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Research Progress of Metals and Alloys by Thermal Layering and...
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Research Progress of Metals and Alloys by Thermal Layering and Deposition

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

Deadline for manuscript submissions: closed (18 February 2023) | Viewed by 15204

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Dr. Ashish Kumar Srivastava

E-Mail Website
Guest Editor
Department of Mechanical Engineering, G.L.Bajaj Institute of Technology and Management, Greater Noida 201308, India
Interests: additive manufacturing; metal additive manufacturing; material processing; material characterization
Special Issues, Collections and Topics in MDPI journals
Dr. Amit Rai Dixit

E-Mail Website
Co-Guest Editor
Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines) Dhanbad, Jharkhand 826004, India
Interests: additive manufacturing; 3D printing technologies; metal matrix composites; nano composites; friction stir processing; friction stir additive manufacturing; non-conventional machining processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In manufacturing, it has been observed that lots of problems are associated with the wear and corrosion of parts, which becomes the main reason for the failure of the complete product. The manufacturing industry needs the attention of researchers to focus on the development of functionally graded materials which can sustain high temperatures and high wear and corrosion. The design of material leads to the modification of their local properties according to their engineering application. Coating is one of the suitable techniques to improve the wear, corrosion and overall life of the component. In addition to it, the methods such as additive layer coatings, friction stir coating, friction stir layer deposition and functionally graded materials are some alternative options to overcome the defects such as high wear and corrosion of the mating parts of the automobile and to improve the mechanical and microstructural properties. Plastic deformation techniques such as severe plastic deformation (SPD) and friction stir processing (FSP) are some key parameters to enhance the overall performance of the material against the wear, tear and corrosion behaviour of the material. The dynamic recrystelization process and lattice dislocation phenomenon of the SPD and FSP process refine the grains and increases the larger number of grain boundaries, hence improving the hardness and strength also. This Special Issue of Coatings is focused on such coating techniques and their microstructural, mechanical, wear, corrosion and thermal characterization.

Therefore, we are inviting the submission of full-length original articles and reviews for this Special Issue of Coatings, titled “Research Progress of Metals and Alloys by thermal layering and deposition”, aiming to cover the scientific knowledge in this area and discuss topics of interest to readers.

In particular, the topics of interest includes but are not limited to:

  • Coating Materials;
  • Wear- and corrosion-resistant coating;
  • Friction stir coatings;
  • Composite coating;
  • Friction stir deposition;
  • Nano-structured coatings;
  • Micro-structured coatings;
  • Thermal layering deposition;
  • Physical Vapor Deposition (PVD) Coating;
  • Chemical Vapor Deposition (CVD) Coating;
  • Micro-Arc Oxidation (MAO) Coating;
  • Electrodeposition Coating;
  • Electrolytic Deposition (ELD) Coating;
  • Electrophoretic Deposition (EPD) Coating;
  • Sol-gel Coating;
  • Thermal Spray Coating;
  • Plasma Spray Coating;
  • Cold Spray Coating;
  • Arc Wire Spray Coating;
  • Warm Spray Coating;
  • Microstructural, mechanical, thermal, wear and corrosion characterization of coatings, deposition and processing.

Dr. Ashish Kumar Srivastava
Dr. Amit Rai Dixit
Guest Editors

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

  • experimental testing
  • microstructural characterization
  • numerical modelling
  • coating materials
  • friction stir coatings
  • composite coating
  • nano-structured coatings
  • micro-structured coatings
  • thermal layering deposition
  • physical vapor deposition (PVD) coating
  • chemical vapor deposition (CVD) coating
  • micro-arc oxidation (MAO) coating
  • electrodeposition coating
  • electrolytic deposition (ELD) coating
  • electrophoretic deposition (EPD) coating
  • sol-gel coating
  • thermal spray coating

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Published Papers (13 papers)

