Special Issue "Advanced Thermal Spray Coatings for Emerging Applications"


A special issue of Coatings (ISSN 2079-6412).

Deadline for manuscript submissions: closed (31 October 2013)

Special Issue Editor

Guest Editor
Prof. Dr. Lech Pawlowski
University of Limoges, SPCTS, 12, rue Atlantis 87068 Limoges, France
E-Mail: lech.pawlowski@unilim.fr
Phone: +33 587 50 24 12
Interests: thermal spray technology of powders and suspension; nanometric coatings tecnology, in particular suspension plasma spray metal oxide coatings (hydroxyapatite, titania, zirconia); laser treatment of materials (laser heating, glazing and engraving); films technologies by laser ablation; characterization techniques by TEM, SEM, XRD, Raman microscopy

Special Issue Information

Dear Colleagues,

Thermal spray is growing in many directions. Probably the most exciting developments for coatings revolve around new applications: for example, coatings that are applied to new forms of energy generation such as electrolysis; self-cleaning surfaces by photocatalysis; biomaterials; electronic-based functionalities and many others. The research considered for this special issue can have theoretical or experimental character. The theoretical studies may include the modeling of thermal spray processes such as plasma spray, HVOF or Cold Spray processes that are related to a new application; as well as modeling of phenomenon during coating build up; such as sintering, the generation of residual stresses and other behavior. The experimental research may concern studies on new types of torches or processes; for example the process of physical vapor deposition that is associated with the plasma spray process or special torches for suspension plasma spraying as well as the investigation of microstructure and of the functional properties of the coatings being developed for new applications. The topics of interest should correspond to coatings used for low temperature applications since the journal proposes a special edition for high temperature coatings. Please contact the Editors of this Special Issue if you have any questions or wish to discuss your topical contribution.

Prof. Dr. Lech Pawlowski
Guest Editors


Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. Papers will be published continuously (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are refereed through a peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed Open Access quarterly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. For the first couple of issues the Article Processing Charge (APC) will be waived for well-prepared manuscripts. English correction and/or formatting fees of 250 CHF (Swiss Francs) will be charged in certain cases for those articles accepted for publication that require extensive additional formatting and/or English corrections.


  • thermal spray application
  • suspension thermal spray
  • solution thermal spray
  • process development
  • thermal spray modeling
  • process diagnostic

Published Papers (7 papers)

Coatings 2014, 4(1), 98-120; doi:10.3390/coatings4010098
Received: 13 November 2013; in revised form: 18 December 2013 / Accepted: 21 January 2014 / Published: 29 January 2014
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Coatings 2014, 4(1), 18-36; doi:10.3390/coatings4010018
Received: 7 November 2013; in revised form: 2 December 2013 / Accepted: 18 December 2013 / Published: 2 January 2014
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Coatings 2012, 2(2), 94; doi:10.3390/coatings2020094
Received: 12 June 2012; Accepted: 12 June 2012 / Published: 19 June 2012
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Coatings 2012, 2(2), 64-75; doi:10.3390/coatings2020064
Received: 9 January 2012; in revised form: 8 March 2012 / Accepted: 12 March 2012 / Published: 28 March 2012
Show/Hide Abstract | Download PDF Full-text (2095 KB) | Download XML Full-text |  Correction

Coatings 2011, 1(2), 117-132; doi:10.3390/coatings1020117
Received: 30 October 2011; in revised form: 11 December 2011 / Accepted: 17 December 2011 / Published: 20 December 2011
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Coatings 2011, 1(2), 88-107; doi:10.3390/coatings1020088
Received: 1 August 2011; in revised form: 22 September 2011 / Accepted: 26 September 2011 / Published: 3 October 2011
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Coatings 2011, 1(1), 17-52; doi:10.3390/coatings1010017
Received: 28 July 2011; in revised form: 19 August 2011 / Accepted: 19 August 2011 / Published: 2 September 2011
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abstract graphic

Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Type of Paper: Article
Title: Thermal Spraying of Quasicrystalline AlCuFe-Coatings by High-Velocity Spray Methods
Authors: Yuriy S. Borisov 1, Alla Borisova 1, Eugeniy A. Astachov 1, Lyudmila I Adeeva 1, Alla Yu. Tunik 1, Prof. B. Wielage 2, T. Lampke 2 and H. Pokhmurska 2
Affiliations: 1 Paton Welding Institute, Bozhenko str.11, Kiev, 03150, Ukraine
2 Institute of Materials Science and Engineering, Chemnitz University of Technology, Chemnitz, D-09107, Germany; E-Mail: hanna.pokhmurska@mb.tu-chemnitz.de (H.P.)
Abstract: Alloys with quasicrystalline structure possess a set of unique physical properties, including a low thermal conductivity combined with a thermal expansion coefficient of typical of metals and alloys that make them attractive for application as thermal barrier coatings. Most of the quasicrystalline phases exist in very narrow composition range. As a result, microstructure, phase composition and properties of thermally sprayed quasicrystalline coatings depend strongly not only on the microstructural features of the feeding material but also on the spraying conditions, which determine powder particles heating and cooling behaviour as well as their acceleration in spray jet. In the present paper an effect of spraying parameters of different high-velocity thermal spray methods on the structure and properties of AlCuFe-coating are reported. The quasicrystalline powders of AlCuFe alloy with different content of quasicrystalline (ψ-) phase were produced by gas atomization of the alloy melt. Spraying of coatings was performed using the supersonic air-gas plasma spraying equipment "Kiev-S" and liquid fuel-kerosene HVOF system (GTV K2), spraying temperature conditions of which are quite different from that produced by gas spray jets. It was established that a phase composition and properties of sprayed AlCuFe-coatings are determined by such factors as burning up of the AlCuFe-alloy components, degree of sprayed material oxidation and substrate temperature, which are different for the applied methods.

Type of Paper: Article
Title: Microstructure, Thermal Properties and Degradation Process of Plasma Sprayed Gd2Zr2O7, Gd2Zr2O7+8YSZ and Gd2Zr2O7/8YSZ Thermal Barrier Coatings
Author: Grzegorz Moskal
Affiliation: Silesian University of Technology, Department of Materials Science, 40-019 Katowice, ul. Krasińskiego 8, Poland; E-Mail: grzegorz.moskal@polsl.pl
Abstract: In presented article three aspects related to: microstructural characterization, thermal insulation properties and basic information about degradation process during static oxidation at temperature 950 °C of thermal barrier coatings of five different types was shown. These five types of TBC was as follow: Gd2Zr2O7, Gd2Zr2O7 + 8YSZ (with proportion of blended feedstock powders: 75/25, 50/50, 25/75) and double ceramic layered (DCL) system of Gd2Zr2O7/8YSZ type. All of them were deposited by atmospheric plasma spraying in the case of insulation layers, and vacuum plasma spraying in the case of NiCrAlY bondcoats. The substrate materials was Ni-based superalloys of AMS 5599 type. In first part of article detailed characterization of overall quality of top surface of all coatings, theirs phases constituent and stress conditions was described as well as a qualitative and quantitative characterization of theirs roughness. Analysis of internal morphology of ceramic layer was presented. Especially characterization of spherical, vertical and horizontal porosity was showed. From the other side the results of qualitative assessment of TBC systems was presented as well. In second part of article results of thermal diffusivity measurement in the range of 25 to 1100 °C was presented. Results for whole system of TBC was presented firstly, in second step results for only ceramic topcoat was calculated (on the base of two-layers method with heat lost). These results was corrected from internal porosity point of view. In the last part of article the results of macroscopic characterization of ceramic top surface degradation was showed as well as a results of TGO thickness measurement after 2, 10, 48, 175 and 500 hours of static oxidation test. Additionally surface distributions of Al, Gd, Ni, Cr and other elements in area of TGO zone was analyzed.

