Advances in Spraying and Deposition Processes for Aerospace Applications

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 December 2026 | Viewed by 878

Special Issue Editor


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Guest Editor
Department of Mechanical Engineering, École de Technologie Supérieure, 1100 rue Notre-Dame Ouest, Montréal, QC H3C1K3, Canada
Interests: investigation of advanced materials processing and joining techniques, including hot deformation, welding, additive manufacturing, cold spray and deposition techniques with a focus on optimizing the microstructure and mechanical performance of metals and alloys for aerospace, transport, and energy applications

Special Issue Information

Dear Colleagues,

Spraying and deposition processes have become indispensable in the fabrication, repair, and enhancement of aerospace components, offering versatile solutions for achieving tailored surface properties, precise geometries, and superior material performance. Over recent decades, advances in thermal spraying, cold spraying, physical and chemical vapor deposition, and related techniques have driven significant improvements in coating adhesion, microstructural control, and functional performance under extreme operating conditions. These processes are key techniques for protecting aerospace structures against wear, corrosion, oxidation, and thermal degradation, while also enabling lightweight design through additive manufacturing and hybrid processing approaches.

In this Special Issue, we invite recent research and developments that advance the science, technology, and application of spraying and deposition techniques for aerospace systems. Contributions may cover innovations in process design, modeling and simulation, in situ monitoring and control, novel coating materials, post-processing treatments, and life-cycle performance evaluation.

Potential topics include, but are not limited to, the following:

  • Thermal spraying, cold spraying, and emerging deposition methods for aerospace components
  • Microstructural engineering and property optimization of deposited layers
  • Process diagnostics, monitoring, and automation for reproducibility and quality assurance
  • Applications in structural, propulsion, and functional aerospace systems

Dr. Mohammad Saadati
Guest Editor

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Keywords

  • cold spray
  • additive manufacturing
  • plasma spray
  • HVOF spray
  • cold spray additive manufacturing
  • osprey
  • aerospace
  • composite interlayer
  • bonding
  • interface
  • spraying parameters
  • aeronautical repair

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Published Papers (1 paper)

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Research

23 pages, 105416 KB  
Article
Effect of Torch Power and Thickness on APS Al2O3 Coatings on 100Cr6 Bearing Steel: Microstructure, Adhesion and Flexural Response
by Nazanin Sheibanian, Raffaella Sesana, Sebastiano Rizzo, Kazuaki Kayahara and Daichi Kawasaki
J. Manuf. Mater. Process. 2026, 10(2), 68; https://doi.org/10.3390/jmmp10020068 - 17 Feb 2026
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Abstract
This research examines how atmospheric plasma spraying torch power and coating thickness jointly affect the adhesion strength, microstructure, porosity, and flexural behavior of Al2O3 coatings on 100Cr6 steel substrates. Optical microscopy, SEM and EDS mapping, 3D surface-roughness analysis, Vickers [...] Read more.
This research examines how atmospheric plasma spraying torch power and coating thickness jointly affect the adhesion strength, microstructure, porosity, and flexural behavior of Al2O3 coatings on 100Cr6 steel substrates. Optical microscopy, SEM and EDS mapping, 3D surface-roughness analysis, Vickers hardness testing (HV2) on polished cross-sections, and three-point bending of extracted beams were employed to develop a processing–structure–property map. This multi-technique approach enables the cross-validation of processing–structure–property relationships and supports a robust identification of the optimal power–thickness condition by jointly considering porosity (densification), adhesion strength, flexural response and failure mode. All conditions resulted in an average surface roughness Ra of approximately 1.0 µm. Increasing torch power to 45 kW generally reduced cross-sectional porosity, except at 500 µm, where globular pores appeared. Hardness (HV2) increased with power and peaked at the intermediate thickness (500 µm); adhesion up to 63 MPa was recorded for the 300 µm/45 kW coating. Flexural strength was highest at 500 µm and was consistently greater at 45 kW than at 39 kW. Fractography showed a shift in failure mode from interface-driven delamination at 39 kW to more cohesive, tortuous intra-coating cracks at 45 kW, aligned with improved splat bonding and crack-path deflection. An intermediate thickness of 500 µm deposited at 45 kW is thus identified as an optimal condition to balance densification and crack-path tortuosity, leading to enhanced hardness and flexural performance. Full article
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