Search Results (115)

To address the key problems of the dual-phase magnesium–lithium alloy LAZ931, such as easy corrosion, flammability and low strength, an AA6061 protective coating was fabricated on LAZ931 alloy via cold spraying to form an Al6061/LAZ931/Al6061 sandwich structure. The strengthening mechanism of the coating on interfacial microstructure, mechanical properties, creep behavior and corrosion resistance was systematically investigated. The results show that the cold-sprayed AA6061 coating is compact and uniform with a low porosity of 0.3% and surface roughness of 37.02 μm, which significantly improves the combustion resistance and corrosion resistance of the alloy. The coating/substrate interface exhibits jagged and tight bonding without obvious cracks or delamination. Abundant dislocations and Al–Mg–Li composite precipitates form at the interface, which effectively strengthen the interfacial bonding and enhance the tensile and yield strengths. Room-temperature creep tests reveal that the creep behavior of the composite is dominated by the LAZ931 matrix, and the coating remains intact and well-bonded throughout creep deformation without compromising the creep resistance. Electrochemical impedance spectroscopy shows that the coating increases the low-frequency impedance by more than two orders of magnitude, greatly elevating corrosion resistance. This study confirms that a cold-sprayed AA6061 protective layer can comprehensively enhance LAZ931 alloy through interfacial bonding, microstructural strengthening and protective barrier effects, providing a new strategy for protection and toughening of ultra-light Mg-Li alloys. Full article

In recent years, the quest for advanced materials has intensified, driving the exploration of innovative coating systems to enhance material properties. Polymeric materials, renowned for their adaptability, have found extensive use across various industries. However, their inherent limitations in mechanical strength, wear resistance, and thermal stability have prompted researchers to seek enhancement avenues. Hybrid polymeric–metallic coatings have emerged as a promising solution, employing thermal spray techniques to metalize polymeric substrates. This amalgamation utilizes the versatility of thermal spraying methods, ranging from cold spraying, flame spraying, arc spraying, to plasma spraying, to achieve robust adhesion between metal and polymer layers. These techniques yield durable composite structures, fortifying surfaces against corrosion and wear while enabling dimensional restoration. Cold spraying, in particular, stands out among thermal spray methods due to its effectiveness in metalizing various materials. This comprehensive review delves into recent advancements in hybrid polymeric–metallic coatings via thermal spray processes. Emphasis is placed on analyzing critical factors influencing coating properties, including various thermal spray parameters. Furthermore, the paper scrutinizes the challenges and future potentials inherent in thermal spray techniques, with a focused exploration of cold spray technology. Understanding these methodologies is pivotal for optimizing the design and durability of structural materials made of polymers or composites. Full article

Cold spray additive manufacturing (CS) has emerged as a transformative solid-state deposition technique for designing advanced functional surfaces with tailored tribological performance. By accelerating micron-scale particles to supersonic velocities and depositing them below their melting point, CS enables the fabrication of dense, oxidation-resistant coatings with strong metallurgical bonding and beneficial compressive residual stresses. These distinctive attributes create unique opportunities for the design-driven engineering of wear-resistant surfaces across aerospace, automotive, marine, biomedical, and industrial sectors. Despite a growing literature on CS processing and properties, a comprehensive framework linking design principles encompassing material selection, coating architecture, process parameter optimization, and post-processing strategies to tribological outcomes is absent from the field. This review addresses that gap by critically examining the design space of CS coatings and positioning tribological performance as an outcome of deliberate engineering decisions. The relationships between coating architecture and tribological behavior, specifically friction control, wear resistance, adhesion-cohesion integrity, and surface roughness, are examined under varying environmental and loading conditions. Design strategies involving composite and hybrid coatings incorporating solid lubricants, ceramic reinforcements, and nanostructured architectures are discussed in the context of achieving specific functional objectives. The influence of process parameters, such as particle velocity, gas temperature, substrate preparation, and post-treatments including heat treatment, friction stir processing, and laser shock peening, on tribological outcomes is critically synthesized. Environmental performance under high-temperature, corrosive, and extreme wear conditions is analyzed through a design lens. A design decision framework summarizing material-process-property linkages for CS tribological coatings is presented to provide practical guidance for engineers and researchers. Future directions include AI-driven process optimization, multi-material architectures, and the integration of CS within broader design-for-manufacturing workflows. Full article

