Previous own works revealed that novel partially amorphous Fe-based alloys have a combination of proper-ties that are beneficial for the application in liquid hydrogen (LH2) tanks, viz low thermal diffusivity, little porosity, and good adhesion. The influence of cryogenic temperatures or hydrogen on coating tensile strength, on the other hand, has not been investigated yet for this material. However, this is crucial for the long-term durability of the coatings under hydrogen and other alternative fuels. Thus, in this work, tubular coating tensile (TCT) tests were performed at room temperature and cryogenic temperatures. In addition, hydrogen charging was carried out to identify a possible regime that is sufficient for TCT tests under the influence of hydrogen. Subsequently, the fracture surfaces were evaluated analytically, optically and profilometrically. Under cryogenic conditions, a significant increase in tensile strength and a finer structure of the fracture surfaces was observed.

For the application of thermally sprayed titanium coatings, the high oxygen affinity and tendency to nitride formation in the presence of nitrogen represents a major challenge. Consequently, thermally sprayed titanium coatings are usually applied by cold gas spraying, vacuum plasma spraying and shrouded spraying processes. Nevertheless, the formation of oxides cannot be completely avoided with these methods. The pre-sent study demonstrates an alternative coating strategy for the application of oxide and nitride free thermally sprayed titanium coatings. Thereby, the previous limitations are overcome by transferring the coating process into a silane-doped argon gas environment to achieve an extremely low oxygen and nitrogen partial pressure. Thus, the created titanium coatings are oxide and nitride free and have an extremely low porosity. Moreover, by transferring of the corundum blasting process to this environment, the native oxide layer on the substrate surface can be removed and its reformation is suppressed. This results in full material bonding conditions with extremely high adhesive tensile strengths.

Plasma spraying is the most versatile coating process for depositing a wide range of materials to enhance material performance in harsh conditions. However, severe oxidation during the plasma spraying of metal coatings often results in coatings with high oxide content, limiting interlamellar bonding. Consequently, as-sprayed metal coatings offer inadequate protection against severe corrosion and wear. To address this challenge, we developed Ni-, Cu-, and Fe-based materials containing boron as a deoxidizer. This innovative approach effectively suppresses in-flight oxidation, producing oxide-free molten droplets and enabling the formation of bulk-like metal coatings with sufficient metallurgical bonding between splats. We employed a modified tensile test to evaluate the adhesive and cohesive strengths of these coatings. The Ni-based coatings exhibited adhesive strength exceeding 150 MPa on Fe-based substrates, while cohesive strength surpassed 260 MPa with a novel bond coat. Corrosion and gas penetration tests confirmed the creation of dense, bulk-like Ni-based alloy coatings, demonstrating their potential for various applications in severe service environments.

Hot section components of stationary gas turbines such as turbine blades are coated with thermal barrier coatings (TBCs) to increase the high thermal strain tolerance thereby the improvement of the performance for the gas turbines. TBCs represent high-performance ceramics and are mostly composed of yttria-stabilized zirconia (YSZ) in order to fulfil the function of thermal insulation. The microstructure of conventional TBCs should be porous to decrease heat conduction. Besides porous TBCs, the recently developed vertically segmented thermal barrier coatings (s-TBCs) feature outstanding thermal durability. In this work, process parameter development for atmospheric plasma spraying (APS) of s-TBCs is presented. Within the experiments, relevant process parameters such as powder feed rate, surface speed and pathway strategy have been optimized. The aim of this work is to achieve a combination of low internal residual stress and high adhesive tensile strength for s-TBCs. For the formation of vertical cracks, the heat input into the powder feedstock material and the substrate must be controlled precisely.

This present work investigates the effect of electromagnetic fields on cold spray processes by means of an induction-heating cold spray (IHCS) system. Aluminum powder was cold sprayed onto inductively heated Ti6Al-4V (Ti64) substrates. These materials were selected to minimize the mechanical contribution to coating adhesion. As a result, changes in coating adhesion strength can be attributed to improved metallic bond formation due to the effect of the electromagnetic field. Four different initial substrate surface temperatures were used in the study to assess the role of initial temperature as well. Deposition efficiency and adhesion and tensile strength measurements were recorded and are used to characterize the hybrid coating process and compare it with traditional techniques.

Tungsten heavy alloy (WHA) of W-Ni composition was deposited from a blend of standard thermal spray powders using a radio frequency inductively coupled plasma torch in a protective atmosphere. The coating contained a fully developed WHA structure, i.e., spherical W particles embedded in a Ni-rich matrix. Bending tensile strength R m , bending yield strength R p,0.2 , and elastic modulus were measured and compared with W-Ni-Co references fabricated by sintered and quenched (SQ) and forged and annealed (FA) powder metallurgy (PM) processes. The fatigue and fracture properties of the plasma spray deposits are comparable with those of the SQ-PM reference material, but inferior to those of the FA-PM reference. The results of various property tests are presented and analyzed in the paper.