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Editorial

Jump to: Research, Review

4 pages, 178 KiB  
Editorial
Research Progress in Metals and Alloys by Thermal Layering and Deposition
by Ashish Kumar Srivastava and Amit Rai Dixit
Coatings 2023, 13(2), 366; https://doi.org/10.3390/coatings13020366 - 6 Feb 2023
Cited by 1 | Viewed by 1443
Abstract
Over the last 20 years, because of their superior hardness, chemical stability, and outstanding oxidation barrier, many coating systems have now been extensively researched using various deposition processes and employed for wear-resistant protection [...] Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)

Research

Jump to: Editorial, Review

24 pages, 10863 KiB  
Article
Firefly Algorithm and Neural Network Employment for Dilution Analysis of Super Duplex Stainless Steel Clads over AISI 1020 Steel Using Gas Tungsten Arc Process
by Mohd. Majid, Love Goel, Abhinav Saxena, Ashish Kumar Srivastava, Gyanendra Kumar Singh, Rajesh Verma, Javed Khan Bhutto and Hany S. Hussein
Coatings 2023, 13(5), 841; https://doi.org/10.3390/coatings13050841 - 27 Apr 2023
Cited by 2 | Viewed by 1613
Abstract
Traditional low-carbon steels provide the strength needed to satisfy industrial demands. Low-carbon steel’s poor corrosion resistance is one of its main drawbacks. Due to this restriction, corrosion-resistant materials such as super duplex stainless steels are frequently used for cladding onto the surface of [...] Read more.
Traditional low-carbon steels provide the strength needed to satisfy industrial demands. Low-carbon steel’s poor corrosion resistance is one of its main drawbacks. Due to this restriction, corrosion-resistant materials such as super duplex stainless steels are frequently used for cladding onto the surface of low-carbon steel. The cladded surface possesses superior chloride stress corrosion cracking resistance, pitting and crevice corrosion resistance, yield strength, ductility, and impact toughness. Mild steel with measurements of 300 × 300 × 12 mm has been selected as the substrate material, and super duplex stainless steel (S32950) with an electrode diameter of 2.4 mm has been selected as the filler wire. Gas Tungsten Arc (GTA) cladding was performed onto the surface of low-carbon steel for experimentation. The clad was deposited in the flat position with four different currents, i.e., 120 A, 130 A, 140 A, and 150 A. Cladding was performed on different layers of each current level, i.e., single layer, double layers, and triple layers. After experimenting and overviewing the outcomes, it can be concluded that the optimum input parameters would be a 3-layered clad at a 140 A current level. Cladding of the super duplex stainless steel over mild steel improves the corrosive properties. The percentage ratio of reactivation current density to activation current density (Ir/Ia%) improves from 29% (mild steel) to 4.1% at the top layer and 11.9% at the intermediate layer. The microhardness of the clad decreases with an increase in both the current level and the number of layers. Microhardness varies between 191–248 at the clad, 170–189 at the HAZ, and 143–153 at the substrate for a 1 kgf load. Dilution refers to the change in the cladding alloy composition due to the mixing of the molten matrix. The composition of the clad changes under a high dilution, resulting in a decrease in the mechanical as well as corrosion properties of the clad. However, if the dilution is too small, the bond between the substrate and the clad is poor. Therefore, dilution is one of the most important process control parameters and the key to obtaining high-quality cladding. Thus, the dilution effect is also analyzed on all three clad layers deposited at various current levels using the firefly algorithm (FA) and artificial neural network (ANN). It is observed that dilution levels are found to be more approachable to the experimental setup data with FA in comparison to ANN for various current levels. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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14 pages, 2998 KiB  
Article
The Effect of Various Contaminants on the Surface Tribological Properties of Rail and Wheel Materials: An Experimental Approach
by Rabesh Kumar Singh, Mahesh Shindhe, Prashant Rawat, Ashish Kumar Srivastava, Gyanendra Kumar Singh, Rajesh Verma, Javed Khan Bhutto and Hany S. Hussein
Coatings 2023, 13(3), 560; https://doi.org/10.3390/coatings13030560 - 5 Mar 2023
Cited by 6 | Viewed by 1878
Abstract