Type of Paper: Article
Development of Kerosene Fuelled HVOF WC-Co Coatings with Bimodal Distributed Carbide Size
Andrew Ang Siao Ming 1,*, Hugo Howse 2 and Christopher C. Berndt 1,3
1 Industrial Research Institute Swinburne, Swinburne University of Technology, H66, P.O. Box 218, Hawthorn, Victoria 3122, Australia; E-Mail: CBERNDT@swin.edu.au
2 United Surface Technologies Pty Ltd, 26-32 Aberdeen Road, Altona, Victoria 3018, Australia
3 Adjunct Professor, Department of Materials Science and Engineering, Stony Brook University, Stony Brook, NY11794, USA; E-Mail: hhowse@ust.com.au
* Author to whom all correspondence should be addressed; E-Mail: AANG@swin.edu.au.
This paper explores the co-deposition of nano and micron-structured tungsten carbide-cobalt (WC-Co) feedstocks to create a unique bimodal coating microstructure with improved mechanical and wear properties. These coatings were produced using an advanced kerosene fuelled HVOF torch, which allowed a lower deposition temperature and hence, preservation of nano WC particles within the coating matrix. To prevent the decomposition of nano-carbide particles, the deposition parameters had to be optimised using an in-flight particle diagnostic system. The mechanical and wear properties of these bimodal structured WC-Co coatings were evaluated against conventional micron-structured WC-Co coatings.
HVOF; nano-structured; bimodal; WC-Co; wear properties; porosity; hardness; tungsten carbide; thermal spray coatings

Type of Paper: Article
Degradation Mechanisms of Plasma Sprayed TBCs in Aeroengines Operating in Aggressive Environments
T. W. Clyne and Maya Shinozaki
Department of Materials Science, University of Cambridge, Cambridge CB3 0FS, UK; E-Mails: twc10@cam.ac.uk (T.W.C.); ms660@cam.ac.uk (M.S.)
Turbine components in aeroengines are required to operate in highly aggressive environments, not only with ever increasing turbine entry temperatures, but also in terms of the ingestion of species such as salt, sulphur compounds and particulate matter collectively termed CMAS (calcia-magnesia-alumina-silica). These can have various deleterious effects on turbine constituents, particularly thermal barrier coatings (TBCs). The focus of this paper is mainly on the effect of CMAS on plasma sprayed TBCs, covering sintering phenomena (which can be substantially accelerated by the presence of CMAS) and resultant spallation or segmentation cracking of the coating. A brief study will also be presented concerning the factors that affect the likelihood of incident CMAS particles adhering to turbine components.

Type of Paper: Article
Title: Tribological Behavior and Corrosion Properties of HVOF-Sprayed Novel Fe-Based Alloy Coatings
Authors: A. Milanti 1, H. Koivuluoto 1, P. Vuoristo 1, G. Bolelli 2, F. Bozza 2 and L. Lusvarghi 2
1 Department of Materials Science, Tampere University of Technology, Tampere, Finland; E-Mail: heli.koivuluoto@tut.fi (H.K.)
Dipartimento Ingn Materials & Ambiente, University of Modena and Reggio Emilia, Modena, Italy
Abstract: Thermally-sprayed Fe-based coatings have shown their potential to use in wear and corrosion applications due to their good coating characteristics. In addition, these kinds of coatings have other advantages, e.g., cost efficiency and positive environmental aspects. In this study, the microstructural details, tribological performances and corrosion properties of Fe-based coatings manufactured by High Velocity Oxygen Fuel (HVOF) thermal spraying process are shown. Traditional Ni-based and hard-metal coatings were chosen as reference coatings. Lower wear and higher corrosion resistance validates Fe-based coating as future alternative to more expensive and less environmentally friendly Ni-based alloys.

Type of Paper: Article
Title: Abrasion, Erosion and Cavitation Wear Properties of Alumina Based Coatings
Authors: V. Matikainen, K. Niemi, H. Koivuluoto and P. Vuoristo
Department of Materials Science, Tampere University of Technology, Tampere, Finland; E-Mail: heli.koivuluoto@tut.fi (H.K.)
Thermally sprayed alumina based materials, e.g. alumina-titania, are commonly applied as wear resistant coatings in industrial applications. Properties of the coatings depend on the spray process, powder morphology and chemical composition of the powder. In this study, wear resistant coatings from alumina based feedstock were sprayed with plasma and HVOF spray processes. The coatings were tested for abrasion, erosion and cavitation resistances in order to study the effect of the coating structure on the wear behaviour.

Last update: 10 February 2014

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