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Advances in Cold Spraying for Thin Film Preparation

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A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Ceramic Coatings and Engineering Technology".

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 13137

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Special Issue Editors

Dr. Agnieszka Baszczuk

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Guest Editor

Department of Mechanics, Materials and Biomedical Engineering Wrocław University of Science and Technology, Wroclaw, Poland
Interests: sol–gel materials; ceramics; coatings; crystal structure; cold spraying

Dr. Marek Jasiorski

E-Mail Website
Guest Editor

Department of Mechanics, Materials and Biomedical Engineering Wrocław University of Science and Technology, Wroclaw, Poland
Interests: sol–gel materials; ceramics; coatings; cold spraying

Special Issue Information

Dear Colleagues,

Cold gas dynamic spraying (CGDS) takes advantage of accelerated to supersonic velocity particles, impacting substrate at a temperature much below the melting point of the feedstock material. With the growing demand for low-cost, high-speed effective and efficient processes, CGDS is a versatile method used extensively for coating production of the broad thickness range, additive manufacturing, and component restoration. Although cold spraying was introduced several decades ago for spraying micro-sized metal particles, there is still a lot of room to broaden the possible range of used materials and their sizes (i.e., nanometric ceramics and polymers). The improvements and modernization of cold spray equipment (e.g., laser-assisted spraying, CGDS system equipped with an atomizer), development of innovative processes for the fabrication of feedstock powders adapted to CGDS, and pre- and post-processing for altering microstructures and properties of the produced coatings are just a few examples for further method progress.

This Special Edition deals with technological advances in cold spraying. We invite authors to demonstrate their scientific and technological contribution to any cold-spray-related issues, including modification of spray equipment and the use of unconventional coating materials or pre- and post-processing of coatings and proposal of new application of the cold spray process. Both theoretical and experimental articles aiming at an understanding of the physicochemical mechanism of the deposition process would also be appreciated.

Dr. Agnieszka Baszczuk
Dr. Marek Jasiorski
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

cold gas dynamic spraying
unconventional feedstock powders
cold spray process modifications
equipment alternation
parameter optimization
numerical calculations

Published Papers (4 papers)

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Research

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18 pages, 6283 KiB

Open AccessArticle

Simulation of Particle Interaction with Surface Microdefects during Cold Gas-Dynamic Spraying

by Olha Aleksieieva, Liliia Dereviankina, Paul Breuninger, Mustafa Bozoglu, Pavlo Tretiakov, Andrii Toporov and Sergiy Antonyuk

Coatings 2022, 12(9), 1297; https://doi.org/10.3390/coatings12091297 - 03 Sep 2022

Cited by 3 | Viewed by 1394

Abstract

The cold gas-dynamic spray (CGDS) technique is utilized for repairing processes of a large number of metallic components in mechanical and process engineering, such as bridges or vehicles. Fine particles impacting on the component surface can be severely deformed and penetrate into the defects, filling and coating them, resulting in possible protection against corrosion or crack propagation. This work focuses on the investigation of the impact behavior of cold sprayed particles with the wall surface having microdefects in the form of cavities. The collision of fine single particles with the substrate, both made from AISI 1045 steel, was simulated with the finite element method (FEM) using the Johnson–Cook failure model. The impact phenomena of particles on different microdefect geometries were obtained and compared with the collision on a smooth surface. The particle diameter and defect were varied to investigate the influence of the size on the deformation behaviour. The different impact scenarios result in different temperature and stress distributions in the contact zone, penetration and deformation behavior during the collision. Full article

(This article belongs to the Special Issue Advances in Cold Spraying for Thin Film Preparation)

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14 pages, 3894 KiB

Open AccessArticle

Microstructure and Properties of Hydroxyapatite Coatings Made by Aerosol Cold Spraying–Sintering Technology

by Grzegorz Kubicki, Volf Leshchynsky, Ahmed Elseddawy, Maria Wiśniewska, Roman G. Maev, Jarosław Jakubowicz and Joanna Sulej-Chojnacka

Coatings 2022, 12(4), 535; https://doi.org/10.3390/coatings12040535 - 15 Apr 2022