This study reports on the tribological behavior of Indian rail track and wheel materials under different contaminants. A pin-on-disc tribometer was selected for the experimental analysis in ambient conditions (temperature of 24.9 °C and relative humidity of 66%). Sand, mist, leaves, and grease [...] Read more.
This study reports on the tribological behavior of Indian rail track and wheel materials under different contaminants. A pin-on-disc tribometer was selected for the experimental analysis in ambient conditions (temperature of 24.9 °C and relative humidity of 66%). Sand, mist, leaves, and grease were the contaminants used in this investigation. The railway track was used to make the pin, and the wheel was used to make the disc. The acquired results were analyzed using frictional force and wear depth as a function of time as the variables. These pollutant effects were compared to no-contaminant conditions. It was observed that the sand increased the friction force and wear depth, whereas oil decreased friction and wear. Mist and leaves also reduced friction and wear. The effect of leaves was higher than the mist. The effect of load on various contaminants was also investigated. The results showed that as the load increased, the friction force and wear also increased for all contaminants. The results of this study can help in understanding the wear phenomenon of wheels and rail tracks in different parts of India. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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14 pages, 5877 KiB  
Article
Effect of Ni Coating on Microstructure and Property of Al Alloy/Steel CMT Welding-Brazing Joints
by Chao Zhang, Mingfang Wu, Juan Pu, Jiawei Rao, Weimin Long and Yuanxun Shen
Coatings 2023, 13(2), 418; https://doi.org/10.3390/coatings13020418 - 12 Feb 2023
Cited by 7 | Viewed by 2299
Abstract
The cold metal transfer (CMT) welding-brazing process was chosen to join Al alloy and Ni-coated steel using AlSi12 as the filler wire. The macrostructure and microstructure of the joints were tested by using an optical microscope (OM), scanning electron microscope (SEM), energy dispersive [...] Read more.
The cold metal transfer (CMT) welding-brazing process was chosen to join Al alloy and Ni-coated steel using AlSi12 as the filler wire. The macrostructure and microstructure of the joints were tested by using an optical microscope (OM), scanning electron microscope (SEM), energy dispersive spectrometry (EDS), and X-ray diffraction (XRD). The tensile properties and corrosion properties of the joints were also tested. The results showed that Ni coating could improve the wettability and spreadability of molten AlSi12 filler metal on the steel surface, resulting in a good appearance for the Al alloy/steel joint. Ni coating could hinder the chemical metallurgical reaction between Al atom and Fe atoms to inhibit the formation of brittle Fe-Al intermetallic compounds (IMCs) and reduce the thickness of the IMCs layer. Meanwhile, the Ni atom reacted with the Fe and Al atoms to form Al3Ni2, (Fe, Ni) Al3 and (Fe, Ni)2Al3, which improved the tensile strength of the joints. All joints with Ni coating cracked near the Al alloy. When the Ni-coating thickness was 5 μm, the tensile strength of the joint reached a maximum of 202.5 MPa. The addition of Ni could also improve the corrosion resistance of the joints. Significantly, when the Ni-coating thickness was 10 μm, most of the Ni coating was still solid, and the interface reaction layer was mainly composed of α-Ni solid solution and some (Fe, Ni)2Al3. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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15 pages, 5464 KiB  
Article
Effect of Mesogenic Phase and Structure of Liquid Crystals on Tribological Properties as Lubricant Additives
by Han Wu, Ying Jiang, Wenjing Hu, Sijing Feng and Jiusheng Li
Coatings 2023, 13(1), 168; https://doi.org/10.3390/coatings13010168 - 12 Jan 2023
Cited by 2 | Viewed by 1898
Abstract
To develop a high-performance additive that can meet different operating conditions, three liquid crystals (LCs) were developed as additives for a base oil. The structures and thermal stabilities of the obtained LCs were characterized by nuclear magnetic resonance (NMR), Fourier transform infrared (FT-IR) [...] Read more.
