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Coatings
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Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour
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Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: 30 July 2025 | Viewed by 7729

Special Issue Editor

Dr. Troy Ansell

E-Mail Website
Guest Editor
Department of Mechanical and Aerospace Engineering, Naval Postgraduate School, Monterey, CA 93943, USA
Interests: composite cold-spray coatings; ferroelectric ceramics; electron microscopy

Special Issue Information

Dear Colleagues,

Cold gas dynamic spray, or cold spray, is a relatively new thermal spray technique capable of depositing relatively thick metal or metal composite coatings within minutes. Typically, the technique is used for coating surfaces or for the repair of damaged surfaces. Increasingly, cold spray is being applied as an additive manufacturing technique capable of building free-standing parts layer by layer, much like laser powder bed fusion or fused filament fabrication. Multiple industries including the aerospace and semiconductor industries are using cold spray in a variety of applications. Industries and militaries are also exploring the implementation of cold spray for the repair of structures and components and the “printing” of replacement parts in the field.

Evidently, there is considerable interest in cold spray technology. Several roadblocks, however, exist in further implementation of the technology. A significant hurdle is the use of helium as a carrier gas. Although He offers the highest deposition efficiency among the common gases, e.g., N2 or air, the gas is expensive and difficult to recover. Process monitoring is another active area of interest and research. In situ monitoring of the cold spray process is difficult. Finally, process optimization must be conducted for every coating/substrate combination, slowing down processing times. Machine learning routines could assist in speeding up the optimization process.

This Special Issue is a call for papers focused on the latest research in the field of cold gas dynamic spray. Original research articles will be considered for publication as well as review papers focused on the technique.

Dr. Troy Ansell
Guest Editor

Manuscript Submission Information

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. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short 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 thoroughly refereed through a single-blind 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 monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • cold spray
  • additive manufacturing
  • wear coatings
  • corrosion coatings
  • thermal spray

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Published Papers (4 papers)

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Research

Jump to: Review

24 pages, 6981 KiB  
Article
Machine-Learning-Driven Optimization of Cold Spray Process Parameters: Robust Inverse Analysis for Higher Deposition Efficiency
by Abderrachid Hamrani, Aditya Medarametla, Denny John and Arvind Agarwal
Coatings 2025, 15(1), 12; https://doi.org/10.3390/coatings15010012 - 26 Dec 2024
Cited by 3 | Viewed by 1421
Abstract
Cold spray technology has become essential for industries requiring efficient material deposition, yet achieving optimal deposition efficiency (DE) presents challenges due to complex interactions among process parameters. This study developed a two-stage machine learning (ML) framework incorporating Bayesian optimization to address these challenges. [...] Read more.
Cold spray technology has become essential for industries requiring efficient material deposition, yet achieving optimal deposition efficiency (DE) presents challenges due to complex interactions among process parameters. This study developed a two-stage machine learning (ML) framework incorporating Bayesian optimization to address these challenges. In the first stage, a classification model predicted the occurrence of deposition, while the second stage used a regression model to forecast DE values given deposition presence. The approach was validated on Aluminum 6061 data, demonstrating its capability to accurately predict DE and identify optimal process parameters for target efficiencies. Model interpretability was enhanced with SHAP analysis, which identified gas temperature and gas type as primary factors affecting DE. Scenario-based inverse analysis further validated the framework by comparing model-predicted parameters to literature data, revealing high accuracy in replicating real-world conditions. Notably, substituting hydrogen as the gas carrier reduced the required gas temperature and pressure for high DE values, suggesting economic and operational benefits over helium and nitrogen. This study demonstrates the effectiveness of AI-driven solutions in optimizing cold spray processes, contributing to more efficient and practical approaches in material deposition. Full article
(This article belongs to the Special Issue Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour)
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18 pages, 32353 KiB  
Article
Numerical Simulation and Experimental Study of Deposition Behavior for Cold Sprayed Dual Nano HA/30 wt.% Ti Composite Particle
by Miao Sun, Xiao Chen, Zecheng Wu, Chengdi Li and Xianfeng Deng
Coatings 2024, 14(10), 1330; https://doi.org/10.3390/coatings14101330 - 17 Oct 2024
Viewed by 817
Abstract
Hydroxyapatite (HA, Ca10(PO4)6(OH)2) composite coatings added in the second phase could improve the mechanical properties and bonding strength. The cold spraying technique, as a technology for the deposition of solid particles at low temperatures, is [...] Read more.
Hydroxyapatite (HA, Ca10(PO4)6(OH)2) composite coatings added in the second phase could improve the mechanical properties and bonding strength. The cold spraying technique, as a technology for the deposition of solid particles at low temperatures, is employed to deposit HA ceramic composite coatings. The nano HA material possesses characteristics that enhance properties and promote interface bonding. Due to the exceptional mechanical properties of Ti material, adding Ti particles could improve the mechanical properties of nano HA/Ti composite coatings. In order to explore the deposition deformation mechanism of composite particles under different cold spraying conditions, numerical simulation and experimental testing of deposition behaviors of dual nano HA/Ti composite particles were analyzed. As the particle velocity increased from 400 m/s to 800 m/s in the numerical simulation analysis, the more serious the deposition deformation. Meanwhile, more cracking and splashing phenomena occurred on the surface of the particle. By analyzing the stress value curve of Ti and HA units under different particle velocities, it was found that the adiabatic shear instability phenomenon occurred during the particle deposition on the substrate. In addition, the degree of particle deformation increased with the decrease in the particle size. The results of the experimental investigation were consistent with that of the numerical simulation. Full article
(This article belongs to the Special Issue Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour)
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25 pages, 12430 KiB  
Article
Coating of Refractory Surfaces with Fine TiO2 Particles via Gas-Dynamic Cold Spraying
by Olha Aleksieieva, Mustafa Bozoglu, Pavlo Tretiakov, Andrii Toporov and Sergiy Antonyuk
Coatings 2024, 14(9), 1151; https://doi.org/10.3390/coatings14091151 - 7 Sep 2024
Cited by 1 | Viewed by 3231
Abstract
Refractory materials are used worldwide in process equipment. However, gaseous and liquid process products penetrate the surface layer and deep into the volume of refractories, destroying rather expensive constructions that are complicated to repair. To address this challenge, there is a need to [...] Read more.
Refractory materials are used worldwide in process equipment. However, gaseous and liquid process products penetrate the surface layer and deep into the volume of refractories, destroying rather expensive constructions that are complicated to repair. To address this challenge, there is a need to develop protective coatings for refractory materials that can limit the penetration of working media and extend their operational lifespan. In this work, the application of gas-dynamic cold spraying (CGDS) to produce a coating on the refractory materials using fine titanium dioxide (TiO2) particles is explored. These particles are accelerated within a nitrogen flow, passing through a Laval nozzle, and then sprayed onto a fireclay surface. The mechanisms of particle deposition and layer formation on porous surfaces through experiments and numerical simulations were investigated. The geometry of a typical refractory pore was determined, which was then incorporated into computational fluid dynamics (CFD) simulations to model the cold spraying process of porous substrates. As a result, the influence of the particle size on its velocity and angle of penetration into pores was established. Experimental findings demonstrate the effective closure of pores and the formation of a particle layer on the refractory surface. Furthermore, the nanoindentation tests for the refractory samples showcase capabilities for checking coating thickness for porous materials. Full article
(This article belongs to the Special Issue Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour)
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Review

