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Progress, Applications and Modern Solutions in Thermal Spraying, Hardfacing and Additive Manufacturing

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 November 2026 | Viewed by 832

Special Issue Editors


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Guest Editor
Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, 50-370 Wrocław, Poland
Interests: thermal spraying; hardfacing; powders; additive manufacturing; diagnostics
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Metal Forming, Welding and Metrology, Faculty of Mechanical Engineering, Wrocław University of Science and Technology, 50-370 Wrocław, Poland
Interests: thermal spraying; hardfacing; joining technologies; material-process-property relationships
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are inviting you to submit a manuscript under the proposed Special Issue entitled ‘Progress, applications and modern solutions in thermal spraying, hardfacing and additive manufacturing’.

Surface engineering is a well-known and important part of modern manufacturing processes. The development of thermal spraying and hardfacing has allowed us to improve surface properties, while surface phenomena in additive manufacturing play an important role in determining the final properties of elements. Significant advancements have been made in the development of new materials and technologies and in improving the properties of deposited coatings and additively manufactured components.

The topics of this Special Issue include, but are not limited to, the following:

  • Advances in thermal spraying (new materials, technology modifications);
  • Advances in hardfacing (new materials, technology modifications);
  • Advances in additive manufacturing (new materials, technology modifications);
  • Material characterization;
  • The properties of coatings and additively manufactured components (mechanical and functional ones);
  • Post-process treatment of coatings and additively manufactured components;
  • Diagnostics of processes;
  • Modeling of processes;
  • Quality control of coatings and additively manufactured elements.

The scope of this SI is also in line with the 7th International Thermal Spraying and Hardfacing Conference that will be held in Wroclaw (Poland) in 2025. To find out more, please visit www.itshc.pwr.edu.pl.

Dr. Pawel Sokolowski
Dr. Leszek Łatka
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 250 words) can be sent to the Editorial Office for assessment.

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. Materials is an international peer-reviewed open access semimonthly 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

  • surface engineering
  • thermal spraying
  • hardfacing
  • surfacing
  • coatings
  • powders
  • additive manufacturing
  • modern manufacturing
  • diagnostics
  • modeling

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Published Papers (1 paper)

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Research

23 pages, 5294 KB  
Article
Enhanced Surface-Engineering Properties of Nanocrystalline Ceramic Coatings for Thermal Spray Applications
by George V. Theodorakopoulos, Nikolaos P. Petsas, Evangelos Kouvelos, Fotios K. Katsaros and George Em. Romanos
Materials 2026, 19(9), 1760; https://doi.org/10.3390/ma19091760 - 25 Apr 2026
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Abstract
Wear remains a dominant cause of performance loss and premature failure in mechanical components, motivating the development of environmentally benign surface-engineering solutions. Among thermal spray systems, high-velocity oxy-fuel (HVOF)-sprayed WC-Co coatings are widely applied under severe wear conditions. The development of nanophase coatings [...] Read more.
Wear remains a dominant cause of performance loss and premature failure in mechanical components, motivating the development of environmentally benign surface-engineering solutions. Among thermal spray systems, high-velocity oxy-fuel (HVOF)-sprayed WC-Co coatings are widely applied under severe wear conditions. The development of nanophase coatings offers the potential for enhanced mechanical performance. However, retaining the nanostructure and limiting decarburization during deposition remain key challenges. In this study, nanophase WC-12Co feedstocks with two particle size ranges, together with Al-modified nanophase powders, were used to deposit coatings under optimized HVOF spraying conditions (spray distance 200 mm, reduced O2/fuel ratio, and high particle velocity) and were benchmarked against a conventional WC-12Co (12 wt.% Co) coating. The coatings were characterized in terms of microstructure and phase constitution (OM, SEM/EDS, XRD) as well as thickness, porosity (0.5–3.6%), adhesion strength (up to 65 MPa), and microhardness (~1040–1210 HV). Tribological behavior was assessed by ASTM G99 pin-on-disk testing and counterbody wear was quantified via geometric volume loss estimations. The use of larger nanophase particles enabled effective nanostructure retention with limited decarburization, whereas reducing particle size intensified decarburization, promoting increased W2C formation, and markedly reduced coating cohesion, despite lower porosity and higher hardness. Aluminum additions enhanced coating microhardness and suppressed Co3W3C formation, indicating improved phase stability with minimal additional decarburization. Although coating wear remained negligible for all systems, Al-containing coatings exhibited increased friction (up to 35%) and significantly higher counterbody wear (up to sevenfold) compared to the Al-free nanophase coating, which was found to correlate with coating microhardness. Overall, the results demonstrate that optimizing nanophase WC-Co coatings requires balancing competing mechanisms between microstructural stability, cohesive integrity, and tribological response, highlighting the critical role of feedstock design in tailoring coating performance. Full article
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