To develop a high-performance additive that can meet different operating conditions, three liquid crystals (LCs) were developed as additives for a base oil. The structures and thermal stabilities of the obtained LCs were characterized by nuclear magnetic resonance (NMR), Fourier transform infrared (FT-IR) spectroscopy, mass spectroscopy (MS), and thermogravimetric analysis (TGA). The effects of mesogenic-phase temperature ranges on tribological properties were analyzed using differential scanning calorimetry (DSC) and polarized optical microscopy (POM). UMT-TriboLab friction and wear tester was used to study the friction-reducing properties of LCs. The width of wear marks was observed by a Contour GT-K 3D profiler to illustrate the anti-wear performance of LCs. The friction surface was characterized by scanning electron microscopy (SEM) and Raman spectroscopy. It was demonstrated that, in comparison with the base oil, the addition of LCs caused a remarkable reduction in the coefficient of friction (21.57%) and wear width (31.82%). In addition, LCs show better tribological abilities in the mesogenic-phase temperature ranges. According to the results, we demonstrated that LCs can be used as lubricant additives, especially for several operating conditions under specific temperatures. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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20 pages, 3204 KiB  
Article
An Investigation for Minimizing the Wear Loss of Microwave-Assisted Synthesized g-C3N4/MoS2 Nanocomposite Coated Substrate
by Mukul Saxena, Anuj Kumar Sharma, Ashish Kumar Srivastava, Narendra Singh and Amit Rai Dixit
Coatings 2023, 13(1), 118; https://doi.org/10.3390/coatings13010118 - 8 Jan 2023
Cited by 11 | Viewed by 2419
Abstract
Mechanical components frequently come into contact against one another causing friction that produces heat at the contact area and wear of the components that shortens part life and increases energy consumption. In the current study, an attempt was made to optimize the parameters [...] Read more.
Mechanical components frequently come into contact against one another causing friction that produces heat at the contact area and wear of the components that shortens part life and increases energy consumption. In the current study, an attempt was made to optimize the parameters for the pin-on-disc wear tester. The experiments were carried out in ambient thermal conditions with varying sliding speeds (0.5 m/s, 0.75 m/s, and 1.0 m/s) and applied loads (5 N, 10 N, and 15 N) for pure molybdenum disulfide with 9% and 20% weight percentage of graphitic carbon nitride (g-C3N4) in molybdenum-disulfide (MoS2)-nanocomposite-coated steel substrate. Analysis of variance (ANOVA) was used to determine the outcome of interaction between various constraints. To identify the minimum wearing conditions, the objective was defined as the criterion ‘smaller is better’. The maximum impact of the applied load on the coefficient of friction and wear depth was estimated to be 59.6% and 41.4%, respectively, followed by sliding speed. The optimal condition for the minimum coefficient of friction and wear was determined to be 15 N for applied load, 0.75 m/s for sliding speed, and weight percentage of 9 for g-C3N4 in MoS2 nanocomposite. At the 95% confidence level, applied load was assessed to have the most significant effect on the coefficient of friction, followed by sliding speed and material composition, whereas material composition considerably impacts wear, followed by loading and sliding speed. These parameters show the effect of mutual interactions. Results from the Taguchi method and response surface methodology are in good agreement with the experimental results. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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14 pages, 6836 KiB  
Article
Surface Modification and Parametric Optimization of Tensile Strength of Al6082/SiC/Waste Material Surface Composite Produced by Friction Stir Processing
by Nitesh Kumar, Rakesh Kumar Singh, Ashish Kumar Srivastava, Akash Nag, Jana Petru and Sergej Hloch
Coatings 2022, 12(12), 1909; https://doi.org/10.3390/coatings12121909 - 6 Dec 2022
Cited by 9 | Viewed by 2052
Abstract
Friction stir processing (FSP) is one of the promising tools to enhance the mechanical and microstructural features of any engineering material due to its excellence in grain refinement. Further, the successful utilization of waste material into a useful product instigates the use of [...] Read more.
