Search Results (91)

This study investigated the effect of adding superhard ReB₂ to atmospheric plasma sprayed (APS) coatings based on 60 wt% Al₂O₃ and 40 wt% ZrO₂. The amorphous phases commonly present in such coatings are known to impair their performance. ReB₂ was introduced as a crystallization nucleus due to its high melting point. ReB₂ decomposes in the presence of moisture and oxygen into H₃BO₃, ReO₃, HBO₂, and HReO₄. ReB₂ was encapsulated with Al₂O₃ via metallothermic synthesis to improve moisture stability, yielding a powder with d₉₀ = 15.1 μm. After milling, it was added at 20 wt% to the Al₂O₃-ZrO₂ feedstock. Agglomeration parameters were optimized, and coatings were deposited under varying APS conditions onto 316L steel substrates with a NiAl bond coat. In the coating with the highest ReB₂ content, the identified phases included ReB₂ (2.6 wt%), Re (0.8 wt%), α-Al₂O₃ (30.9 wt%), η-Al₂O₃ (32.4 wt%), and monoclinic and tetragonal ZrO₂. The nanohardness of the coating, measured using a Vickers indenter at 96 mN and calculated via the Oliver–Pharr method, was 9.2 ± 1.0 GPa. High abrasion resistance was obtained for the coating with a higher content of η-Al₂O₃ (48.7 wt%). The coefficient of friction, determined using a ball-on-disc test with a corundum ball, was 0.798 ± 0.03. After 15 months, the formation of (H₃O)(ReO₄) was observed, suggesting initial moisture-induced changes. The results confirm that Al₂O₃-encapsulated ReB₂ can enhance phase stability and crystallinity in APS coatings. Full article

The development of power engineering requires the introduction of new materials and technologies to improve the quality and durability of products. One promising direction is the creation of heat-protective coatings for the protection of working surfaces of turbine blades of gas turbine engines operating at temperatures up to 1000–1200 °C. Intermetallic coatings based on iron aluminides (Fe₃Al, FeAl) have high resistance to oxidation due to the formation of an oxide layer: Al₂O₃. However, their application is limited by brittleness due to the so-called third element effect, which can be reduced through alloying with chromium. In this study the processes of formation of Fe–Al–Cr intermetallic coatings produced by air plasma spraying and the mechanisms affecting their stability at high temperatures were investigated. Experimental studies included the analysis of the microhardness, wear resistance, and corrosion resistance of coatings, as well as their phase composition and microstructure. The results showed that the optimization of sputtering parameters, especially in the FrCrAl (30_33) mode, promotes the formation of a coating with improved tribological and anticorrosion characteristics, which is associated with its dense and uniform structure. These data have an important practical significance for the creation of wear-resistant and corrosion-resistant coatings applicable in power engineering. Full article

Modern industrial systems and biomass-fired furnaces require surface treatments that can withstand aggressive chemical, thermal, and corrosive environments. This study investigates the corrosion and thermal resistance of plasma-sprayed Al₂O₃-TiO₂ coatings produced using a DC air–hydrogen plasma spray process. Coatings of compositions of Al₂O₃, Al₂O₃-3 wt.% TiO₂, Al₂O₃-13 wt.% TiO₂, and Al₂O₃-40 wt.% TiO₂ were deposited on steel substrates with a Ni/Cr bond layer by plasma spraying. The coatings were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to evaluate their morphology, elemental composition, and crystalline phases. Electrochemical tests were performed in a naturally aerated 0.5 mol/L NaCl solution and cyclic thermal–chemical exposure tests (500 °C using 35% KCl) to assess their corrosion kinetics and thermal stability. The results indicate that pure Al₂O₃ and low TiO₂ (3 wt.%) coatings exhibit fine barrier properties, while coatings with a higher TiO₂ content develop additional phases (e.g., Ti₃O₅, Al₂TiO₅) that improve thermal resistance but reduce chemical durability. Full article

