In this study, nine coating systems of Yb 2 Si 2 O 7 /Si-HfO 2 EBCs with varying spraying process parameters were deposited on silicon carbide (SiC) substrates using the air plasma spraying (APS) process and an orthogonal experimental method. The effects of variations in spraying distance, current, and hydrogen flow rate on spraying power and coating bond strength were investigated.

In this work, thermal sprayed coatings based on high-alloy steel (Batch 1), Al, Zn, pseudo alloys thereof and CuSn6 (Batch 2) were applied to spheroidal cast iron materials subject to fatigue stress to prevent corrosion and preserve fatigue strength.

This study presents initial findings on three methods for adding carbon to WC-17Co powder to prevent carbide degradation in coatings. The approach had two objectives: first, to saturate the molten cobalt binder with carbon, thereby reducing the dissolution of tungsten carbide; and second, to replace carbon lost during the spraying process, ensuring the final composition could form stoichiometric WC + Co either immediately after spraying or following heat treatment.

This research examines the combination of a corrosion-resistant CoNiCrAlY binder with Cr 3 C 2 carbide particles. The powder was applied using two contrasting thermal conditions: low-energy HVOF and high-energy shrouded plasma spraying. This approach created a wide range of carbide dissolution and peritectic decomposition outcomes. The study includes detailed characterization of the feedstock powder composition to explain the phase formation during sintering compared to the original powder components.

The commonly used method for preparing EBCs is atmospheric plasma spraying (APS), but it has problems such as easy oxidation of the coating, low spraying power, and low substrate temperature, resulting in the coating having multiple pores, cracks, and insufficient density. The new plasma spraying physical vapor deposition (PS-PVD) technology can solve these problems. This article compares the microstructure, mechanical properties, and phase composition of EBCs prepared using APS and PS-PVD processes.

This study offers a comprehensive understanding of NiCrSiBMoFeCuC coating deposited via HVOF through the use of high-resolution TEM imaging, which provides detailed crystallographic information and defect analysis capabilities. The chemical composition of the coating was evaluated with both SEM-EDS and TEM-EDS, while lattice parameter values were measured using both x-ray diffraction and transmission electron microscopy.

This study examines the development of plasma-sprayed quasicrystalline Al-Cu-Fe coatings with wear-resistant, low-friction, and non-stick properties. Varying hydrogen flow rates during plasma spraying were investigated, revealing that moderate hydrogen addition creates an optimal balance of quasicrystalline phases and oxide formation. These optimized coatings demonstrated superior sliding wear resistance compared to the baseline. Post-treatment by grinding reduced surface roughness, achieving a non-stick surface.

This study presents a general overview of ceramic abradable coatings used in the high-pressure section of turbines that are sprayed over superalloys.

This paper focuses on WC-NiMoCrFeCo composite powder. The effects of high-energy ball milling processes under different conditions on the mechanical alloying of the powder and the acid corrosion resistance of the coating after spraying were studied.

This study focuses on the development of three TiO 2 -based coatings using suspension flame spray process. Superhydrophobic properties were achieved by creating surface roughness and reducing energy with stearic acid. The effects of polydimethylsiloxane and epoxy on these properties and durability were tested under UV light and low temperatures.

The primary goal of this research work is to enable methane decomposition in absence of inert conditions as well as comparatively lower catalyst activation temperatures using thermally sprayed optimized catalytic coatings. Preliminary tests of twin-wire arc thermally sprayed coatings of metal alloys confirm the decomposition of methane gas.

This study analyzes the influence of reactive elements like H 2 regarding hydrogen embrittlement to determine whether the porous structure of the plasma sprayed coating itself, or the thermal treatment with H 2 is influencing the cohesion and microstructure. To exclude substrate-related influencing factors during testing, tensile rods of thermally sprayed coatings were manufactured.

The objective of this study is to optimize thin electric and mechanical functional copper coatings using atmospheric plasma spray by determining the impact of particle temperature and velocity on coating properties. A particular focus is placed on the formation of real contact between the particles within the coating, which is crucial for electrical conductivity while the contact at the interface is essential for adhesive strength.

The present study explores the feasibility of utilizing both cold and flame spray processes to fabricate the latest version of the resistive heating coating-based system for steel pipes, focusing on a straightforward design that minimizes material and labor costs.

The aim of this study is to develop a solid shroud to minimize in-flight oxidation using the particle swarm optimization (PSO) algorithm. Additionally, the shroud is specially designed to use air as a cooling medium instead of water and is made from common stainless steel to help reduce equipment and process costs.

This study employs an XAI framework to gain insights into Residual Network and Artificial Neural Network models trained on both simulations and experimental data to predict deposition efficiency (DE) in atmospheric plasma spraying (APS). SHapley Additive exPlanations (SHAP), an interpretability framework, was then applied to help identify which process parameters have the most significant influence on the DE and to reveal how changes in specific parameters affect the DE by elucidating their impact on the model predictions.

Thermal spray coatings are typically applied to grit-blasted, rough surfaces, though coating models generally assume smooth substrates. This research involved simulating nickel coating formation on rough stainless-steel substrates in an atmospheric plasma spray process. The researchers evaluated coating topography, porosity, thickness, and roughness using a Monte-Carlo stochastic algorithm. The temperature differential between coating and substrate creates residual thermal stresses, which were analyzed using NIST's Object Oriented Finite element software (OOF). Results indicate that substrate roughness increases coating roughness and creates non-uniform stress distribution with concentration points at the coating-substrate interface.

The aim of this work is to propose a novel low-cost non-contact infrared pyrometric technique for in-situ temperature measurement at different depths of the substrate without interfering with the coating process from the backside of the substate. This procedure allows not only to obtain the temperature variation in the region close to the substrate surface, reducing the external interferences associated with the thermal spraying process, but also to observe with high accuracy the temperature variation in the substrate thickness over time, which can be used for the subsequent experimental validation of numerical simulation models of the coating process.

This study investigated a new two-step approach in interface modification. First, a steel-based bipolar plate (BPP) is coated by thermal spraying. Second, a thermally sprayed porous transport layer (PTL) is directly applied onto the coating, reducing construction gaps in the cell design. The interface modification is evaluated by measuring the interfacial contact resistance. The resistance is successfully reduced by this approach.

This study investigates the cold gas spraying (CGS) process as an innovative approach for fabricating cBN-copper composite coatings. CGS, a low-temperature thermal spray and additive manufacturing process, prevents thermal degradation of sensitive materials such as cBN and ensures a dense coating with a high bond strength. The research focuses on key parameters such as primary gas temperature and pressure as well as the ratio of cBN to copper, analyzing their effects on coating performance.