Review
Materials Science, Multidisciplinary
Pedro Poza, Miguel Angel Garrido-Maneiro
Summary: Cold spray (CS) is a solid-state processing technique for depositing coatings on bulk materials to improve functionality and extend service life. Coatings generated via CS exhibit similar properties to bulk materials.
PROGRESS IN MATERIALS SCIENCE
(2022)
Article
Nanoscience & Nanotechnology
S. Janakiram, P. Sudharshan Phani, Govind Ummethala, Sairam K. Malladi, J. Gautam, Leo A. Kestens
Summary: This study investigates the structure-property correlations at the micrometer length scale during recovery and early recrystallization of a cold rolled high strength steel composed of ferrite and pearlite. High resolution nano-indention mapping technique and electron microscopy were used to study the local microstructure and hardness variations with annealing temperature. A clustering algorithm was employed to determine the properties of the constituent microstructural features.
SCRIPTA MATERIALIA
(2021)
Article
Materials Science, Ceramics
YanXin Dan, Takashi Costa, Atsushi Nakamura, Keiji Komatsu, Hidetoshi Saitoh
Summary: This study investigates the influence of carrier gas type and ratio on the solidification mechanism of flame sprayed Er2O3 splats deposited on aluminum alloy substrates, and proposes a spraying method combined with multidimensional modes to control splat morphology. The results show that carrier gas type (N-2) and ratio significantly affect the flattening behavior of molten droplets, providing insights into optimizing coating methodologies.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Ceramics
Shahid Anwar, Sheeba Sonali, Sharmistha Anwar
Summary: In this study, AlSi nanocomposite coating was deposited on float glass substrate by RF magnetron sputtering in Ar/N2 reactive atmosphere. The effect of deposition time on microstructure, mechanical and optical properties was investigated. The XRD analysis revealed the formation of h-AlN phase in the film deposited for 2 h, indicating a transition from amorphous to polycrystalline structure. The coating thickness increased with deposition time, as confirmed by stylus profiler. The coating exhibited high optical transparency (>90%) and low surface roughness (Ra < 2 nm). The maximum hardness of the coating was 31 GPa with an elastic recovery of 92%.
CERAMICS INTERNATIONAL
(2023)
Article
Materials Science, Multidisciplinary
Ji-Eun Ahn, Young-Kyun Kim, Sang-Hoon Yoon, Kee-Ahn Lee
Summary: An equiatomic CoCrFeMnNi high entropy alloy (HEA) coating layer was successfully prepared via a cold spray process, with heat treatments employed to control its microstructure and nano-indentation properties. Fine Cr-rich precipitates were found at grain boundaries and particle boundaries after heat treatment, and deformation twins were observed to significantly affect hardness improvement.
METALS AND MATERIALS INTERNATIONAL
(2021)
Article
Materials Science, Multidisciplinary
Hossein Besharatloo, Jeffrey M. Wheeler
Summary: The development of high-speed nanoindentation has allowed for the acquisition of rich mechanical property data in a short amount of time, but the influences of indentation size and deconvolution method on phase properties remain unclear. By exploring different depth/spacing increments on two materials systems and comparing various statistical analyses, this study reveals the different sensitivities of deconvolution methods to errors in phase identification.
JOURNAL OF MATERIALS RESEARCH
(2021)
Article
Nanoscience & Nanotechnology
Charles Miller, Christopher DellaCorte, Min Zou
Summary: The nanomechanical properties of hardened 60NiTi were studied using nanoindentation, revealing that the Ni3Ti phase has higher hardness and elastic modulus. The presence of Ni3Ti may indicate reduced amounts of Ni4Ti3, leading to lower overall hardness of the material.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Materials Science, Multidisciplinary
Pasquale Daniele Cavaliere, Antonella Rizzo, Daniele Valerini, Laura Capodieci
Summary: The wear and fretting behavior of IN625 cold spray coatings were analyzed, demonstrating that coatings produced under specific conditions can offer improved wear resistance and energy dissipation capabilities. Nanoindentation evaluation revealed an increase in hardness from the surface towards the substrate, leading to enhanced resistance to wear. Scratch tests at increasing loads also showed the coating's ability to resist damage under triaxial stresses.
