Residual stresses arising during high-velocity oxyfuel (HVOF) spraying usually impose a limit on coating thickness. In this work, dry-ice blasting is used in combination with HVOF spraying to produce thick WC-Co coatings characterized by compact microstructure, crystal refinement, high hardness, and excellent sliding wear resistance.

In this work, alumina coatings are produced by atmospheric plasma spraying using dry-ice blasting to prepare substrate surfaces. Feedstock powder and coating microstructure are examined and dielectric strength and ac-dc breakdown voltages are measured. The results show that dry-ice blasting improves the dielectric properties of alumina coatings produced by atmospheric plasma spraying.

This study evaluates the effects of heat treating on the microstructure, phase composition, and friction and wear behavior of plasma sprayed FeAl coatings. Fe-40Al feedstock powder was deposited on mild steel substrates by atmospheric plasma spraying and the coatings were vacuum annealed at 500, 650, 900, and 1000 °C. An examination of coating cross-sections revealed the presence of diffusion layers in the samples treated at 900 and 1000 °C. XRD analysis indicates that annealing at 650°C facilitates the transformation of Fe(Al) solid solution into FeAl intermetallic phase, resulting in an increase in coating hardness. At higher temperatures, however, Al depletion occurs along with a reduction in hardness. Tribological testing showed that both the friction coefficient and the effects of wear increased after heat treatment.

This study assesses the effects of dry ice blasting on the lifetime and durability of thermal barrier coatings (TBCs). Three sets of TBCs consisting of a CoNiCrAlY bond coat and YSZ topcoat were deposited by air plasma spraying, each set with a different dry ice blasting treatment. Different microstructures were obtained in both the bond coat and topcoat depending on blasting conditions. Bond coat oxidation and thermal shock lifetime of the TBC are also shown to vary with the blasting treatment. TBCs where both the bond coat and topcoat are dry-ice blasted proved to be the most durable with the biggest improvement in lifetime. They also exhibited the most regular surface roughness.

In this work, Fe-40Al coatings are produced by atmospheric plasma spraying using a nanostructured feedstock exhibiting a very low degree of order. The as-sprayed deposits consist of fundamental FeAl phases, Fe3Al phases, and oxides and are found to be ferromagnetic due to the low degree of order and the presence of unmelted nanoparticles retained from the feedstock. The magnetic properties of the coatings are shown to be heterogeneous in the parallel and vertical direction.

This study investigates the effect of dry-ice blasting distance on the deposition of CoNiCrAlY coatings obtained by plasma spraying. Dry-ice blasting was used before, during, and after spraying and its effect on coating quality was measured. The results show how blasting distance influences the deposition efficiency as well as the microstructure, porosity, adhesion strength, hardness, and oxide content of plasma-sprayed coatings. The optimal dry-ice blasting distance was proposed as 25 mm.

Dry-ice blasting, as an environmental-friendly method, was used to pretreat the substrate to be coated. In the present paper plasma-sprayed CoNiCrAlY splats were examined on the dry-ice blasted substrate. The cleaning effect of dry-ice blasting was demonstrated accompanying the condensation phenomenon, which is also harmful for the formation of ideal disk-like splat. A solution of ensuring the substrate temperature over dew point temperature was proposed for the proper application of dry-ice blasting during droplet flattening.

Atmospheric plasma spray is considered as one of the most efficient methods for forming FeAl intermetallic coatings. But the performance of plasma-sprayed FeAl coatings was remarkably limited because of oxidation and phase transformation during the preparation. In the present work, FeAl intermetallic coatings were prepared by atmospheric plasma spray combined with dry-ice blasting. The microstructure, oxidation and porosity of FeAl intermetallic coatings were investigated. In addition, XRD measurements were also employed to illustrate the lattice-scale performance, e.g., dislocation density. The temperatures during plasma spray were also measured using an infrared pyrometer system. The results show that a denser B2-FeAl coating with a lower content of oxide and lower phase transformation can be achieved because of the cryogenic effect and the mechanical effect of dry-ice blasting. Moreover, the microhardness of FeAl coating was nearly increased by 72%, due to the lower porosity and higher dislocation density.

A previous study indicated that improved adhesions of plasma-sprayed Al 2 O 3 coatings have been achieved by using dry-ice blasting. Therefore, it is important to understand the mechanisms involved. In this study, the surface roughness of different substrates treated by dry-ice blasting was firstly examined. And then the surface wettability was characterized in order to clarify the effect of dry-ice blasting on the substrate surface properties. The effect of dry-ice blasting on Al 2 O 3 splat morphology with different treatment times was investigated. The residual stress of plasma-sprayed Al 2 O 3 coatings using dry-ice blasting was measured and compared with that of coatings deposited with conventional air cooling. Based on these numerous assessment tests, it could be concluded that the cleaning effect of dry-ice blasting on different organic substances adsorbed on the substrates was the most important influence on the adhesion improvement of Al 2 O 3 coatings.

Dry-ice blasting, as an environmental-friendly method, was used during atmospheric plasma spraying for improving coating properties. This process is believed to be capable to reduce the porosity and the oxide of the coating and to increase the deposition efficiency, etc. Considering dry-ice pellets are carried and accelerated by compressed air through a convergent-divergent nozzle, the computational fluid dynamic (CFD) approach was firstly employed in this study to evaluate the effects of nozzle geometry, accelerating gas conditions as well as properties of pellets, on the pellet velocity variation and further to optimize the process. Moreover, the experiment with a steel powder was then carried out and the results indicate that a denser coating with a lower content of oxide can be achieved with the application of dry-ice blasting during the plasma spraying.

Solution precursor plasma spraying (SPPS) was employed to prepare porous Sm 0.5 Sr 0.5 CoO 3 (SSC) cathode for solid oxide fuel cell (SOFC). The surface and cross-sectional morphology of the SSC deposit were characterized by scanning electron microscopy. The effect of annealing on SSPS SSC microstructure was examined. The electrochemical behavior was investigated through the impedance spectroscopy. The results showed that the SPPS SSC cathode deposited at a spray distance of 80 mm exhibits multidimensional porous microstructure. The porous film of the partially crystalline perovskite phase with a fine microstructure was obtained after annealing at 900 °C for 2 hours in air. The electrochemical measurement showed that the specific surface resistance of SSC decreased significantly with the increase of test temperature and yielded a specific surface resistance of 2.6 Ω·cm 2 at 800°C.