Search Results (91)

The 2011 Fukushima accident highlighted the vulnerability of traditional Zr alloy fuel cladding under loss-of-coolant accident (LOCA) conditions, prompting the development of accident-tolerant fuel (ATF) systems. A promising near-term solution involves depositing protective coatings on existing Zr alloy cladding. Among various deposition techniques, cold spray technology has emerged as one of the leading methods due to its solid-state, low-temperature process, which minimises thermal degradation and allows for the deposition of a wide range of high-performance materials. This review provides a comprehensive examination of recent advances in cold-sprayed coatings for ATF cladding, beginning with an overview of the fundamentals of cold spray technology and its specific advantages for nuclear applications. The core of the review critically analyses three primary coating systems: Cr, FeCrAl alloys, and MAX phase composites, with a particular focus on Cr coatings, as they have been more extensively studied compared to the other two material systems. Key coating properties, including microstructure of the coating-substrate interface, mechanical properties, thermal conductivity, oxidation resistance, irradiation tolerance, and performance under normal operation and simulated LOCA conditions, are discussed in detail, with particular emphasis on the potential of cold-sprayed Cr coatings to enhance Zr alloy cladding. Cr coatings demonstrate significant improvements in oxidation resistance and irradiation stability, but also face challenges such as high-temperature interfacial reactions. To address these issues, promising solutions, such as diffusion-barrier bilayer systems, are being explored. Additionally, the review discusses FeCrAl and MAX phase composite coatings, highlighting their promising long-term performance under extreme conditions. The review concludes with recommendations for further research to optimise cold spray processes and ensure the robustness of coatings in operational reactor environments. Full article

Frost accumulation on heat exchangers severely limits the efficiency and reliability of air-source heat pumps (ASHPs) in cold, humid environments. Superhydrophobic coatings fabricated via electrostatic spraying offer a promising energy-free strategy for frost suppression. In this study, a robust superhydrophobic coating was deposited on the heat exchanger of a residential ASHP using this scalable technique. Under low-temperature heating conditions (2/1 °C), the coated exchanger delayed frost completion by a factor of 2.83 and shortened defrosting time by 33.3% compared to a conventional hydrophilic counterpart. These improvements translated to a 6.24% increase in average heating capacity and a 2.83% gain in the coefficient of performance (COP). Although the thicker superhydrophobic coating resulted in a marginal 3.1% reduction in cooling capacity during free-cooling operation, the significant enhancements in frost resistance and heating performance underscore its practical value. This work demonstrates that electrostatic spraying is a viable and effective method for fabricating high-performance superhydrophobic heat exchangers, paving the way for more efficient and frost-resistant ASHPs. Full article

Marine engineering equipment operates under extreme conditions such as high salinity, humidity, and flow velocity during marine resource exploration. These harsh environments impose strict requirements on surface performance, especially in terms of wear and corrosion resistance. Wear-resistant coatings are increasingly regarded as a crucial surface engineering approach to mitigate multi-mechanism degradation and improve the long-term reliability of marine equipment. In this review, the typical wear mechanisms in marine environments are systematically analyzed. Corresponding to different service scenarios, the main categories of coating materials, such as metal matrix composite coatings, cermet coatings, functionally graded coatings, and nanolayered coatings are summarized in terms of their structure and performance characteristics. Furthermore, mainstream fabrication techniques, including high-velocity oxy-fuel (HVOF), high-velocity air-fuel (HVAF), laser cladding, cold spray, and physical/chemical vapor deposition (PVD/CVD), are reviewed with respect to their influence on coating micro-structure and properties. Standardized evaluation methods for coating performance are also discussed. Finally, the current research challenges are identified, and future development trends are outlined, with an emphasis on multifunctional, intelligent, and environmentally friendly coating systems. This work aims to provide a systematic reference and theoretical basis for the design and application of wear-resistant coatings in marine environments. Full article

The impingement of a molten droplet on a solid surface, forming a “splat,” is a fundamental phenomenon observed across numerous industrial surface engineering techniques. For example, thermal spray deposition is widely used to create metal, ceramic, polymer, and composite coatings that are vital for aerospace, biomedical, electronics, and energy applications. Significant progress has been made in understanding droplet impact behavior, largely driven by advancements in high-resolution and high-speed imaging techniques, as well as computational resources. Although droplet impact dynamics, splat morphology, and interfacial bonding mechanisms have been extensively reviewed, a comprehensive overview of the mechanical behaviors of single splats, which are crucial for coating performance, has not been reported. This review bridges that gap by offering an in-depth analysis of bonding strength and residual stress in single splats. The various experimental techniques used to characterize these properties are thoroughly discussed, and a detailed review of the analytical models and numerical simulations developed to predict and understand residual stress evolution is provided. Notably, the complex interplay between bonding strength and residual stress is then discussed, examining how these two critical mechanical attributes are interrelated and mutually influence each other. Subsequently, effective strategies for improving interfacial bonding are explored, and key factors that influence residual stress are identified. Furthermore, the fundamental roles of splat flattening and formation dynamics in determining the final mechanical properties are critically examined, highlighting the challenges in integrating fluid dynamics with mechanical analysis. Thermal spraying serves as the primary context, but other relevant applications are briefly considered. Cold spray splats are excluded because of their distinct bonding and stress generation mechanisms. Finally, promising future research directions are outlined to advance the understanding and control of the mechanical properties in single splats, ultimately supporting the development of more robust and reliable coating technologies. Full article