Friction stir processing (FSP) is one of the promising tools to enhance the mechanical and microstructural features of any engineering material due to its excellence in grain refinement. Further, the successful utilization of waste material into a useful product instigates the use of chicken bone powder (CBP), walnut shell powder (WSP), and rice husk powder (RHP) as secondary reinforcement to develop surface composites and metal matrix composites to enhance the mechanical properties. In the present work, a surface composite of base alloy Al6082 is developed through the utilization of SiC as primary reinforcement and CBP, WSP, and RHP as secondary reinforcement. The experiments were performed as per Taguchi’s L9 orthogonal array and the analysis of variance (ANOVA) response is discussed in detail. The process parameters taken for the study are the type of tool pin profile such as hexagonal, square, and cylindrical threaded along with rotational speed and tool tilt angle. The result revealed the microstructural characterization through field emission scanning electron microscopy (FESEM) images equipped with energy-dispersive X-ray spectroscopy (EDS) phase mapping and elemental spectrum. The tensile strength of each specimen was tested through a horizontal tensometer and further studied to get the optimized value of the process parameter to achieve a larger value. The use of a hexagonal pin profile with the optimized value of the rotational speed of 1500 rpm and 3° tilt angle gives the higher tensile strength of 250.64 MPa. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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16 pages, 5904 KiB  
Article
Microwave-Assisted Synthesis, Characterization and Tribological Properties of a g-C3N4/MoS2 Nanocomposite for Low Friction Coatings
by Mukul Saxena, Anuj Kumar Sharma, Ashish Kumar Srivastava, Rabesh Kumar Singh, Amit Rai Dixit, Akash Nag and Sergej Hloch
Coatings 2022, 12(12), 1840; https://doi.org/10.3390/coatings12121840 - 28 Nov 2022
Cited by 17 | Viewed by 2523
Abstract
This study explores the tribological performance of microwave-assisted synthesized g-C3N4/MoS2 coatings. The two-dimensional transition metal dichalcogenide (TMD) nanosheet is getting prominence in the study of tribology due to its layered structure. The graphitic carbon nitride (g-C3 [...] Read more.
This study explores the tribological performance of microwave-assisted synthesized g-C3N4/MoS2 coatings. The two-dimensional transition metal dichalcogenide (TMD) nanosheet is getting prominence in the study of tribology due to its layered structure. The graphitic carbon nitride (g-C3N4) nanosheet was made using the calcination method and its nanocomposite with molybdenum disulfide (MoS2) was produced using a microwave-assisted method. The structure and morphology of the samples were characterized by some well-known methods, and tribological properties were studied by a pin-on-disc (POD) apparatus. Morphological analysis revealed that graphitic carbon nitride and molybdenum disulfide coexisted, and the layer structured MoS2 was well dispersed on graphitic carbon nitride nanosheets. BET analysis was used to determine the pore volume and specific surface area of the synthesized materials. The inclusion of MoS2 nanoparticles caused the composite’s pore volume and specific surface area to decrease. The reduction in g-C3N4 pore volume and specific surface area confirmed that the pores of calcinated graphitic carbon nitride were filled with MoS2 nanoparticles. The tribological property of g-C3N4/MoS2 nanocomposite was systematically investigated under different factors such as applied loads (5N to 15N), sliding speed (500 to 1000 mm/s) and material composition (uncoated, MoS2-coated, 9 wt.% of g-C3N4 and 20 wt.% of g-C3N4 in the composite). The optimal composite material ratio was taken 9%, by weight of g-C3N4 in the g-C3N4/MoS2 composite for a variety of levels of loads and sliding speeds. The results indicates that the incorporation of g-C3N4 in nanocomposites could reduce friction and improve wear life, which were better than the results with single MoS2. This study demonstrates a solution to broaden the possible uses of g-C3N4 and MoS2-based materials in the field of tribology. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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15 pages, 5199 KiB  
Article
Microstructural Evaluation of Graphene-Reinforced Nickel Matrix Ni-P-Gr Coating on Ti-6Al-4V Alloy by the Electroless Coating Method
by Hatice Gunduz, Ramazan Karslioglu and Fahrettin Ozturk
Coatings 2022, 12(12), 1827; https://doi.org/10.3390/coatings12121827 - 25 Nov 2022
Cited by 3 | Viewed by 2208
Abstract