Cited by 4 | Viewed by 2144

Abstract

Hydroxyapatite is a widely used material used for the bioactivation of an implant’s surface. A promising hydroxyapatite coating approach is the kinetic deposition of powder particles. The possibility of solid-state deposition improvement through the merging of Aerosol Deposition and Low Pressure Cold Spraying techniques is a promising prospect for improving the deposition efficiency and the quality of coatings. The objective of the paper is to study the possibilities of hydroxyapatite coating structure modification through changes in the coating process and post-heat treatment. The novel Aerosol Cold Spraying system joining Low Pressure Cold Spraying and Aerosol Deposition was used for the deposition of coatings. The coating’s post-processing was conducted using two techniques: Spark Plasma Sintering and Pressureless Sintering. The coating’s structure was examined using scanning, transmission, and light microscopy, and X-ray diffraction. Substrate–coating bond strength was assessed using a tensile test. Homogenous buildup using Aerosol Cold Spraying of hydroxyapatite was achieved. Various pores and microcracks were visible in the sprayed coatings. The deposition process and the thermal post-processing did not lead to significant degradation of the hydroxyapatite phase. As a result of the Spark Plasma Sintering and Pressureless Sintering at 800 °C, an increase in tensile adhesion bond strength and crystal size was obtained. Full article

(This article belongs to the Special Issue Advances in Cold Spraying for Thin Film Preparation)

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19 pages, 7133 KiB

Open AccessArticle

Preparation of Visible-Light Active Oxygen-Rich TiO₂ Coatings Using Low Pressure Cold Spraying

by Anna Gibas, Agnieszka Baszczuk, Marek Jasiorski, Marcin Winnicki and Daniel Ociński

Coatings 2022, 12(4), 475; https://doi.org/10.3390/coatings12040475 - 31 Mar 2022

Cited by 4 | Viewed by 2420

Abstract

Visible-light active photocatalysts in the form of coatings that can be produced using large-scale methods have attracted considerable attention. Here we show a facile approach to deposit coatings using the low pressure cold spray (LPCS) from oxygen-rich amorphous titanium dioxide, which is a structurally-unconventional feedstock powder for LPCS. We synthesized amorphous TiO₂, in which we introduced numerous defects, such as oxide groups (peroxy and superoxy) in volume and hydroxyl groups on the surface. Then we deposited as-prepared powder preserving the presence of active groups, which we demonstrated using Raman spectroscopy. To show the activity of the prepared coatings, we perform methylene blue degradation under visible light. Our research shows that it is worth considering the internal atomic structure and surface chemistry of the powders to be preserved after low pressure cold spraying. Full article

(This article belongs to the Special Issue Advances in Cold Spraying for Thin Film Preparation)

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Review

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51 pages, 20379 KiB

Open AccessReview

Advanced Functional Metal-Ceramic and Ceramic Coatings Deposited by Low-Pressure Cold Spraying: A Review

by Marcin Winnicki

Coatings 2021, 11(9), 1044; https://doi.org/10.3390/coatings11091044 - 30 Aug 2021

Cited by 30 | Viewed by 6044

Abstract

Based on the recent analysis of various databases, cold spray (CS), the newest method among thermal spraying technologies, has received the unabated attention of hundreds of researchers continuously since its invention in the 1980s. The significance of CS lies in the low process temperature, which usually ensures compressive residual stresses and allows for the formation of coatings on a thermally sensitive substrate. This paper concerns the low-pressure cold spray (LPCS) variant employed for forming metal matrix composites (MMCs) with high ceramic contents and all-ceramic coatings. At the very beginning, the influence of LPCS process parameters on deposition efficiency (DE) is analysed. In the next part, the most useful feedstock powder preparation techniques for LCPS are presented. Due to the combination of bottom-up powder production methods (e.g., sol-gel (SG)) with LCPS, the metal matrix that works as a binder for ceramic particles in MMC coatings can be removed, resulting in all-ceramic coatings. Furthermore, with optimization of spraying parameters, it is possible to predict and control phase transformation in the feedstock material. Further in the paper, differences in the bonding mechanism of metal–ceramic mixtures and ceramic particles are presented. The properties and applications of various MMC and ceramic coatings are also discussed. Finally, the exemplary direction of CS development is suggested. Full article

(This article belongs to the Special Issue Advances in Cold Spraying for Thin Film Preparation)

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