FeCoNiCrAl high-entropy alloy (HEA) coating was prepared by air plasma spraying, and the coating’s morphology and properties under different power parameters were analyzed. The results show that the spraying power significantly affects the morphology of the coating during plasma spraying. The molten droplets formed during the preparation process of HEA coatings tend to combine with oxygen, with aluminum bonding particularly strongly with oxygen, resulting in the presence of aluminum oxide within the coating, while other elements exhibit weaker bonding with oxygen. The optimal spraying power is 12 kW, and coatings prepared at this optimal power exhibit advantages such as low porosity, uniform element distribution, and excellent corrosion resistance. The aluminum in the HEA coating forms a relatively stable compound with oxygen, creating a Cr-depleted and Al-enriched region. This region is less prone to passivation during corrosion and more susceptible to reacting with corrosive media, leading to localized corrosion of the coating. Full article

This study investigates the enhancement of thermal durability in multilayer yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC) with porosity-controlled structures. Conventional single-layer YSZ and multilayer TBCs with dense and porous layers were fabricated by air plasma spraying and the TBC specimens were subjected to furnace cyclic testing. The single-layer TBC suffered from catastrophic delamination under cyclic thermal loading, driven by the mismatch in thermal expansion, while the multilayer TBCs exhibited a significant increase in thermal durability, by up to 50%. The relevant delamination mechanism was suggested with microstructural analysis, showing that the multilayer structure effectively relieved residual stresses by forming horizontal cracks, thereby mitigating crack propagation. This study emphasizes that the multilayer design in TBC with controlled porosity significantly enhances thermal durability, improving the operational lifespan of gas turbine hot components. Full article

Innovation in cultivation methods is essential to address the growing challenges in agriculture, including abiotic and biotic stress, soil degradation, and climate change. Aeroponics, a particular type of hydroponics, presents a promising solution by improving yield and resource use efficiency, especially in controlled environments such as plant factories with artificial lighting (PFALs). Additionally, non-thermal plasma (NTP), a partially ionized gas containing reactive oxygen and nitrogen species, can affect plant development and physiology, further enhancing crop production. The objective of this study was to explore the potential of NTP as an innovative method to enhance crop production by treating the nutrient solution in aeroponic systems. During this study, three experiments were conducted to assess the effects of NTP-treated nutrient solutions on baby leaf lettuce (Lactuca sativa L.) aeroponically grown indoors. The nutrient solution was treated with ionized air in a treatment column separated from the aeroponic system by making the ionized air bubble from the bottom of the column. After 2 min of NTP application, a pump took the nutrient solution from the treatment column and sprayed it on the roots of plants. Various frequencies of NTP application were tested, ranging from 2.5% to 50% of irrigation events with nutrient solution activated with NTP. Results indicated that low-frequency NTP treatments (up to 5% of irrigations) stimulated plant growth, increasing leaf biomass (+18–19%) and enhancing the concentration of flavonoids (+16–18%), phenols (+20–21%), and antioxidant capacity (+29–53%). However, higher NTP frequencies (25% and above) negatively impacted plant growth, reducing fresh and dry weight and root biomass, likely due to excessive oxidative stress. The study demonstrates the potential of NTP as a tool for improving crop quality and yields in aeroponic cultivation, with optimal benefits achieved at lower treatment frequencies. Full article

Due to the extremely high hardness of high-entropy monoborides (HEMB), this study successfully prepared a new type of HEMB-(V_0.2Cr_0.2Ta_0.2Mo_0.2W_0.2)B coating by adjusting the spraying process using atmospheric plasma spraying technology. The high-entropy coating was characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The change rule concerning the alteration in the phase composition of the coating surface with power and protective atmosphere was explored, indicating that with the decrease in power and the application of a protective atmosphere, the generation of oxide on the coating surface is successfully inhibited. The wear resistance of the coating in a temperature range from room temperature to 800 °C was evaluated in dry sliding wear test conditions. The results indicated that the wear mechanism of (V_0.2Cr_0.2Ta_0.2Mo_0.2W_0.2)B coating below 400 °C is abrasive wear, and above 400 °C, the wear mechanism is mainly oxidative wear. Full article