In this study, a novel strategy to manufacture high strength cold-sprayed Al coating by using powder with wide size distribution is proposed. The microstructure and mechanical properties of deposited coating sprayed at three typical impact velocities before and after heat treatment are investigated. Furthermore, the deposition and strengthening mechanisms of the coating sprayed at various impact velocities are clarified. The results show that the coating with higher density and mechanical properties can be successfully fabricated by cold spray at comparatively low particle impact velocity. The mechanical properties were enhanced with the contribution of heat treatment process. It is the in-process tamping effect induced by larger powder that results in the severe plastic deformation thus leads to densification and excellent mechanical properties of the cold-sprayed Al coating.

In this work, advanced Al/diamond wear-resistance composites were fabricated by solid-state cold spray additive manufacturing using core-shell-structured diamond powders. Based on the experimental results and thorough discussion, it is found that core-shell-structured diamond powders were much easier to deposit than pure Al by cold spray, showing great potentials as feedstock for cold spraying. The deposition mechanism of the Al/diamond composites were dominated by the true metallic bonding between Al matrix and Cu layer, which is different from other conventual cold sprayed metal matrix composites. Tensile tests indicated that the tensile strength of the Al/diamond composites can be higher than cold sprayed pure Al. In addition, the Al/diamond composites had super wear-resistance performance. The wear rate was reduced by 17.8 times for the N 4-1 composite and by 37.5 times for the N 1-1 composite as compared with cold sprayed Al/Al 2 O 3 composite.

Direct Metal Laser Sintering (DMLS) technique is one of the technologies which is generally used to built prototypes and tooling applications. DMLS uses powder bed fusion to bond particles together by laser energy. A new powder layer is spread on top of the previous layers and the process is repeated up to required shape of part can be produced. This review paper presents development, current status and challenges of the DMLS technique with emphasises on material processed by DMLS and is aimed to understand influence of density, microstructure, micro-hardness, tensile strength and wear behaviour of built-up parts. It also highlights the process through proofs based on classical results in terms of advantages and applications.

Inconel 718 is a precipitation-hardenable nickel-base superalloy with decent corrosion resistance, high strength at ambient temperature, and excellent creep and fatigue strength at high temperature. In this study, Inconel 718 was deposited by cold spraying with nitrogen and helium gas. Particle velocities were measured and splat morphology and coating microstructure were observed. Mechanical properties, including hardness, bond strength, and tensile strength, were also investigated. Although the deposits sprayed with helium had slightly better mechanical properties, nitrogen-sprayed Inconel 718, post heat treatment, exhibited mechanical properties similar to those of the bulk material.

In this study, stainless steel powder is mixed with commercially pure iron and cold sprayed on steel in order to produce a metal composite with controlled properties. For these composites, porosity is very low, and annealing at 600-1100°C for an hour reduces it further. Annealing also sinters interparticle interfaces, leading to vastly improved fracture properties. Fully annealed single-component stainless steel exhibits a much higher strength than annealed CP iron, but adding just 20% stainless steel to iron produces a composite with the same fully annealed strength as that of stainless steel.

This study investigates the effects of spark plasma sintering (SPS) on the microstructure and properties of cold-sprayed metallic coatings. Water-atomized Cu powder was deposited on Al 5052 substrates by high-pressure cold gas spraying, and the resulting coatings were treated by spark plasma sintering and annealing heat treatment (AHT) at 200°C, 300°C, and 400 °C. To assess the effects of diffusion generated by pulsed dc power, a vertical load was not applied in the SPS system. In addition, a short duration time was used to inhibit crystal grain growth. Treated specimens were evaluated by SEM, EBSD, and hardness and tensile testing. The findings show that the microstructure and hardness of SPS specimens treated at 300 °C are close to that of AHT specimens treated at 400 °C. Tensile strength, however, is clearly higher in the SPS300 specimens, indicating that pulsed dc power accelerates particle interdiffusion due to Joule heating and electromigration, thereby increasing adhesion strength between particles in the coating.

Cold spray processing of stainless steel coatings, which represent a cost-effective method for wear and corrosion resistance, has been demonstrated as technically feasible. However, these coatings have very low tensile strength in the as-sprayed condition and may also exhibit a marginally higher wear rate. In this study, the cold spraying of 316L stainless steel coatings was investigated to assess the effect of powder size distribution and post-spray heat treatment on strength and wear properties. Coatings on aluminum and steel substrates were produced with a feedstock powder obtained in three particle size distributions. All coatings were deposited under the same conditions using nitrogen as the propellant gas, and then annealed at the optimum temperature. The microstructure and mechanical properties of both as-sprayed and heat-treated coatings were evaluated and the results are presented in the paper.

