electron Microscopy were used to characterize the applied CMAS and the penetration kinetics and conditions. Samples with longer exposure time had a considerable volume increase. The conditions to guarantee the formation of the silicate and its consequent wettability are also discussed.

In the study, Axial Suspension Plasma Spray (SPS) was used to produce a range of columnar microstructures from Yttria Stabilized Zirconia (YSZ) suspension after an extensive experimental design. The optimized microstructure was applied to a multi-layer GZ/YSZ system, in which both layers were sprayed with SPS. In addition to SPS, a new GZ coating using Axial Solution Precursor Plasma Spray (SPPS) was developed and deposited on top of the SPS GZ coating. The durability in the furnace cycling test (FCT), as well as the consequences of CMAS infiltration into the columnar coatings was extensively studied on different microstructures. Preliminary CMAS test on the SPS coatings infiltrated them completely, leading to delamination. To minimize the detrimental effect of CMAS on the underlying SPS, the dense solution precursor GZ layer was aimed to act as a sealant to protect the underlying columnar SPS-GZ layer from molten CMAS infiltration.

Atmospheric plasma sprayed (APS) CuNiIn coatings have been widely used for fretting wear protection in many important areas such as aircraft engines for decades. The oxides in CuNiIn coating prepared by APS hinder splat bonding formation and thus degrade the coating fretting performance. In this study, CuNiIn powders of different boron contents were designed to realize the self-oxide-cleaning effect for in-flight molten droplets and thus deposit the dense CuNiIn coating with high fretting performance. Scanning electron microscope was used to characterize the microstructure. The oxygen content in the coating was measured by the inert gas fusion technique. Fretting test was performed for three coatings under different loadings. The results show that CuNiIn2B and CuNiIn4B coatings presented the oxide content of 0.40wt% and 0.38wt%, which are lower than 1.6wt% of the CuNiIn coating. The oxygen content in the CuNiIn4B coating decreased with the increase of spray distance while the oxygen content in CuNiIn coating increased with the increase of the spray distance. Such results clearly reveal the boron in-situ deoxidizing effect of inflight molten droplets. As a result, the dense CuNiIn2B and CuNiIn4B coatings were deposited with oxide-free molten droplets. The test results showed that the fretting wear performance of B-alloyed CuNiIn coatings were increased by a factor over three comparing with conventional CuNiIn coating.

This paper evaluates the cavitation erosion wear rate and failure modes of WC-10Co-4Cr coatings. These coatings are used in various industrial applications to protect against erosive, abrasive, sliding and cavitation wear in corrosive environments. Cavitation erosion tests were performed using a modified ASTM G-32 cavitation test rig. Thermally sprayed High Velocity Oxy-Fuel (HVOF) WC-Co-Cr coatings were deposited using industrially optimised coating process parameters on carbon steel and stainless-steel substrate coupons. Coatings were tested to simulate the cavitation bubbles occurring in valves, pumps, and ship propellers. Indirect cavitation was used to impact the cavitation bubbles on the test specimen at a fixed offset distance from the vibrator end. Test specimens were immersed in natural seawater. A water circulation cooling system was used to control the temperature of the water. The cumulative mass cavitation erosion and erosion rate results were evaluated. The coating microstructure was analysed using Scanning Electron Microscopy (SEM) and x-ray diffraction. Post-test evaluations included SEM observation in combination with energy dispersive x-ray analysis (EDX) to understand the failure modes. Results are discussed in terms of the factors controlling the cavitation erosion rate.

Iron-based coatings are often considered as replacement of hard chromium and WC-Co, as they pose lower health and environmental impact. In many cases the combination of mechanical and chemical properties of ferrous based alloys may be satisfactory and their relatively low cost make these coatings an interesting candidate for many applications. This study is inspired by opportunities to harden the ferrous base materials by strain hardening, solid solution strengthening, dispersion strengthening, and precipitation hardening. Already commercially available Fe-based coating materials with precipitates of mixed carbides and borides in the metastable austenitic matrix achieve a high hardness. In this study the cavitation erosion and abrasion resistance of various Fe-based coatings produced by HVAF and HVOF processes were investigated. Two experimental precipitation containing materials were prepared, and the sprayed coatings were tested for abrasive and cavitation erosion wear. In addition to precipitations, the importance of proportion of ferrite and retained austenite phases were studied by affecting the microstructure by heat treatments as the ability of different phases to affect hardening and ductility may become crucial in generating desired material properties. The properties of experimental and some commercial Fe-based alloys are compared with WC-Co and Cr 3 C 2 -NiCr coatings by property mapping.