Thermal barrier coatings (TBCs) and air film-cooling technology have been extensively utilized in nickel-based, single-crystal turbine blades to enhance their heat resistance. However, structural complexity and material property mismatches between layers can affect residual stresses and potentially lead to coating failure. In this study, a three-dimensional finite element model with atmospheric plasma-spraying thermal barrier coatings (APS-TBCs) deposited on air-cooled, nickel-based, single-crystal blades was established to investigate residual stress character under centrifugal load, considering the effect of temperature, crystal orientation deviation angle, oxide layer thickness, and the number of cycles. The results show that when the centrifugal load is increased from 300 MPa to 700 MPa, the absolute value of the residual stress at the crest of the interface between Top Coat (TC) and Thermally Grown Oxide (TGO) increases by only 8.5%, whereas in the region of compressive to tensile stress conversion, residual stress decreases by 100.9%. As the crystal orientation deviation angle increases, the absolute value of the residual compressive stress increases and the absolute value of the residual tensile stress decreases, but the performance is more special in the valley region, where the absolute value of the residual stress increases with the increase in the deviation angle. Special attention is required, as the increase in temperature leads to a rise in the absolute value of residual stress. For example, at the trough of the TC–TGO interface, when the temperature increases from 910 °C to 1100 °C, the residual stress increases by 9.8%. The effect of the number of cycles on residual stress is relatively weak. For instance, at the wave crest of the TC–TGO interface, the residual stress differs by only 0.6 MPa between one cycle and three cycles. The effect of oxide layer thickness on residual stress in the TBCs after a single cycle is nonlinear. When the oxide layer thickness is 0, 4, and 7 μm, the residual stress undergoes a transition between tensile and compressive directions at different locations. The exploration of these results has yielded some valuable laws that can provide a reference for the study of the damage mechanism of TBCs, as well as a guide for the optimization of nickel-based turbine blades in the manufacturing and use processes. Full article

In this study, we examined the impact of droplet size and laser energy on droplet fragmentation and the resulting species composition due to laser irradiation of an acoustically levitated heptane droplet. Using shadowgraphy and spatially resolved laser-induced breakdown spectroscopy (LIBS), we observed two different fragmentation regimes for the conditions studied. The experiments demonstrated that low laser energy densities (<~70 mJ/mm³), designated as regime 1, resulted in a single plasma breakdown event accompanied by broadband emission and C₂ Swan bands, suggesting weak plasma formation. Conversely, high energy densities (>~70 mJ/mm³), designated as regime 2, resulted in multiple plasma breakdowns that resulted in the emission of H_α, O, and N, implying a full laser breakdown in the gaseous reactive mixture. Additionally, in regime 2, we calculated the electron density using Stark broadening of the H_α line and temperature using Boltzmann analysis of O lines at 715 nm and 777 nm. We found that the electron densities and temperatures within the air spark and heptane droplets are quite similar. The findings from this research could impact the design of spray ignition systems and may also aid in validating the modeling efforts of aerosols, droplet breakdown, and ignition. Full article

In order to further improve the oxidation resistance of SiC-coated C/C composites used in extreme environments, TaSi₂ coatings were deposited on the surfaces of SiC-coated C/C composites by supersonic air plasma spraying (SAPS) with different spraying power parameters, under other fixed parameter (gas flow, power feed rate, spraying distance and nozzle diameter) conditions. The micro-structures and phase characteristics of the TaSi₂ coatings prepared with the four kinds of spraying powers (40 kW, 45 kW, 50 kW and 55 kW) were analyzed. Also, the inter-facial bonding strengths and fracture modes between the four TaSi₂ coatings and the SiC coating were studied. The results showed that with an increase in the spraying power, the morphologies of the TaSi₂ coatings appeared from loose to dense to loose. When the spraying power was 50 kW, the deposition rate reached a maximum of 39.8%. The TaSi₂ coating presented an excellent micro-structure without obvious pores and microcracks, and its inter-facial bonding strength was 15.3 ± 2.3 N. Meanwhile, the fracture surface of the sample exhibited a brittle characteristic. Full article