Using low-pressure cold spray technique, Fe-Al composite coatings with different Al contents were applied to the surface of 45 steel to improve its corrosion resistance in chloride-containing settings. The microstructure, mechanical characteristics, and electrochemical corrosion behavior of the coatings were thoroughly examined in relation to the Al content (2, 4, 6, and 8 wt.%). The findings show that the microhardness of the composite coating decreases monotonically (from 157.98 HV to 99.29 HV) as the Al content rises because of the increased proportion of the soft phase; in contrast, the porosity and corrosion current density show a pattern of first decreasing and then increasing. The coating porosity was reduced to a minimum (1.37%) when the Al concentration reached 6 wt.% because the soft Al particles experienced enough plastic flow to fill the holes in the hard Fe matrix. The 6Al composite coating demonstrated the best electrochemical protection performance in a 3.5 wt.% NaCl solution, with the lowest corrosion current density (2.237 × 10⁻⁴ A/cm²) and the strongest interfacial charge transfer resistance. The synergistic corrosion protection mechanism comprising significantly densified physical shielding and microgalvanic sacrificial anode protection by the active Al phase was clarified in this study. The ideal composition ratio for this system was determined to be 6 wt.% Al by carefully matching the coating’s mechanical load-bearing needs with long-term corrosion prevention goals. Full article

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

The AZ31 magnesium alloy is an attractive lightweight metallic material, but its low corrosion resistance and wear resistance significantly limit its widespread application in fields such as aerospace, the automotive industry, and mechanical engineering. Moreover, most coating systems currently cannot restore their original functions and dimensions after localized damage. Based on this, this study combined cold spray (CS), micro-arc oxidation (MAO), and magnetron sputtering (MS) to develop a high-performance and repairable composite modification strategy. First, a 5056 aluminum alloy coating was prepared on AZ31 via CS, followed by the growth of a hard alumina (Al₂O₃) coating via MAO and a diamond-like carbon (DLC) coating via MS on the 5056 aluminum alloy surface. The microstructure, phase composition, hardness, tribological properties, and electrochemical corrosion behavior of the coatings were evaluated using scanning electron microscopy/energy-dispersive X-ray spectroscopy (SEM/EDS), X-ray diffraction (XRD), Vickers hardness testing, ball-on-disk dry sliding wear testing, and potentiodynamic polarization testing in a 3.5% sodium chloride solution. The CS 5056 aluminum alloy coating reduced the corrosion current density of AZ31 from 4.098 × 10⁻⁵ A/cm² to 2.714 × 10⁻⁶ A/cm². The MAO alumina coating increased the hardness of AZ31 from 68.60 HV_0.05 to 1614.00 HV_0.05 and decreased the wear rate from 1.703 × 10⁶ μm³/(N·m) to 2.038 × 10³ μm³/(N·m). The DLC coating further reduced the average coefficient of friction of the alumina coating from 0.48 to 0.27, decreased the wear rate to 6.979 × 10² μm³/(N·m), and lowered the corrosion current density from 3.020 × 10⁻⁶ A/cm² to 8.860 × 10⁻⁹ A/cm². This indicates that the three-phase composite coating achieves synergistic improvements in the corrosion and wear resistance of AZ31 through complementary advantages. Additionally, the thick CS aluminum alloy underlayer provides potential repairability, enabling the restoration of function and dimensions after damage without compromising the magnesium substrate. Overall, the proposed 5056Al/Al₂O₃/DLC composite coating strategy offers a reliable protective approach for AZ31 components and is expected to further expand their application fields. Full article

Many special structures such as pipeline, revolving gears, and tanks suffer from biofouling used in marine environment, which could induce serious results in the ship system such as blockage and stuck, consequently lead to failure of the mechanical system and power system. Generally, coatings with antifouling agents are used for protecting metal structures from biofouling, but coatings are not conveniently applicable in the high velocity flowing seawater and narrow space. Electrochlorination and electrolysis of copper and aluminum anode are usually used in these circumstances, but the electric power will lead to stray current corrosion to the component. For the sake of convenience and safety, Cu-Ti pseudo alloy antifouling anode was proposed in this work for antifouling in pipeline and other narrow spaces without external electric power. Four Cu-Ti pseudo alloy antifouling anodes with different Ti contents (mass fraction) of 0 wt.%, 5 wt.%, 10 wt.%, and 15 wt.% were investigated with computational method, and a 15 wt.% Ti content Cu-Ti pseudo alloy antifouling anode was prepared by cold spray, and the microstructure and composition of the anode were observed by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). Electrochemical tests were conducted to obtain the corrosion potential, potentiodynamic polarization curve, and micro zone electrochemical information in natural seawater, and the Cu ions releasing behavior were analyzed using inductively coupled plasma (ICP). The results indicated that in natural seawater, copper particles, and titanium particles on the surface of anode samples can form micro galvanic couples. With the increase in Ti mass fraction, the number of micro primary cells composed of copper particles and titanium particles increases, and the corrosion rate of Cu particles increased. When the Ti mass fraction is 15%, the corrosion rate is the fastest, and the copper ion release rate increases by nearly ten times, reaching 147 μg/(cm²·d). This method can effectively accelerate the releasing rate of Cu ions in Cu-Ti pseudo alloy anode and promote the antifouling effect. Full article

