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Keywords = combustion-assisted flame spraying (CAFSY)

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29 pages, 9266 KiB  
Article
Electrochemical Behavior of Nickel Aluminide Coatings Produced by CAFSY Method in Aqueous NaCl Solution
by Amalia Marinou, Angeliki G. Lekatou, Galina Xanthopoulou and George Vekinis
Coatings 2022, 12(12), 1935; https://doi.org/10.3390/coatings12121935 - 8 Dec 2022
Cited by 2 | Viewed by 2147
Abstract
Combustion-assisted flame spraying (CAFSY) is a novel method that allows in-flight synthesis of alloys during flame spraying. The in-flight synthesis of alloys by the CAFSY method during flame spraying combines two different methods: the self-propagating high-temperature synthesis (SHS) and flame spraying (FS). The [...] Read more.
Combustion-assisted flame spraying (CAFSY) is a novel method that allows in-flight synthesis of alloys during flame spraying. The in-flight synthesis of alloys by the CAFSY method during flame spraying combines two different methods: the self-propagating high-temperature synthesis (SHS) and flame spraying (FS). The present work studies the corrosion performance (by cyclic polarization and chronoamperometry in aerated 3.5 wt.% NaCl) of NiAl coatings fabricated by the CAFSY technique in relation to main process parameters (composition of the initial feedstock, spraying distance, substrate temperature, postdeposition heat treatment) and their effect on the microstructure and porosity of the coatings. Most of the coatings exhibited limited susceptibility to localized corrosion. In all cases, the steel substrate remained intact despite corrosion. Interconnected porosity was the main parameter accelerating uniform corrosion. Localized corrosion had the form of pitting and/or crevice corrosion in the coating that propagated dissolving Al and Al-rich nickel aluminides along coating defects. Substrate preheating and postdeposition heat treatment negatively affected the corrosion resistance. A short spraying distance (1.5 inch) increased the corrosion resistance of the coatings. Full article
(This article belongs to the Special Issue Surface Modification/Engineering for Electrochemical Applications)
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12 pages, 3720 KiB  
Article
Combustion Synthesis during Flame Spraying (“CAFSY”) for the Production of Catalysts on Substrates
by Galina Xanthopoulou, Amalia Marinou, Konstantinos Karanasios and George Vekinis
Coatings 2017, 7(1), 14; https://doi.org/10.3390/coatings7010014 - 20 Jan 2017
Cited by 6 | Viewed by 5836
Abstract
Combustion-assisted flame spraying (“CAFSY”) has been used to produce catalytically active nickel aluminide coatings on ceramic substrates. Their catalytic activity was studied in CO2 (dry) reforming of methane, which is particularly significant for environmental protection as well as production of synthesis gas [...] Read more.
Combustion-assisted flame spraying (“CAFSY”) has been used to produce catalytically active nickel aluminide coatings on ceramic substrates. Their catalytic activity was studied in CO2 (dry) reforming of methane, which is particularly significant for environmental protection as well as production of synthesis gas (CO + H2). By varying the CAFSY processing parameters, it is possible to obtain a range of Ni–Al alloys with various ratios of catalytically active phases on the substrate. The influence of the number of coating layers and the type of substrate on the final catalyst composition and on the catalytic activity of the CAFSY coatings was studied and is presented here. The morphology and microstructure of the composite coatings were determined by scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDX) elemental analysis, X-ray diffraction (XRD), and Brunauer–Emmett–Teller (BET) specific area analysis. Catalytic tests for dry reforming of methane were carried out using crushed pellets from the coatings at temperatures of 750–900 °C, and gas chromatography showed that methane conversion approached 88% whereas that of carbon dioxide reached 100%. The H2/CO ratio in the synthesis gas produced by the reaction varied from about 0.7 to over 1.2, depending on the catalyst and substrate type and testing temperature. Full article
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22 pages, 1455 KiB  
Article
Ni-Al and NiO-Al Composite Coatings by Combustion-Assisted Flame Spraying
by Galina Xanthopoulou, Amalia Marinou, George Vekinis, Aggeliki Lekatou and Michalis Vardavoulias
Coatings 2014, 4(2), 231-252; https://doi.org/10.3390/coatings4020231 - 17 Apr 2014
Cited by 29 | Viewed by 9404
Abstract
A new, cost-efficient and on-site-applicable thermal spraying process for depositing NiAl metallic overlay or bond-coat coatings for high temperature applications by synthesizing the desired intermetallic phases in-flight during oxy-acetylene flame spraying is presented. Base-metal powders were used for spraying and, by adjusting the [...] Read more.
A new, cost-efficient and on-site-applicable thermal spraying process for depositing NiAl metallic overlay or bond-coat coatings for high temperature applications by synthesizing the desired intermetallic phases in-flight during oxy-acetylene flame spraying is presented. Base-metal powders were used for spraying and, by adjusting the spraying conditions, excellent NiAl-based coatings were achieved on various substrates, including mild steel, stainless steel and aluminium alloys. Expensive, pre-alloyed or agglomerated powders are avoided and the method is very promising for in-situ work and repairs. We call the new method “Combustion-Assisted Flame Spraying” (CAFSY) and its viability has been demonstrated at a pre-industrial level for coating metallic substrates. The NiAl-based coatings produced by CAFSY exhibit very high integrity with good adhesion, very low porosity, high surface hardness and high erosion resistance at a substantially lower cost than equivalent coatings using pre-prepared alloy powders. Full article
(This article belongs to the Special Issue Advanced Thermal Spray Coatings for Emerging Applications)
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