In this study, the influence of laser shock peening as a post-treatment on cold-sprayed Inconel 625 deposits is investigated to demonstrate the effects of inducing plastic deformation and residual stresses by LSP in order to heal out non-bonded interfaces within the coatings.

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.

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.

In this work, cold spray shot peening was used to treat interstitial-free (IF) steel. Different numbers of impact passes were evaluated and the microstructure and hardness evolution in IF steel were analyzed. Based on the experimental results, the potential of CSSP to achieve surface strengthening and properties enhancement in metallic materials is demonstrated.

The aim of this study is to compare the performance of a nickel-based hard-facing alloy cladded with a novel high-power laser cladding process with claddings done by conventional plasma transferred arc claddings with special regards to the wear protection potential.

This paper presents the development of a modified tool steel (X30CrMnMoN13-3-1) specifically designed for defect-free processing via laser powder bed fusion (LPBF) without requiring complex machine modifications. The research addresses the dual challenge of carbon-containing tool steels in additive manufacturing: maintaining wear resistance while preventing cracking. Through optimization of the alloying system—particularly with carbon, nitrogen, chromium, molybdenum, and manganese—and the use of moderate preheating (150 °C), the authors achieved crack-free components with hardness levels up to 57 HRC after appropriate heat treatment.

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 aims to investigate the influence of alumina in-flight particle characteristics on coating properties and deposition efficiency. To this end, velocity and surface temperature measurements were carried out on the in-flight particles. Resulting coatings were characterized in terms of porosity, hardness, and related to particle properties. The final goal was to obtain an optimized coating with low porosity, high hardness, manufactured with a high powder flow rate and deposition efficiency.

We expand on our previous numerical framework to account for and study strain-induced thermal effects in cold spray bonding. The new enhancement considers the work of plastic strain, G , as the driving mechanism behind bonding and strain-induced heat. Only a portion of G , called the stored energy of cold work, contributes to bonding, with the remaining portion resulting in an adiabatic increase in temperature.

This study examines the effects of N 2 and He process gases and heat treatment on the microstructure and mechanical properties of 3D-printed pure copper produced using a low-pressure cold spray system. Microstructural analysis is performed through optical microscopy, while tensile tests are used to evaluate mechanical properties. Samples processed with N 2 demonstrate improved plastic deformation, leading to reduced porosity compared to those processed with He.

This study aims to comprehensively examine and analyze the basic mechanical properties, oxidation resistance, high-temperature hardness, fretting wear, and simulated operating conditions of CuAl/PHB coatings. The objective is to investigate the optimal combination of resistance to fretting wear and abradability for these coatings.

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.

In this study, we deposited alumina (Al 2 O 3 ) coatings from powder consisting of dense particles using aerosol deposition. The powders were ball milled with zirconia (ZrO 2 ) milling media for 0 to 9 hours to optimize the deposition performance. We investigated the impact of high-energy ball milling on the shape, size, and crystal structure of the Al 2 O 3 powders, as well as their deposition behaviors.

In this study, we focus on developing effective repair procedures by optimizing key processing parameters such as gas pressure, gas temperature, and traverse speed. To achieve this, a combination of machine learning and experimental testing was employed on cold-sprayed Ni-based superalloy (IN 625). The prepared samples were assessed for microhardness, adhesion strength, and porosity, and these experimental results were subsequently used to train a machine learning model. This model predicts material properties under varying process conditions, ensuring precision in parameter selection.

Additive brazing is a highly advanced process for producing functional and highly durable coatings. By creating a material bond between components through diffusion without the use of flux, dense, wear-resistant, and crack-free layers are formed, which are particularly useful in areas such as wear protection and the reclamation of components. The ability to adjust the coating thickness and hardness makes the process extremely flexible, allowing it to meet the specific requirements of a wide range of applications. Particularly innovative is the ability to precisely and locally braze using laser energy, further enhancing the efficiency and precision of the process. This paper provides an overview of the process, properties of brazed coatings, and applications.

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.

This study investigates the application of a commercially available Cr 3 C 2 -NiCr powder using the ID-HVOF coating process. A central composite design within a design of experiments framework was employed to analyze the effects of key process parameters—kerosene flow, hydrogen flow, oxygen flow, and the powder feed rate—on the coating performance. The validation test successfully produced a coating that matches the predicted parameters from the design framework.

This research proposes an experimental methodology towards visually observing high strain rate polymer deformation characteristics at scales relevant to cold spray particle impacts. Macro-scale (~ 3 mm) polymer impact testing via a light gas gun has shown evidence of cold spray indicative features at certain (material, particle/substrate temperature, velocity, etc.) conditions.

For this study, a fixed high-end primary parameter set with respect to gas pressure and temperature was selected for depositing Al6061 powder feedstock on Al6061-T6 substrate sheets. The influences of different parameter variations on spray deposit build-up and performance were investigated by evaluations of deposit efficiency, deposit microstructures, porosities, deposit hardness, and electrical conductivity.

In this research work, MoNbZrTiV and AlNbTaTiV refractory high-entropy alloy (RHEA) material combinations were investigated as potential candidates for feedstock materials for cold spray additive manufacturing. The two RHEA materials as precursors for developing micron-sized particles were alloyed mechanically through high-energy ball milling following a rigorous material design-of-experiments curriculum on account of elemental melting point differences. Detailed particle characterization techniques were employed to gain insights into the RHEA particle properties.