Article
Materials Science, Coatings & Films
Alessia Bruera, Pietro Puddu, Stephan Theimer, Maria Villa-Vidaller, Alexander List, Giovanni Bolelli, Frank Gaertner, Thomas Klassen, Luca Lusvarghi
Summary: This study investigates the adhesion of cold-sprayed copper particles onto differently adjusted hardness and roughness values of AISI 304 stainless steel surfaces. With SEM analysis and nano-indentation tests, it was found that grit-blasting causes severe plastic deformation of the surface, while vacuum annealing can restore the original hardness. The adhesion of cold-sprayed copper particles was found to be higher on roughened and softened substrates than on polished surfaces.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Physics, Condensed Matter
Barsha Priyadarshini, Shahid Anwar, Bishnu Choudhary, Sharmistha Anwar
Summary: The thermal and chemical stability of CrAlN coatings were studied. The coatings showed good properties below 700 degrees C, but degradation and crack formation occurred at temperatures above 800 degrees C. Corrosion tests and electrochemical impedance spectroscopy confirmed outstanding corrosion resistance of the coatings, even at 800 degrees C.
PHYSICA B-CONDENSED MATTER
(2023)
Article
Nanoscience & Nanotechnology
Dallin J. Barton, B. Chad Hornbuckle, Kristopher A. Darling, Luke N. Brewer, Gregory B. Thompson
Summary: LACS of ODS Fe91Ni8Zr1 alloy was conducted at 650°C and 950°C, resulting in a ferritic phase with a DE of 7.3% at the lower temperature while an austenitic phase with a DE of 32.4% at the higher temperature. The increase in deposition temperature led to grain growth, oxide particle coarsening, and a reduction in hardness. Grains were found to be the dominant strengthening mechanism with these microstructural changes.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Construction & Building Technology
Guohao Fang, Qiang Wang, Mingzhong Zhang
Summary: This study systematically investigates the micromechanical properties of the interfacial transition zone (ITZ) in alkali-activated fly ash-slag (AAFS) concrete, revealing that the properties depend on the chemical composition of reaction products and microstructural characteristics, with the evolution divided into three stages.
CEMENT & CONCRETE COMPOSITES
(2021)
Article
Materials Science, Ceramics
Shi-Kuan Sun, Jin-Hao Yuan, Wei-Ming Guo, Xiao-Ming Duan, De-Chang Jia, Hua-Tay Lin
Summary: This study investigated the effects of the initial thickness on the densification, microstructure, and nanoindentation hardness of SiC ceramics prepared by the spark plasma sintering process. The results showed that the initial thickness played a significant role in the densification and hardness of the materials.
JOURNAL OF THE AMERICAN CERAMIC SOCIETY
(2023)
Article
Chemistry, Physical
Alexander S. Kuprin, Adam Gilewicz, Tatyana A. Kuznetsova, Vasilina A. Lapitskaya, Galina N. Tolmachova, Bogdan Warcholinski, Sergei M. Aizikovich, Evgeniy V. Sadyrin
Summary: The research investigated the influence of oxygen concentration on the adhesion, color, structure, and mechanical properties of transition metal oxynitride ZrON coatings. The results revealed changes in color, crystallite size, and hardness with increasing oxygen concentration, while adhesion showed a strong dependence on the oxygen concentration.