This study employs numerical simulations and experiments to examine the cold spray deposition of nanostructured hydroxyapatite (Ca₁₀(PO4)₆(OH)₂, HA)/70wt.%Ti composite particles under different processing conditions, based on the features of nanocomposites that strengthen interfacial adhesion and improve coating interfacial strength. Using ABAQUS/CAE combined with LS-PrePost 4.9-x64 software, the deposition behavior of the composite particles during deposition under various impact velocities was analyzed, along with the stress of the HA and Ti particles within the composite particle. The deposition behavior of both single and multiple composite particles under different gas temperatures was studied through cold spray experiments, and composite coatings were fabricated. The microstructure and phase composition were analyzed using scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results showed that the numerical simulations were consistent with the experimental analyses. As the particle velocity or gas temperature increased, the degree of particle deformation upon deposition became more pronounced, accompanied by phenomena such as cracking or fragmentation and splashing rebound. At a gas temperature of 700 °C, both the bonding density of individual particles and the bonding effectiveness of multi-particle deposits were lower than those achieved at 500 °C. The coating prepared at a gas temperature of 500 °C exhibited a flatter surface, better overall bonding with the Ti interlayer, and higher internal density. Full article

Cold-spray additive manufacturing (CSAM) is an emerging solid-state deposition technology that effectively mitigates common defects associated with conventional thermal processes, such as oxidation, phase transformation, and residual stresses. In this study, copper–titanium (Cu-Ti) composite coatings were fabricated via high-pressure CSAM using mixed powders with Ti contents of 3, 6, and 10 wt.%. The influence of Ti content and post-heat treatment (350–400 °C) on the tensile properties of the composites was systematically investigated. The results indicate that the ultimate tensile strength (UTS) remained consistently within the range of 265–285 MPa under all conditions, showing only a mild positive correlation with Ti content. In contrast, ductility was significantly influenced by Ti addition, with elongation decreasing markedly as the Ti content increased. Notably, the composite with 3 wt.% Ti heat-treated at 400 °C exhibited a well-balanced combination of tensile strength (270 MPa) and ductility (20% elongation). These findings demonstrate that CSAM-fabricated Cu-Ti composites possess attractive mechanical properties, which can be tailored through Ti content and heat treatment. 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

Iron-based metallic glasses are gaining increased interest due to their good glass-forming ability, high compressive strength, high corrosion resistance, catalytic properties, excellent soft magnetic properties, and relatively low cost. Cold spraying was successfully used to produce amorphous coatings from commercially available powder without any crystallization due to its high cooling rate and short processing time, minimizing thermal influences. Thick and dense amorphous coatings were obtained. The effect of a substrate on the microstructure, phase composition, microhardness, flexural strength, and wear behaviour of the coatings was investigated. The cold sprayed coatings revealed an almost complete amorphous structure and negligible porosity. The coating deposited on the steel substrate showed higher microhardness, better resistance to loose abrasive wear, and a slightly lower wear index tested in the coating and Si₃N₄ ball tribological association than that cold sprayed on an Al alloy. The force required to destroy the durability of the coating–steel substrate system estimated during three-point bending tests was also much higher. Both coatings were characterized by a comparable friction coefficient. Full article

Cold gas dynamic spraying (CGDS) enables the production of protective coatings without melting or oxidation. In this study, Al–Zn–TiO₂ composite powders were prepared by wet agglomeration with binders and by dry mechanical mixing, and deposited onto mild steel substrates. COMSOL simulations of gas dynamics and particle acceleration identified optimal parameters (0.6 MPa, 600 °C, 15 mm, 90°), which were then validated experimentally. Coatings formed under these conditions exhibited dense microstructures, minimal porosity (~0.5%), and continuous, defect-free interfaces with the substrate. SEM and XRD confirmed solid-state bonding without new phase formation. Corrosion tests in 3.5% NaCl revealed a tenfold reduction in corrosion current density compared to bare steel, resulting from synergistic sacrificial (Zn), barrier (Al), and reinforcing/passivating (TiO₂) effects. Tribological tests demonstrated reduced friction (CoF ≈ 0.4–0.5) and wear volume. Compared with reported Al- or Zn-based cold- and thermal-sprayed coatings, the optimized Al–Zn–TiO₂ system shows superior performance, highlighting its potential for industrial anti-corrosion and wear-resistant applications. Full article

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. 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