A previous study indicated that dense thick Cu-4Cr-2Nb coatings could be formed by cold spraying, and the post-spray heat treatment could significantly influence the microstructure and microhardness of the as-sprayed Cu- 4Cr-2Nb coatings. In this study, the tensile strength and fracture performance of the Cu-4Cr-2Nb coatings after annealing were investigated. The vacuum heat treatment was conducted under 10-2 Pa at 850°C for 4 h. Results showed that the heat treatment had a great contribution to the healing-up of the incompleteness of the interfaces between the deposited particles. In addition, the coating microhardness decreased from 156.8±4.6 Hv0.2 for the as-sprayed coatings to 101.7±4.5 Hv 0.2 for the annealed ones. The mean tensile strength of the annealed coatings was approximately 298.8±31.5 MPa compared to that of 45±10.5 MPa for the as-sprayed ones, which results from the partially metallurgically bonded zones between the deposited particles inducing by the heat treatment process.

In the past years a number of publications reported about Titanium coatings cold sprayed with a nominal power input between 17 to 47 KW (e. g Kinetiks 4000) reaching gas temperatures of maximum 850 °C and gas pressure of maximum 4 MPa. In a recent study at Helmut-Schmidt University (HSU), a Kinetiks 8000 prototype was used to spray titanium, employing a nominal power of about 92 KW to increase the gas temperature up to 1000°C at a pressure of 4 MPa. Under these parameters, a high tensile strength of over 480 MPa and a deposition efficiency (DE) close to 100% were achieved. The present study focuses on further enhanced gas and particle velocities by optimized nozzle designs. The increased particle velocities in comparison to that obtained by using commercial nozzles (types 24, 51) result in better coating performance and allow deviations from ideal (90°) impact angle without significantly reducing coating strength. The influences of process conditions are evaluated and discussed on the basis of coating strengths by Micro Flat Tensile and Tubular Coating Tensile tests, as well as electrical conductivities, nitrogen and oxygen contents.

The work deals with the evaluation of strength characteristics of thermally sprayed coatings. The main aim was concentrated on the tensile and shear loading of HVOF (Stellite Alloy 6, Tribaloy 400) and arc sprayed (13%Cr, CuAl8) coatings. The investigation of the coatings behaviour on the coating-substrate interface is important for the evaluation of one of significant coating mechanical properties that influence properties of the whole coating-substrate system. The magnitude of the coating bond strength during tensile and shear stresses predicates the coating stability, reliability, impact resistance, resistance against failure and mostly operating lifetime. The determination adhesive-cohesive strength was performed according to EN 582 and EN 15340 Standards.

A novel process to produce dense, well adherent aluminium coatings on ceramic materials is cold gas spraying (CGS). The mechanical, physical and chemical processes leading to the bonding of cold-sprayed coatings on ceramic substrates have only been described rudimentarily. A survey of the literature on adhesion mechanisms of cold spray coatings is given, where influences on bond strength are discussed and parameters identified. Using the example of coating Al 2 O 3 and AlN substrates with pure aluminium via cold gas spraying, a process and substrate parameter variation is presented. A significant raise in tensile coating strength was seen at elevated substrate temperatures and after subsequent annealing. Tensile strength also depended on chemical composition and roughness of the substrate. The results allow the discussion of the bonding mechanisms of cold spray aluminium on ceramic substrates as a function of deposition and annealing parameters.

The interaction between thermal spray parameters and coating characteristics of atmospheric plasma sprayed WC-12Co was investigated by means of statistically designed experiments. A central composite design was employed to study the influence of the process parameters’ ratio Ar/H 2 , plasma gas volume flow, powder feed rate and stand-off distance on the deposition efficiency, tensile strength, porosity, roughness, particle temperature, particle velocity and the percentage of molten carbides. The process parameters’ volume flow and powder feed rate showed a considerable impact on the microstructure and morphology of the coatings, which could be traced back to a change in the melting degree of the powders as well as a change in particle temperature and velocity. On the basis of the statistical experiments, mathematical expressions were found to describe the coating characteristics. The quality of the mathematic model was scrutinized in a subsequent evaluation stage.

In this study, an aluminum coating with dispersed quasicrystalline particles is produced by cold spraying. The spraying was done using helium gas at a temperature of 400 °C. The obtained coating exhibited a relatively precise microstructure with almost no macroscopic voids. X-ray and TEM analyses confirmed that the coating retained its quasicrystal structure on the surface as well as internally. TEM analysis also revealed that metallic bonding occurred at powder-powder and powder-substrate interfaces. Although the hardness of the coating was higher than that of extruded bulk alloy, tensile strength was found to be much lower, which is attributed to defects at particle-particle interfaces.

Arc spraying metal onto a master pattern is an emerging method for making molds and dies. The process, called arc spray metal tooling, involves several steps, which are shown in this paper. Three sheet metal forming dies of varying complexity were made to demonstrate and assess the process. Press tests were performed at a mold and die making facility. Arc-sprayed metal shells produced from carbon steel wire were found to have a tensile strength of approximately 23 kg/mm 2 , a Vickers hardness of 330 HV, and a dimensional accuracy of about ± 0.1 mm.