Article
Materials Science, Coatings & Films
Kyle Tsaknopoulos, Jack Grubbs, Matthew Siopis, Aaron Nardi, Danielle Cote
Summary: The study found that heat treatment can induce microstructural modifications in both the powder and sprayed deposits, and X-ray diffraction showed the presence of eutectic Si, Mg2Si and SiO2 in all specimens. Spheroidization of Si significantly increased during heat treatment, with an increase in the fraction of Mg2Si during both treatments.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Yinyin Zhang, David Chern, Robert Schulz, Janine Mauzeroll, Richard R. Chromik
Summary: Self-lubricating duplex composites consisting of a top layer of polymer composites and a bottom layer of infiltrated metal networks were produced with varying graphite content, showing that the graphite content affects the performance of the graphite composites and providing insights into the design principles for manufacturing self-lubricating polymer matrix composites.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Materials Science, Coatings & Films
R. Ortiz-Fernandez, S. Imbriglio, R. Chromik, B. Jodoin
Summary: The study reveals that substrate preheating in induction heating cold spray significantly enhances adhesion strength, increases bonded area, and alters the characteristics of failure mode.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Alexandre R. C. Nascimento, Richard R. Chromik, Robert Schulz
Summary: This study investigated the friction and wear behavior of three materials commonly used in industrial bearing applications: a Sn-based Babbitt, polytetrafluoroethylene (PTFE), and a polyether ether ketone (PEEK) composite. The effects of load and sliding velocities on wear rates were evaluated by regression analysis, with a focus on the relationship between wear and materials mechanical properties. The ranking of wear performance correlated most strongly with the ratio of hardness to reduced modulus, with implications for estimating oil film thickness in lubrication regimes.
Article
Engineering, Mechanical
Sima A. Alidokht, Richard R. Chromik
Summary: Metal matrix composites reinforced with WC particles and Co or Ni matrices are known for their unique combination of hardness, toughness, and superior wear performance. This study focused on Ni-WCNi composite coatings and found that coatings with higher WC fill ratios displayed better wear resistance due to the uniform distribution of WC particles and shorter mean free path reducing adhesive wear. However, at higher loads, subsurface crack propagation at WC particle interfaces led to a reduction in the protective role of mechanically mixed layers. Scratch tests were used to qualitatively compare coating cohesion strengths and correlate them to wear properties.
Article
Engineering, Mechanical
M. Koricherla, T. B. Torgerson, S. A. Alidokht, V. N. V. Munagala, R. R. Chromik, T. W. Scharf
Summary: Ti and Ti-based alloys are commonly used in aerospace and automotive components, but face challenges in wear resistance at elevated temperatures. The study found that Ti-xTiC composite coatings exhibit improved friction and wear performance compared to baseline Ti coatings, with Ti-35%TiC showing the best overall performance at 575 degrees C. The tribological behavior was attributed to the formation of stable oxide layers on the wear surfaces containing TiO2, WO3, and CoWO4.
Article
Materials Science, Coatings & Films
Venkata Naga Vamsi Munagala, Richard R. Chromik
Summary: Ti6Al4V-TiC metal matrix composite (MMC) coatings were cold sprayed using spherical and irregular Ti6Al4V powders with plasma gas atomization and the Armstrong process, respectively. Composite coatings deposited using irregular powders exhibit higher ceramic retentions and lower porosity compared to those made with spherical powder. In wear tests, irregular powder composites showed resistance to abrasive wear mechanisms with lower coefficients of friction and wear rates due to the presence of islands of tribolayers, while increasing ceramic content led to even lower wear rates and continuous tribolayer formation at higher loads. The formation of tribolayers resulted in coarser-grain microstructures in the worn subsurface, indicating less stress transfer and lower wear rates.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Priyadarshi Behera, Richard R. Chromik, Stephen Yue
Summary: The study showed that changes in relative humidity and coating type have a 10-fold difference in wear rate of the steel substrate. The Cd coating decreases substrate wear, while the Al coating increases it. Residual third bodies, which were oxides and hydroxides of the coating, affect the wear process of the steel substrate after coating wear-through.