This study investigates the solid particle erosion performance of cold sprayed tungsten carbide-nickel coatings using alumina particles as erodent material. After coating fabrication, specimens were annealed in an electric furnace at a temperature of 600 °C for 1 hour. The coatings were examined in terms of microhardness and microstructure in the as-sprayed (AS) and annealed (AN) conditions. Subsequently, the erosion tests were carried out using a General Full Factorial Design with two control factors and two replicates for each experimental run. The effect of the annealing on the erosion behavior of the coating was investigated at the two levels (AS and AN conditions), along with the impact angle of the erodents at three levels (30°, 60°, 90°). Finally, two regression models that relate the impact angle to the mass loss were separately obtained for the two cold spray coatings.

This work provides a new in-situ measurement method for the analysis of the spray-spot geometry and the thermal properties of the coating. The new approach is based on infrared detection of the thermal radiation from the coating surface combined with a subsequent automated spray-spot characterization. With this method it is possible to describe the geometry, the axis-position of the torch, the powder injection properties, and the temperature distribution in of the spray-spot. Especially for the automated production in high quantity the spray-spot analysis is a useful assistance for the operator because the detector reacts very sensitive on small changes of the process conditions. With regard on important fields of application (e.g., gas turbine production) the sensor is suitable to detect drifting spray system parameters. Also, the progression of wear at the nozzle, injector and electrode can easily be estimated. In recent research the in-situ spray spot analysis is being developed further for the characterization of multipair electrode plasma generators.

In this work, a novel liquid fuel HVOF process fueled with ethanol was used to prepare 75wt%Cr 3 C 2 –25wt%NiCr coatings on AISI304 stainless steel substrate. Taguchi method was employed to optimize the spray parameters (ethanol flow rate, oxygen flow rate, powder feed rate and standoff distance) to achieve better erosion resistance at 90° impact angle. The results indicated that ethanol flow rate and oxygen flow rate were identified as the highly contributing parameters on the erosion wear loss. The important sequence of the spray parameter is ethanol flow rate > oxygen flow rate > standoff distance > powder feed rate. The optimal spray parameter (OSP) for minimum erosion wear loss was obtained under ethanol flow rate of 28slph, oxygen flow rate of 420slpm, powder feed rate of 76.7 g/min and standoff distance of 300mm. The phase composition, microstructure, hardness, porosities, and the erosion wear behaviors of the coatings have been studied in detail. Besides, erosion wear testing of the optimized coating was conducted at 30°, 60° and 90° impact angle using air jet erosion testing machine. The SEM images of the erodent samples were taken to analyze the erosion mechanism.

Manufacturing of steel components is often done at high temperatures (HT) posing a serious challenge to components such as forming tools. Thermal spray coatings provide a cost-effective solution for surface protection under HT, corrosive environments and severe wear conditions. Thermally sprayed coatings based on cubic hard materials such as TiC and TiCN can provide an alternative to widely used Cr3C2-NiCr. While the latter possess a superb oxidation resistance and wear resistance at HT, they are prone to degradation in the presence of Mn, an element commonly alloyed in many modern steel grades such as TWIP (twinning-induced plasticity steel). In this study, a (Ti,Mo)(C,N)-29% Ni hardmetal feedstock powder was prepared by agglomeration and sintering. Coatings were deposited using a high velocity air-fuel (HVAF) spray process. The coating was benchmarked against a standard Cr3C2-NiCr coating obtained with the same spray process. Our work comprises analyses of the feedstock powder along with the resulting coating microstructure after deposition and heat treatment. Further, the HT sliding behavior against TWIP steel using a HT pin-on-disc tribometer at 700°C was investigated. The results showed a clear benefit of the TiCN-based coating, with almost no wear detected, while the Cr3C2-coating showed a significant wear loss. Based on these results, the TiCN-based coating is regarded as potential solution for prospective forming applications of modern high Mn steels, such as TWIP.