Titanium and its alloys are well-suited for marine engineering owing to their high specific strength and superior corrosion resistance. However, their high cost remains a key barrier to widespread marine application. Titanium/steel (Ti/Fe) dissimilar materials provide a promising solution by integrating titanium’s corrosion resistance with the high strength of steel, thereby significantly reducing costs. This review systematically assesses the potential preparation strategies for Ti/Fe dissimilar materials, such as explosive welding, rolling, high-energy beam cladding, and cold spray, to meet the large-scale application requirements in marine engineering. Advanced welding techniques for joining Ti/Fe joints are also discussed. The advantages and issues of Ni, Cu, Fe, and Al interlayers suitable for marine engineering applications in inhibiting Fe-Ti IMCs are introduced, with a focus on their potential in promoting the development of economically efficient ocean engineering. A comprehensive evaluation is conducted on the performance of Ti/Fe dissimilar materials, particularly their corrosion resistance and fatigue resistance in marine environments. This review aims to provide a reference for the theoretical research, preparation strategies, and application expansion of low-cost Ti/Fe dissimilar materials in marine engineering. Full article

The continuous discharge voltage waveform and phenomena between the electrode and substrate were explored in this paper to study the ultrasonic electro-spark deposition process. Additionally, the impact of ultrasonics on the ultrasonic electro-spark deposition process and the properties of the deposition layer were examined. The results show that the charge–discharge frequency of the ultrasonic electro-spark deposition process was commensurate with the discharge frequency of the ultrasonic electro-spark deposition power source, and the voltage waveform was stable. When ultrasonics is introduced, the molten droplet spray trajectory is efficiently guided, resulting in the spark spray trajectory displaying notable directional concentration characteristics. During a single charging and discharging phase, the electrode and substrate made roughly 15 mechanical contacts, 1 of which was discharging, and the remaining 14 were mechanically contacted reinforcement. The surface of the ultrasonic electro-spark deposition layer exhibited a sputtering morphology with no surface cracks. Phase structures such as Co₃W₃C, Fe₃W₃C, Fe₆W₆C, WC, and W₂C constituted the majority of the ultrasonic electro-spark deposition layer’s microstructure and showed strong metallurgical bonds with the substrate. The ultrasonic electro-spark deposition layer has a surface roughness of 2.554 μm, a cross-section porosity of 1.3%, and a maximum microhardness of 1038.8 HV_0.025. Comparative analysis demonstrates that the addition of ultrasonics can significantly enhance the deposition layer’s quality and performance. When compared to the electro-spark deposition layer, the surface roughness of the ultrasonic electro-spark deposition layer decreases by roughly 61.4%, the cross-sectional porosity decreases by around 57.5%, and the maximum microhardness increases by about 15.5%. Many cracks and much high surface roughness in the conventional electro-spark deposition layer are resolved by the ultrasonic electro-spark deposition technique, which is crucial for cold drawing mold surface strengthening. Full article

In this study, nanocrystalline (NC) aluminum (Al) and magnesium (Mg)-doped Al bulk components were fabricated using a hybrid manufacturing process that combines cryomilling and high-pressure cold spray (HPCS) additive deposition techniques. Yttria-stabilized zirconia (YSZ) was also added during the HPCS process to improve deposition efficiency and build-up thickness via peening. The evolution of morphology, crystallite size, and elemental composition of both cryomilled powders and cold-sprayed (CS’ed) components was systematically characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Transmission Electron Microscopy (TEM). Mechanical characterization was performed using Vickers microhardness and uniaxial tensile testing, while the tribological behavior was assessed using sliding wear tests under dry/lubricated conditions. XRD analysis revealed that increased cryomilling duration led to significant crystallite refinement, which directly correlated with enhanced hardness and strength. This mechanical strengthening was accompanied by an increase in coefficient of friction (COF) and lower wear rates. The results also showed that the Mg-doped Al exhibited superior hardness, tensile strength, and tribological performance compared to pure Al. The study further explores the underlying mechanisms responsible for these enhancements, highlighting the potential of solute-assisted grain boundary stabilization in tailoring high-performance NC Al alloys. Full article

