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Volume 13
Issue 3
10.3390/coatings13030538
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Review

Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities

by
Desmond Klenam
1,2,
Tabiri Asumadu
3,
Michael Bodunrin
2,
Mobin Vandadi
4,
Trevor Bond
5,
Josias van der Merwe
2,
Nima Rahbar
4,5 and
Wole Soboyejo
5,*
1
Academic Development Unit, Faculty of Engineering and the Built Environment, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg 2001, South Africa
2
School of Chemical and Metallurgical Engineering, University of the Witwatersrand, 1 Jan Smuts Avenue, Johannesburg 2001, South Africa
3
Department of Materials Engineering, Sunyani Technical University, Sunyani P.O. Box 206, Ghana
4
Department of Civil Engineering, Worcester Polytechnic Institute, 100 Institute Road, Worcester, MA 01609, USA
5
Department of Mechanical Engineering, Worcester Polytechnic Institute, 100 Institute Road, Worcester, MA 01609, USA
*
Author to whom correspondence should be addressed.
Coatings 2023, 13(3), 538; https://doi.org/10.3390/coatings13030538
Submission received: 30 January 2023 / Revised: 21 February 2023 / Accepted: 24 February 2023 / Published: 1 March 2023
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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Abstract

Complex concentrated alloys (CCAs) are structural and functional materials of the future with excellent mechanical, physical, and chemical properties. Due to the equiatomic compositions of these alloys, cost can hinder scalability. Thus, the development of CCA-based coatings is critical for low-cost applications. The application of cold spray technology to CCAs is in its infancy with emphasis on transition elements of the periodic table. Current CCA-based cold spray coating systems showed better adhesion, cohesion, and mechanical properties than conventional one-principal element-based alloys. Comprehensive mechanical behavior, microstructural evolution, deformation, and cracking of cold spray CC-based coatings on the same and different substrates are reviewed. Techniques such as analytical models, finite element analysis, and molecular dynamic simulations are reviewed. The implications of the core effects (high configurational entropy and enthalpy of mixing, sluggish diffusion, severe lattice distortion, and cocktail behavior) and interfacial nanoscale oxides on the structural integrity of cold spray CCA-based coatings are discussed. The mechanisms of adiabatic heating, jetting, and mechanical interlocking, characteristics of cold spray, and areas for future research are highlighted.
Keywords: complex concentrated alloys; cold spray; adiabatic heating; solid-state coating; metallurgical bonding; mechanical interlocking; severe lattice distortion; Johnson–Cook model; finite element method; sluggish diffusion; microstructural evolution complex concentrated alloys; cold spray; adiabatic heating; solid-state coating; metallurgical bonding; mechanical interlocking; severe lattice distortion; Johnson–Cook model; finite element method; sluggish diffusion; microstructural evolution

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MDPI and ACS Style

Klenam, D.; Asumadu, T.; Bodunrin, M.; Vandadi, M.; Bond, T.; van der Merwe, J.; Rahbar, N.; Soboyejo, W. Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities. Coatings 2023, 13, 538. https://doi.org/10.3390/coatings13030538

AMA Style

Klenam D, Asumadu T, Bodunrin M, Vandadi M, Bond T, van der Merwe J, Rahbar N, Soboyejo W. Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities. Coatings. 2023; 13(3):538. https://doi.org/10.3390/coatings13030538

Chicago/Turabian Style

Klenam, Desmond, Tabiri Asumadu, Michael Bodunrin, Mobin Vandadi, Trevor Bond, Josias van der Merwe, Nima Rahbar, and Wole Soboyejo. 2023. "Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities" Coatings 13, no. 3: 538. https://doi.org/10.3390/coatings13030538

APA Style

Klenam, D., Asumadu, T., Bodunrin, M., Vandadi, M., Bond, T., van der Merwe, J., Rahbar, N., & Soboyejo, W. (2023). Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities. Coatings, 13(3), 538. https://doi.org/10.3390/coatings13030538

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