Higher operating temperatures for gas turbine engines require highly durable thermal barrier coatings (TBCs) with improved insulation properties. A suspension plasma spray process (SPS) had been developed for the deposition of columnar-structured TBCs. SPS columnar TBCs are normally achieved at a short standoff distance (50.0 mm–75.0 mm), which is not practical when coating complex-shaped engine hardware since the plasma torch may collide with the components being sprayed. Therefore, it is critical to develop SPS columnar TBCs at longer standoff distances. In this work, a commercially available pressure-based suspension delivery system was used to deliver the suspension to the plasma jet, and a high-enthalpy TriplexPro-210 plasma torch was used for the SPS coating deposition. Suspension injection pressure was optimized to maximize the number of droplets injected into the hot plasma core and achieving the best particle-melting states and deposition efficiency. The highest deposition efficiency of 51% was achieved at 0.34 MPa injection pressure with a suspension flow rate of 31.0 g/min. With the optimized process parameters, 1000 μm thick columnar-structured SPS 8 wt% Y₂O₃-stabilized ZrO₂ (8YSZ) TBCs were successfully developed at a standoff distance of 100.0 mm. The SPS TBCs have a columnar width between 100 μm and 300 μm with a porosity of ~22%. Furnace cycling tests at 1125 °C showed the SPS columnar TBCs had an average life of 1012 cycles, which is ~2.5 times that of reference air-plasma-sprayed dense vertically cracked TBCs with the same coating thickness. The superior durability of the SPS columnar TBCs can be attributed to the high-strain-tolerant microstructure. SEM cross-section characterization indicated the failure of the SPS TBCs occurred at the ceramic top coat and thermally grown oxide (TGO) interface. Full article

Defects such as interconnected pores and cracks can improve the abradability of ceramic-based abradable sealing coatings (ASCs) but may reduce the lifetime. Self-healing can potentially close cracks and transform interconnected pores into isolated ones through filling and sintering effects. Ti₃AlC₂ (TAC) was incorporated into LaMgAl₁₁O₁₉ (LMA) as both the self-healing agent and sintering aid, and plasma-sprayed LMA-based composite coatings were annealed at 1200 °C to assess their self-healing capabilities and then subjected to oxidation in air and corrosion in steam at 1300 °C to study their long-term stability. Results indicated that increasing TAC content significantly enhances self-healing effectiveness, evidenced by the closure of cracks and the isolation of pores. Oxidation and corrosion at 1300 °C led to significant grain growth and the formation of equiaxed grains with an aspect ratio of approximately 3, which may impair the toughening mechanism. Meanwhile, due to the preferential volatilization of Al in a steam environment, LTA decomposed into α-La_2/3TiO₃ and La₄Ti₃O₁₂ phases, and the accelerated mass transfer also resulted in grain coarsening. Interestingly, the L20T composite coating with a porosity of 32.17 ± 0.94% and a hardness of 74.88 ± 1.55 HR15Y showed great potential for abradable applications due to its stable phase composition and uniform pore distribution. Full article

This work represents a preliminary study of atmospheric plasma-sprayed (APS) Yttria-Stabilized Zirconia (YSZ)-based thermal barrier coatings (TBCs) deposited on forged and additive manufactured (AM) HAYNES^®282^® (H282) superalloy substrates. The effect of different feedstock morphologies and spray gun designs with radial and axial injection on APS-deposited YSZ layer characteristics such as microstructure, porosity content, roughness, etc., has been investigated. The performance of TBCs in terms of thermal cycling fatigue (TCF) lifetime and erosion behaviour were also comprehensively investigated. In view of the high surface roughness of as-built AM surfaces compared to forged substrates, two different types of NiCoCrAlY bond coats were examined: one involved high-velocity air fuel (HVAF) spraying of a finer powder, and the other involved APS deposition of a coarser feedstock. Despite the process and feedstock differences, the above two routes yielded comparable bond coat surface roughness on both types of substrates. Variation in porosity level in the APS topcoat was observed when deposited using different YSZ feedstock powders employing axial or radial injection. However, the resultant TBCs on AM-derived substrates were observed to possess similar microstructures and functional properties as TBCs deposited on reference (forged) substrates for any given YSZ deposition process and feedstock. Full article

