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.

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 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 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 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.

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 aims to develop strategies for coating free-form surfaces and assess their effectiveness as heating elements. Atmospheric plasma spraying was used to apply heating coatings to samples with various radii. Different coating strategies were evaluated, and their effects on the coating quality (and heating behavior) were analyzed.

In this study, an internal powder injection was employed with a modified anode nozzle. The effects of the anode geometry and spray particle size on spray particle temperature were investigated. Moreover, the effect of spray particle temperature on the in-situ in-flight deoxidization and intersplat bonding formation were examined with both boron and carbon deoxidizers.

In this study, a high-entropy alloy (HEA) powder containing boron (NiCrCuMoB) was developed for atmospheric plasma spraying to produce coatings with minimal oxide formation in the molten droplets. The in-situ deoxidizing effect of boron during flight was investigated by analyzing collected HEA particles. The oxidation behavior of individual splats deposited on polished stainless-steel substrates was also examined. The resulting coating microstructure and mechanical properties were characterized. The results demonstrate that the addition of boron effectively suppresses in-flight oxidation of the molten particles, leading to the production of HEA particles with low oxide content. Consequently, bulk-like HEA coatings exhibiting strong metallurgical bonding and a reduced oxide content were achieved due to the deoxidizing action of boron.

In this study, axisymmetric two-dimensional numerical analysis was performed to clarify the particle behavior in supersonic hybrid aerosol deposition (HAD). The predicted result showed that the small particles, which can deposit via HAD, impact the substrate on a wide region while the large particles, which can abrade the surface of film and substrate, impact around the center.

This study investigates the effects of varying particle size and particle size distribution of stoichiometric Yb 2 Si 2 O 7 feedstock powder on SiO volatilization, Yb 2 SiO 5 secondary phase formation, and crack behavior in Yb 2 Si 2 O 7 EBCs.

This paper presents a comparative analysis of three coating types—W 2 C/WC12Co (Metco71NS), Cr 2 O 3 -4SiO 2 -3TiO (Metco136F), and Co25.5Cr10.5Ni7.5W0.5C (Metco45C-NS)—applied to disc harrow components, focusing on their microstructural and tribological properties.

All solid-state sodium-ion batteries (ASS-SIBs) have great potential for application to large-scale energy storage devices due to their safety advantages by avoiding flammable organics and the abundance of sodium. In this study, plasma spraying was used to deposit Na 3 Zr 2 Si 2 PO 12 (NZSP) electrolyte for assembling high performance ASS-SIBs. NZSP electrolyte layers were deposited at different spray conditions using NZSP powders in different particle sizes. The factors influencing the microstructure and compositions of NZSP layers were examined by characterizing the compositions of splat and cross-sectional microstructures of the deposits. It was found that the preferential evaporation loss of Na and P elements occurs severely to result in a large composition deviation from initial powders and spray particle size is key factor which dominates their evaporation loss. The APS NZSP electrolytes present a dense microstructure with well bonded splats which is attributed to low melting point of NZSP. The apparent porosity of the as-sprayed NZSPs was lower than 3 %. The effect of annealing on the microstructure of APS NZSP was also investigated. The performance of typical APS NZSP was also evaluated by assembling an ASS-SIB battery with APS NaxCoO2 (NCO), Na 3 Zr 2 Si 2 PO 12 (NZSP) and Li 4 Ti 5 O 12 (LTO) as cathode, electrolyte and anode, respectively. Results showed that columnar-structured grains with a chemical inter-splat bonding were formed across the interfaces between electrodes and electrolyte. There is no evidence of inter-diffusion of zirconium, cobalt and silicon across the NCO/NZSP interface. With the preliminary battery, the solid electrolyte exhibited an ionic conductivity of 1.21 × 10 -4 S cm -1 at 200 o C. The SIB can operate at 2.5 V with a capacity of 10.5 mA h g -1 at current density of 37.4 μA cm -2 .

Cold atmospheric plasma spraying is used to produce thin coatings of copper and tin between 20-80 μm thickness for use in diffusion soldering. This study presents an alternative process to apply composite solders directly onto power electronic bare dies. The formation of intermetallic phases may be promoted by the homogeneous distribution of the Cu and Sn particles as they are presented not in a layered structure but as a pseudo alloy within the coating. The Cu and Sn powder is mixed in situ using two powder conveyors, enabling adjustable mix ratios. The presented approach has been shown to produce a homogeneous particle distribution within the coating. Furthermore, preliminary experiments indicate the feasibility of the technology for applications in diffusion soldering.

Surface structures are of vital importance for the wetting behaviors of hydrophobic coatings. In this work, rare earth oxide coatings with different surface structures were deposited via the solution precursor atmospheric plasma spray (SPAPS) process and solution precursor vacuum plasma spray (SPVPS) process, respectively. The SPAPS coatings showed hierarchical cauliflower-like surface structures composed of micron-sized clusters and nanometer-sized particles, while the SPVPS coatings showed relatively flat topographies with small and short bumps. The formation of different surface structures in the SPAPS and SPVPS processes was investigated by modelling the movement of in-flight particles in the vicinity of the substrate. The properties of plasma jets and the characteristics of in-flight particles in the two processes were correlated. The effects of diverted plasma gas flow on the trajectories of particles impinging on the substrate and the resultant surface structures were elaborated, revealing different shadowing effects in the SPAPS and SPVPS processes. The SPAPS coatings were superhydrophobic due to the presence of hierarchical surface structures, which showed larger water contact angles and smaller roll-off angles than the SPVPS coatings. The correlations between the surface structures and wetting behaviors of different coatings were investigated.

The ingestion of siliceous particulate debris into the gas turbine engines during operation caused the deposition of so-called CMAS (calcium-magnesium-alumino-silicate) on the hotter thermal barrier coating (TBC) surfaces. The penetration of these particles into the TBC at temperatures above 1200°C caused the loss of strain tolerance and premature failure of the TBCs. To mimic real-world conditions, a commercially available CMAS precursor dust powder was sprayed onto 8YSZ coatings using an atmospheric plasma spraying process. The substrate temperature was maintained at an average of 1100°C and 525°C during spraying. The effect of the spraying parameters on the deposition, microstructure, and composition of the CMAS coatings was investigated. In addition, to understand the CMAS build-up on the high-temperature surfaces, the CMAS splat formation behavior was also analyzed on the polished samples at temperatures ~1100°C. SEM/EDS analyzes were performed to identify and quantify the elements of the CMAS deposits. It was found that the surface temperature, deposition time, and different nozzles could play a significant role in having different phases of CMAS deposits.

It is well known that legacy one-cathode/anode thermal spray guns are sensitive to aging. One reason is the large power density in particular at the arc roots on the cathode tip and the anode wall. Anode wear was studied in showing that it leads to a thinner boundary layer and a reduced motion of the arc root, which increases the local thermal load. This also results in a voltage drop, and thus in power level reduction if the power source is operated in a constant current mode. In this case, it is widely practiced to increase the secondary plasma gas flow, which, however, can only be of some help.