Titanium alloys are widely used in many industrial applications, from aerospace to automotive, and from defense to medical, as they combine superior properties such as high strength and low density. Still, titanium and its alloys are insufficient in environments with friction and wear [...] Read more.
Titanium alloys are widely used in many industrial applications, from aerospace to automotive, and from defense to medical, as they combine superior properties such as high strength and low density. Still, titanium and its alloys are insufficient in environments with friction and wear because of their weak tribological properties. In the literature, numerous research works on improving the surface quality of titanium alloys have been conducted. Electroless coatings, on the other hand, are one of the most widely used surface improvement methods due to its homogeneous thickness achievement, high hardness, and good corrosion resistance. The autocatalytic reduction in the coating process enhances the surface quality of the material or alloy considerably. In addition, many studies in the literature aim to carry the properties of electroless coatings to a higher point by creating a composite coating with the addition of extra particles. In this study, graphene-reinforced nickel matrix Ni-P-Gr coating was applied to the surface of Ti-6Al-4V alloy, in order to enhance weak tribological behaviors, by the electroless coating method. Moreover, the coated and uncoated, heat-treated, and non-heat-treated specimens were subjected to abrasion in linear reciprocating ball-on-plate configuration to observe tribological properties. Microstructure examination of the samples was performed using a scanning Electron Microscope (SEM), X-ray Diffractometer (XRD), X-ray Photon Spectrometry (XPS), and Raman Spectroscopy. Specific wear rates of specimens were calculated using microstructural analysis and the hardness of the produced samples was measured using the Vickers hardness test. Results indicate that both the coating and the heat treatment improved the microstructure and tribological properties significantly. With the graphene-reinforced Ni-P coating via electroless coating process, the hardness of the substrate increased by about 34%, while it increased by approximately 73% using subjected heat treatment. Furthermore, the wear rate of the Ti-6Al-4V substrate was approximately 98% higher than that of the heat-treated nanocomposite coating. The highest wear resistance was obtained at the heat-treated nanocomposite coating. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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17 pages, 3359 KiB  
Article
Control of Static and Dynamic Parameters by Fuzzy Controller to Optimize Friction Stir Spot Welding Strength
by Maha M. A. Lashin, Ali M. Al Samhan, Ahmed Badwelan and Muhammad Ijaz Khan
Coatings 2022, 12(10), 1442; https://doi.org/10.3390/coatings12101442 - 30 Sep 2022
Cited by 5 | Viewed by 2058
Abstract
Solid-state welding is a derivative of the friction stir spot welding (FSSW) technique, which has been developed as a new method for joining aluminum alloys. FSSW is a variant of linear friction stir welding intended to deal with lightweight alloy resistance spot welding [...] Read more.
Solid-state welding is a derivative of the friction stir spot welding (FSSW) technique, which has been developed as a new method for joining aluminum alloys. FSSW is a variant of linear friction stir welding intended to deal with lightweight alloy resistance spot welding (RSW) and riveting. Tensile strength refers to a material’s ability to withstand excessive stress when being stretched or pulled before necking; it is expressed in terms of force per unit area. The tensile strength in stir spot welding is affected by dynamic and static parameters. The control of dynamic parameters and static parameters is studied in this paper to optimize the friction stir spot welding strength. A fuzzy logic control system is used to optimize the process as a new approach that can be used in this field. The obtained results prove that the fuzzy logic control system is an easy and inexpensive technology that can be used in prediction and optimization for the strength of FSSW. Furthermore, the results show the efficacy and adequacy of the proposed fuzzy logic control system. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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12 pages, 3137 KiB  
Article
Tribological Characteristics of Al359/Si3N4/Eggshell Surface Composite Produced by Friction Stir Processing