Jump to: Research

36 pages, 24456 KiB  
Review
Research Progress on Numerical Simulation of the Deposition and Deformation Behavior of Cold Spray Particles
by Zhihao Liu, Jianwu Liu, Haifeng Li, Zizhao Wu, Yuan Zhong, Chidambaram Seshadri Ramachandran, Yingliang Cheng and Qun Wang
Coatings 2024, 14(7), 913; https://doi.org/10.3390/coatings14070913 - 21 Jul 2024
Cited by 1 | Viewed by 1747
Abstract
It is of significant theoretical and practical value to study the deposition process and deformation behavior of cold-sprayed particles to find the deposition mechanism of cold-sprayed coatings, further improve the coating performance, and expand its application scope. However, observing the deposition process and [...] Read more.
It is of significant theoretical and practical value to study the deposition process and deformation behavior of cold-sprayed particles to find the deposition mechanism of cold-sprayed coatings, further improve the coating performance, and expand its application scope. However, observing the deposition process and particle behavior through experiments is difficult due to the brief deposition duration of cold spray particles. Numerical simulation offers a means to slow the deposition process and predict the critical velocity, deformation behavior, bonding mechanism, and residual stress of cold-sprayed particles. This paper uses finite element analysis software, including ANSYS LS Dynamic-2022 R1 and ABAQUS-6.14, alongside various prevalent finite element methods for numerically simulating cold spray particle deposition. These methods involve the Lagrange, Euler, arbitrary Lagrange-Euler (ALE), and Smoothed Particle Hydrodynamics (SPH) to investigate the cold spray particle deposition process. The recent literature primarily summarizes the simulation outcomes achieved by applying these methodologies for simulating the deposition process and deformation characteristics of different particles under varying cold spraying conditions. In addition, the reliability of these simulation results is analyzed by comparing the consistency between the simulation results of single-particle and multi-particle and the actual experimental results. On this basis, these methods’ advantages, disadvantages, and applicability are comprehensively analyzed, and the future simulation research work of particle deposition process and deformation behavior of cold spraying prospects is discussed. Future research is expected to provide a more in-depth study of the micro-mechanisms, such as the evolution of the inter-particle and internal organization of the particles, near the actual situation. Full article
(This article belongs to the Special Issue Functional Coatings: Microstructure, Mechanical Properties, and Wear Behaviour)
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