Superhydrophobic coatings possess distinct wettability characteristics and hold significant potential in metal corrosion protection and underwater drag reduction. However, their practical application is often hindered by poor durability arising from the fragility of their micro/nanostructured surface roughness. In this study, a durable superhydrophobic coating featuring a hierarchical, hydrangea-like micro/nanostructure was successfully fabricated on an aluminum alloy substrate via a simple one-step cold-spraying technique. The coating consisted of hydrangea-shaped SiO₂ nanoparticles modified with 1H,1H,2H,2H-perfluorodecyltrimethoxysilane (PFDT) to produce multiscale roughness, while epoxy resin (EP) served as the binding matrix to enhance mechanical integrity. The hydrangea-like SiO₂ nanostructures were characterized by solid cores and wrinkled, petal-like outgrowths. This unique morphology not only increased the surface roughness but also provided more active sites for air entrapment, thereby enhancing the coating’s overall performance. The h-SiO₂@PFDT-EP composite coating exhibited excellent superhydrophobicity, with a WCA of 170.1° ± 0.8° and a SA of 2.7° ± 0.5°. Durability was evaluated through sandpaper abrasion, tape peeling, acid and alkali immersion, artificial weathering, and salt spray tests. The results demonstrated that the coating retained stable superhydrophobic performance under various environmental stresses. Compared with bare 6061 aluminum and EP coatings, its corrosion current density was reduced by four and three orders of magnitude, respectively. Furthermore, the coating achieved a maximum drag-reduction rate of 31.01% within a velocity range of 1.31–7.86 m/s. The coating also displayed excellent self-cleaning properties. Owing to its outstanding durability, corrosion resistance, and drag-reducing capability, this one-step fabricated superhydrophobic coating showed great promise for applications in marine engineering and defense. Full article

Modern nanoindentation equipment allows for highly precise measurements of mechanical properties such as hardness and elastic modulus, generating detailed load–unload curves using advanced techniques and specialised software. In this study, titanium coatings were deposited on various metallic substrates using cold gas spraying. Before deposition, the spraying parameters (temperature, pressure, velocity, and distance) were statistically optimised using the Taguchi method, reducing the number of experiments required from 81 to 9. This approach allowed the identification of optimal spray conditions (T = 731.0 °C, p = 33.0 bar, V = 343.6 mm/s, d = 35.5 mm), which were then applied to substrates including brass, steel, titanium, Al7075, copper, magnesium, and Al2024. Mechanical characterisation included hardness (H), reduced modulus (E), coating adhesion, and dissipated energy, calculated from the area of the load–unload hysteresis loop. Each coating–substrate combination underwent 36 nanoindentation tests, and adhesion was evaluated by pull-off tests. The initial results showed a poor correlation between adhesion and conventional mechanical properties (χ² of 17.1 for hardness and 16.2 for modulus, both with R² < 0.24). In contrast, the dissipated energy showed an excellent correlation with adhesion (χ² = 0.52, R² = 0.92), suggesting that dynamic deformation mechanisms better describe bonding. This introduces a new perspective to predict and optimise cold-spray adhesion in industrial applications. Full article

Green soybeans, or edamame (Glycine max L. Merril), serve as a superior source of phytochemicals and other nutritive substances and are commonly used as ingredients and additives in food products due to their polyphenols’ functional properties and antioxidant activity. Hence, it is very important to use a process to extract compounds with functional roles from plants as efficiently as possible. In this study, we sought to identify the optimal conditions for extracting genistein, belonging to the aglycone subgroup of isoflavones, from edamame using the cold plasma (CP) and enzyme method. Additionally, the impact of various drying techniques (spray-drying and freeze-drying) and storage conditions on the crude genistein extract powder was evaluated. The findings showed that the maximum values for the total phenolic content (TPC), total flavonoid content (TFC), and genistein (22.5 ± 0.23 mg of gallic acid equivalents (GAE)/100 g; 15.3 ± 0.13 mg of catechin equivalents (CAE)/100 g; and 12.6 ± 0.10 mg/100 g, respectively) were achieved under optimal pretreatment conditions using a CP gas flow rate of 5 L/min for 30 min, followed by enzymatic treatment at a specific enzyme concentration of 2.0% (v/v) for 240 min of incubation. Moreover, a scanning electron microscopy (SEM) analysis demonstrated that the CP and enzyme treatment induced significant structural changes, as evidenced by the presence of deeper pores on the surface of the powder granules. Spray-drying demonstrated a superior efficacy compared to freeze-drying for encapsulating the crude isoflavone extract. This study’s results also demonstrated that storage at 4 °C significantly stabilized the TPC, TFC, and genistein content and the antioxidant activity while preserving the physical properties (solubility and color) of the crude extract powder for up to 45 days. In summary, cold plasma pretreatment and enzymatic treatments offer practical solutions by enhancing the efficiency of non-thermal extraction processes, thereby increasing the yield of bioactive compounds, maintaining quality, and diminishing reliance on traditional, harsh methods. The elevated genistein content in the crude extract powder indicates its prospective application as a functional ingredient in various food and nutraceutical contexts. Full article