by Ashish Kumar Srivastava, Suryank Dwivedi, Ambuj Saxena, Deepak Kumar, Amit Rai Dixit, Gyanendra Kumar Singh, Javed Khan Bhutto and Rajesh Verma
Coatings 2022, 12(9), 1362; https://doi.org/10.3390/coatings12091362 - 18 Sep 2022
Cited by 13 | Viewed by 2575
Abstract
In the present study, the surface composite Al359/Si3N4/Eggshell is prepared by friction stir processing (FSP). The effect of reinforced particle volume fraction on the microstructural and tribological properties of the Al359/Si3N4/Eggshell surface composites was investigated and compared with the friction stir processed (FSPed) [...] Read more.
In the present study, the surface composite Al359/Si3N4/Eggshell is prepared by friction stir processing (FSP). The effect of reinforced particle volume fraction on the microstructural and tribological properties of the Al359/Si3N4/Eggshell surface composites was investigated and compared with the friction stir processed (FSPed) Al359 alloy. The microstructural properties were further investigated by light microscopy, FESEM, and EDS mapping. The tribological properties of the developed composite and FSPed Al359 were investigated using a reciprocating ball-on-plate universal tribometer. The microstructural results showed that defect-free composite surfaces are produced due to improved physical properties, severe plastic deformation, and better grain refinement. Moreover, the mean value of the friction coefficient (µ) for the developed composite and FSPed alloy are 0.36 µ and 0.47 µ, respectively. The obtained results indicated that Si3N4/Eggshell is a promising reinforced particle for improving microstructural and tribological performance in journal bearing, rotors, and machinery applications. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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9 pages, 1125 KiB  
Article
Effective Evaluation of Elastic Properties of a Graphene and Ceramics Reinforced Epoxy Composite under a Thermal Environment Using the Impact Hammer Vibration Technique
by Nitesh Kumar, Ananda Babu, Alok Kumar Das and Ashish Kumar Srivastava
Coatings 2022, 12(9), 1325; https://doi.org/10.3390/coatings12091325 - 12 Sep 2022
Cited by 5 | Viewed by 2033
Abstract
This paper presents an evaluation of the mechanical properties of nanocomposites when a lower concentration of nanoparticles graphene and ceramics are mixed with epoxy to determine the damping and stability characteristics of hybrid epoxy, using vibration techniques to extract accurate results. The effectiveness [...] Read more.
This paper presents an evaluation of the mechanical properties of nanocomposites when a lower concentration of nanoparticles graphene and ceramics are mixed with epoxy to determine the damping and stability characteristics of hybrid epoxy, using vibration techniques to extract accurate results. The effectiveness of the Impact hammer vibration technique is validated with mechanical testing such as three-point bending in terms of Young’s modulus of the nanocomposite. The graphene nanocomposite carries nanoparticle 1 wt.% of epoxy, while the ceramic nanocomposite carries 3 wt.% of epoxy. It is observed that the reduction in frequency under a thermal environment is significantly less for graphene and ceramic reinforced hybrid nanocomposites, whereas the reduction in pure epoxy under a thermal environment is high. Thus, the results show that the addition of nanoparticles to composites shows improvement in the mechanical and thermal stability of elastic properties. The elastic properties obtained from the vibrational analysis are more consistent and economical than the three-point bending test for the evaluation of hybrid nanocomposites. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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Review

Jump to: Editorial, Research

50 pages, 15570 KiB  
Review
Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities
by Desmond Klenam, Tabiri Asumadu, Michael Bodunrin, Mobin Vandadi, Trevor Bond, Josias van der Merwe, Nima Rahbar and Wole Soboyejo
Coatings 2023, 13(3), 538; https://doi.org/10.3390/coatings13030538 - 1 Mar 2023
Cited by 16 | Viewed by 4710
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 [...] Read more.
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. Full article
(This article belongs to the Special Issue Research Progress of Metals and Alloys by Thermal Layering and Deposition)
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