Complications such as peri-implantitis could ultimately affect the survival of a dental implant. The prevention and treatment of peri-implant diseases require managing bacterial biofilm and controlling environmental risks, including the presence of pro-inflammatory titanium (Ti) particles in the peri-implant niche. Objectives included the evaluation of the size and quantity of Ti particles released from moderately roughened Ti surfaces during common mechanical surface decontamination methods. One hundred and forty moderately roughened Ti discs were divided into seven groups (n = 20 per group); six groups received mechanical decontamination procedures (ultrasonic scaling (US) with a metal tip and poly-ether-ketone (PEEK) under low and medium power settings, air-polishing with erythritol powder, and Ti brush), and the control group underwent air–water spray using a dental triplex. The rinsing solution was collected for Ti mass analysis using inductively coupled plasma mass spectrometry (ICPMS), as well as for Ti particle size and count analysis under scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS). US metal tip instrumentation generated 34.00 ± 12.54 μg and 34.44 ± 6.08 μg of Ti under low and medium power settings, respectively. This amount of Ti generation was significantly higher than other instrumentation methods. The mean Ti particle size of the US groups ranged from 0.89 ± 0.27 μm to 1.25 ± 0.24 μm. No statistically significant difference was found in the particle size among US groups and Ti brush group (1.05 ± 0.11 μm), except for US with the PEEK tip, where a significantly smaller mean particle diameter was found at the low power setting (0.89 ± 0.27 μm). Mechanical instrumentation can produce Ti particulates and modify the implant surfaces. US using a metal tip generated the highest amount of Ti with smaller Ti size particles compared to all other commonly used mechanical surface instrumentations. The EDS analysis confirmed Ti in PEEK US tips. It can be suggested that deterioration from the PEEK US tip and Ti brush, as observed under SEM, is an additional source of Ti release during Ti surface decontamination. Full article

In this research, a life cycle inventory (LCI) is developed for tungsten carbide–cobalt (WC-Co) coatings deposited via atmospheric plasma spray (APS), high-velocity oxy-fuel (HVOF), and cold gas spray (CGS) techniques. For the APS process, a mixture of Ar/H₂ was used, while the HVOF process was fueled by H₂. The carrier gas for CGS was N₂. This study aims to determine and quantify the inputs (consumption of inputs and materials) and outputs (emissions to air, soil, water, and waste generation) that could be used in the life cycle analysis (LCA) of these processes. The dataset produced will allow users to estimate the environmental impacts of these processes using WC-Co feedstock powder. To obtain a complete and detailed LCI, measurements of electrical energy, gas, WC-CO powder, and alumina powder consumption were performed (the use of alumina was for sandblasting). Furthermore, emissions like carbon dioxide (CO₂), carbon monoxide (CO), and noise were also measured. This practice allowed us to determine the input/output process quantities. For the first time, it was possible to obtain LCI data for the APS, HVOF, and CGS deposition processes using WC-12Co as a feedstock powder, allowing access to the LCI data to a broader audience. Comparisons were made between APS, HVOF, and CGS processes in terms of consumption and emissions. It was determined that the APS process consumes more electrical energy and that its deposition efficiency is higher than the other processes, while the HVOF process consumes a large amount of H₂, which makes the process costlier. CGS has comparatively low electricity consumption, high N₂ consumption, and low deposition efficiency. The APS, HVOF, and CGS processes analyzed in this study do not emit CO, and CO₂ emissions are negligible. Full article