Thermal Spray Processes: The Evolution of Equipment, Technology and Feedstock

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 December 2018) | Viewed by 13590

Special Issue Editors


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Guest Editor
Institut de recherche sur les céramiques IRCER - UMR, University of Limoges, 87068 Limoges, France
Interests: plasma spraying; laser treatment of ceramic coatings; suspension and solution precursor plasma spraying (titania, zirconia and hydroxyapatite) for emerging applications
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Guest Editor
Institute for Manufacturing Technologies of Ceramic Components and Composites (IMTCCC), University of Stuttgart, Allmandring 7b, 70569 Stuttgart, Germany
Interests: thermally sprayed functional coatings (flame spraying, high velocity flame spraying, plasma spraying, cold gas spraying, warm spraying, High velocity air fuel spraying, HVOF, HVAF, APS, VPS, arc spraying ...)

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Guest Editor
Fraunhofer Institute for Material and Beam Technology (IWS), Group Manager Thermal Spraying, Business Unit Thermal Surface Technology, Winterbergstrasse 28, D-01277 Dresden, Germany
Interests: research and development of ceramic; hardmetal and metal coatings by various thermal coating processes and their industrial applications; thermal spraying with suspensions from the development of appropriate hardware components to the tailored coating solutions and technology transfer

Special Issue Information

Dear Colleagues,

Thermal spraying is one of most versatile technologies in coatings deposition. Its attractiveness results from its high efficiency of deposition of a broad range of materials, including ceramics, metals, and alloys. In the last few years, new emerging spray technologies, mainly cold spraying and thermal spraying with liquid feedstocks, have become of increasing interest. The torches used to spray use cold or warm gases accelerated in a De Laval nozzle; hot gases or plasmas being heated by gas combustion or by an electric arc. The evolutions in torches design include the ways of feedstock injection and methods of gas heating. The use of liquid feedstock, such as suspensions and solution precursors, enabled the achievement of new coating architectures and the achievement of promising mechanical or thermophysical properties. On the other hand, development of metal-cladded ceramic powders paves the way to obtain cermet coatings with the use of the cold spray technique.

The proposed Special Issue of Metals invites the authors of papers that are active in the development of these new thermal spray processes, as well as on the design of new concepts for feedstock.

Prof. Dr. Lech Pawlowski
Prof. Dr. Andreas Killinger
Dr. Filofteia-Laura Toma
Guest Editors

Manuscript Submission Information

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Keywords

  • Cold gas spraying
  • Suspension thermal spraying
  • Solution precursor thermal spray
  • Plasma spray torches evolution
  • Metal cladded ceramic powder for cold spray

Published Papers (2 papers)

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Research

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10 pages, 6655 KiB  
Article
The Properties of Arc-Sprayed Aluminum Coatings on Armor-Grade Steel
by Marcin Adamiak, Artur Czupryński, Adam Kopyść, Zbigniew Monica, Małgorzata Olender and Aleksander Gwiazda
Metals 2018, 8(2), 142; https://doi.org/10.3390/met8020142 - 22 Feb 2018
Cited by 19 | Viewed by 5715
Abstract
This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense, [...] Read more.
This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating. Aluminum coatings were characterized in accordance with ASTM G 65-00 abrasion resistance test, ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV0.1 hardness tests and metallographic analyses. Results demonstrate properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required. Full article
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Review

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18 pages, 7522 KiB  
Review
Current Progress in Solution Precursor Plasma Spraying of Cermets: A Review
by Romnick Unabia, Rolando Candidato, Jr. and Lech Pawłowski
Metals 2018, 8(6), 420; https://doi.org/10.3390/met8060420 - 04 Jun 2018
Cited by 19 | Viewed by 6960
Abstract
Ceramic and metal composites, known also as cermets, may considerably improve many material properties with regards to that of initial components. Hence, cermets are frequently applied in many technological fields. Among many processes which can be employed for cermet manufacturing, thermal spraying is [...] Read more.
Ceramic and metal composites, known also as cermets, may considerably improve many material properties with regards to that of initial components. Hence, cermets are frequently applied in many technological fields. Among many processes which can be employed for cermet manufacturing, thermal spraying is one of the most frequently used. Conventional plasma spraying of powders is a popular and cost-effective manufacturing process. One of its most recent innovations, called solution precursor plasma spraying (SPPS), is an emerging coating deposition method which uses homogeneously mixed solution precursors as a feedstock. The technique enables a single-step deposition avoiding the powder preparation procedures. The nanostructured coatings developed by SPPS increasingly find a place in the field of surface engineering. The present review shows the recent progress in the fabrication of cermets using SPPS. The influence of starting solution precursors, such as their chemistry, concentration, and solvents used, to the micro-structural characteristics of cermet coatings is discussed. The effect of the operational plasma spray process parameters such as solution injection mode to the deposition process and coatings’ microstructure is also presented. Moreover, the advantages of the SPPS process and its drawbacks compared to the conventional powder plasma spraying process are discussed. Finally, some applications of SPPS cermet coatings are presented to understand the potential of the process. Full article
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