In this investigation, NiTi coatings are applied by atmospheric plasma spraying. Surface and interface morphology of the as-deposited material is studied using scanning electron microscopy, the presence of the different phases are revealed by X-ray diffractometry, and microhardness is determined by Vickers hardness testing. The as-deposited coatings are exposed to air-borne particle erosion to investigate their wear properties while varying erodent impact pressure and angle. It was found that the plasma sprayed NiTi splats are well formed with significant amounts of intermetallic and oxide phases at the surface and interface, contributing to dense splat formation and higher hardness.

This study investigates the synergistic effects of cavitation and corrosion on Cr 3 C 2 -25NiCr coatings with different levels of porosity. The coatings are deposited by HVOF spraying and evaluated based on SEM analysis, Vickers microhardness, potentiodynamic polarization measurements, and cavitation erosion tests in various environments under ultrasonic vibration. The results show that higher porosity reduces both cavitation and corrosion resistance, as expected. However, the samples did not show significant alteration of their cavitation properties in NaCl, probably because of the high corrosion resistance of the different phases in the coating. The influence of HVOF fuel-oxygen ratio and total gas flow on coating porosity, as well as phase morphology, is also discussed.

The current study investigates the influence of the grain size fraction D of a FeCrB/WC-Co feedstock material on the coating properties. In previous studies, novel FeCrB/WC-Co wear and corrosion protection coatings applied by means of high velocity air-fuel (HVAF) spraying were developed by the authors. It was observed that coatings, which were produced with a slightly decreased powder grain size fraction and identical chemical composition showed improved coating properties, i.e. reduced crack formation in the coating at high powder feed rates . and lower current densities at high overpotentials. The goal of this study is to investigate the influence of the powder grain size fraction on the coating properties in more detail. Furthermore, the underlying mechanism for the improved coating properties, with regard to their corrosion behaviour, is investigated. Therefore, the FeCrB/WC-Co feedstock material with the grain size fractions of -20 +3 μm and -32 +11 μm and identical chemical composition was applied by means of HVAF-spraying and the coatings were subsequently analysed. Light microscopy was used to investigate the microstructure of the coatings. The wear and corrosion properties were analysed using pin-on-disc (POD) and electrochemical polarization tests respectively. XRD-measurements were used to investigate the phase composition and to develop a hypothesis for the different corrosion behaviours of the investigated coatings. The results show that HVAF-sprayed FeCrB/WC-Co coatings produced with a powder grain size fraction of -20 +3 μm exhibit lower current densities at high overpotentials, compared to the coatings produced with a powder grain size fraction of -32 +11 μm.

A common method to combat abrasive wear and prolong the life of a component is to hardface the exposed region by overlay welding. State of the art coatings for these applications consist of a nickel-based ductile matrix with hard tungsten carbide particles embedded in it. An alternative with low environmental impact in combination with high performance to cost ratio is to use iron-based alloys. Critical in affecting the abrasive and impact wear resistance of these alloys is the coating quality e.g. porosity, cracks, dilution from the substrate combined with chemistry, size and volume fraction of the hard phase particles formed during solidification. Selection of the process parameters is critical for producing sound clads with expected properties. This paper focuses on the properties of PTA welded and laser cladded M2, M4 and A11 high speed steel coatings. Clad quality, hardness, abrasive wear resistance and microstructure are presented and interpreted with support of thermodynamic simulations.

A known family of rare-earth oxide (REO) ceramics have recently been found to exhibit intrinsic hydrophobicity, even after exposure to high temperatures and abrasive wear. In this study, thin CeO 2 coatings were developed for hydrophobic applications using suspension high velocity oxy-fuel (SHVOF) thermal spray. It is an efficient method to produce large superhydrophobic surfaces with a unique hierarchically textured structure on a variety of substrates. The use of suspension also enables the process of fine-grained powders to form nanostructured coatings with significant improvement of mechanical and chemical properties for numerous applications. An aqueous suspension with a solid concentration of 30 wt.% sub-micron CeO 2 particles (<200 nm) was used as suspension feedstock. The as-sprayed CeO 2 coating on a stainless steel significantly improved the substrate’s surface hydrophobicity from a low contact angle of 57° to nearly 150°. The surface chemistry of SHVOF thermal sprayed CeO 2 coatings was also investigated by X-ray photoelectron spectroscopy (XPS). It was confirmed that the near-super-hydrophobicity was mainly attributed to its unique hierarchically structured surface.