Tantalum (Ta), along with its compounds and alloys, is extensively applied in the chemical, electronic, biological, and aerospace industries due to its excellent ductility, thermodynamic stability, and corrosion resistance. In recent years, coatings of Ta and its composites, fabricated using methods such as magnetron sputtering (MS), chemical vapor deposition (CVD), electrospark deposition (ESD), and cold spraying (CS), have undergone significant performance enhancements through extensive research efforts. This paper provides a comprehensive overview of the preparation techniques, applications, and improvement techniques associated with Ta and its compounds’ coatings. The preparation process parameters, mechanical properties, and corrosion resistance of Ta alloy coating and Ta non-metallic compound coating are discussed in detail. The findings aim to contribute to the design and development of innovative Ta and its compounds’ coating systems or the refinement of existing systems. Full article

Surface coatings are essential for enhancing the mechanical and functional properties of materials. Among these, annealed high-entropy alloy (HEA) coatings have gained attention for improving wear resistance and durability. This study comprehensively analyzes HEA-annealed coatings, focusing on their surface roughness and wear behavior. A systematic and thorough approach is employed to examine the impact of annealing on coating characteristics. The research involves depositing Al _0.1–0.5 CoCrCuFeNi and MnCoCrCuFeNi coatings using the cold spray (CS) method, followed by a controlled annealing process. Surface roughness is evaluated through profilometry and microscopy techniques to assess modifications due to annealing. Tribological tests are conducted to investigate the wear performance of the coatings, and the findings are correlated with roughness measurements, offering insights into the relationship between surface texture and wear resistance. Full article

Cold spraying (CS), also known as cold gas dynamic spraying or supersonic cold spraying, is a process in which particles collide with the substrate at a speed greater than the critical value and deposit layer by layer to form a coating. As an emerging coating preparation technology that has been developed rapidly in recent years, CS is characterized by a low deposition temperature, a minimal thermal effect on substrate, and a high deposition efficiency. It has received extensive attention from industry. However, the inherent high strength and low plasticity of CS coatings and the numerous defects present limit their wider application to some extent. Therefore, various post-treatment technologies are successfully applied to the CS coatings to improve their comprehensive performance. This paper reviews the latest research progress of common post-treatment techniques for CS coatings, including five categories: thermal, mechanical, thermo-mechanical, chemical, and electrochemical processing. A considerable amount of experimental research has demonstrated that post-treatment can effectively enhance the microstructure and properties of CS coatings, and this can serve as a powerful approach to expand the application scope of CS technology. In addition, the relevant post-processing parameters and corresponding results are summarized and compared systematically. Full article

Wear-resistant coatings applied to the surface of copper and copper alloys through diverse advanced technologies can substantially enhance their wear resistance and broaden their application spectrum. This paper provides a comprehensive review of the development and current research status of wear-resistant coatings fabricated on copper and its alloys. It presents the research findings on the preparation of wear-resistant coatings using both one-step methods (such as laser cladding, electroplating, thermal spraying, cold spraying, electro-spark deposition, etc.) and two-step methods (chemical plating and heat treatment, electrodeposition and laser cladding, laser cladding and in situ synthesis, etc.). This paper provides an in-depth examination of the characteristics, operating principles, and effects of various coating techniques on enhancing the wear resistance of copper and copper alloys. The advantages and disadvantages of different coating preparation methods are compared and analyzed; meanwhile, a prospective outlook on the future development trends is also offered. Full article

The design and implementation of two-dimensional materials into a metal matrix have been the focus of considerable research interest for achieving enhanced properties. Nevertheless, conventional and modern manufacturing techniques often struggle to fabricate bulk 2D metal matrix composites (2DMMCs) while preserving the desired distribution and preventing thermomechanical damage to the constituent phases. Cold spray technology is a solid-state manufacturing method known for maintaining the composition of the original feedstock without causing significant detrimental changes during the deposition process. This study investigates the influence of cold spray process parameters on the microstructure, porosity, and microhardness of copper composites reinforced with 1 wt.% graphene platelets. The copper–graphene composite powder was synthesized via high-energy ball milling and subsequently deposited using two distinct sets of cold spray parameters employing medium- and high-pressure systems. Scanning electron microscopy, dispersive X-ray spectroscopy, porosity measurements, microhardness testing, and Raman spectroscopy were used to comprehensively evaluate the deposits. The findings demonstrate the preservation of the 2D phase and show how cold spray parameters influence porosity, hardness, and the incorporation of graphene within the copper matrix. Full article