Article
Engineering, Mechanical
B. C. N. M. de Castilho, N. Sharifi, S. A. Alidokht, K. Harrington, P. Stoyanov, C. Moreau, R. R. Chromik
Summary: NiCr-Cr2O3-Ag-BaF2/CaF2 (PS304) and NiMoAl-Cr2O3-Ag-BaF2/CaF2 (PS400) coatings exhibit low wear and friction at temperatures ranging from 25 to 700 degrees C. However, the formation of small precipitates in high temperatures due to expansion of NiCr matrix component can pose challenges for coating integrity in gas turbine applications. Experimental evidence suggests that the precipitates are formed by fluorine diffusing from fluorides to NiCr, driven by oxidation of the fluorides to form BaCrO4 and CaCrO4. PS400 coatings show superior thermal stability and wear resistance compared to PS304 coatings under tested conditions.
Review
Materials Science, Coatings & Films
Sara I. Imbriglio, Richard R. Chromik
Summary: Research on metal/ceramic interfaces created by cold spray is expanding due to their interesting applications, where adhesion of particles is achieved by high-speed impact while remaining in the solid state. The combination of mechanical interlocking and physicochemical interactions is considered crucial for adhesion, with the formation and contribution of physicochemical interactions remaining of interest.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Chemistry, Physical
Venkata Naga Vamsi Munagala, Rohan Chakrabarty, Jun Song, Richard R. Chromik
Summary: By adjusting the properties of metal powders, such as surface morphology and porosity, MMCs with higher ceramic retentions can be deposited using the cold spray process, affecting the quality of the coatings.
SURFACES AND INTERFACES
(2021)
Article
Materials Science, Coatings & Films
Samantha Michelle Gateman, Sima Ahmad Alidokht, Emmanuel Mena-Morcillo, Robert Schulz, Richard R. Chromik, Anne-Marie Kietzig, Ivan P. Parkin, Janine Mauzeroll
Summary: This work combines thermal spray and compression molding methods to create wear-resistant and solid-lubricating composite coatings suitable for high load applications. The coatings fabricated on SS444 substrates consist of a mixture of PTFE and PI, with the addition of graphite to lower material costs and increase load capacity. The coatings show low wear rates and coefficient of frictions, with the influence of graphite on wear properties found to be minimal.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Materials Science, Coatings & Films
Payank Patel, Sima A. Alidokht, Navid Sharifi, Amit Roy, Kelly Harrington, Pantcho Stoyanov, Richard R. Chromik, Christian Moreau
Summary: High entropy alloys (HEAs), characterized by containing five or more principal elements, are considered as potential candidates for high-temperature applications due to their superior mechanical and thermal properties. In this study, the microstructure and wear behavior of CrMnFeCoNi HEA coatings were evaluated, revealing equivalent behavior of as sprayed and annealed coatings on polished surfaces and higher wear rates on rough surfaces.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2022)
Review
Chemistry, Physical
Payank Patel, Amit Roy, Navid Sharifi, Pantcho Stoyanov, Richard R. Chromik, Christian Moreau
Summary: This review article discusses the synthesis methods, microstructural characteristics, and tribological performance of high-entropy coatings (HECs). HECs exhibit favorable mechanical and tribological properties at high temperatures.
Article
Materials Science, Multidisciplinary
Nhat Minh Dang, Wen-Yen Lin, Zhao-Ying Wang, Sima Ahmad Alidokht, Richard R. Chromik, Terry Yuan-Fang Chen, Ming-Tzer Lin
Summary: This study investigated the mechanical properties and residual stress of high-power impulse magnetron sputtering (HiPIMS) titanium nitride (TiN) thin film capping on a cold spray titanium (Ti) coating. The results showed that the TiN/Ti duplex coating exhibited excellent mechanical properties, and the residual stresses did not significantly change with different Ti cold spray substrates, indicating the feasibility of coating technology in the aerospace industry.
Article
Materials Science, Multidisciplinary
S. A. Alidokht, Y. Gao, B. C. N. M. de Castilho, N. Sharifi, M. Harfouche, P. Stoyanov, M. Makowiec, C. Moreau, R. R. Chromik
Summary: In this study, two Co-based Tribaloy powders were coated on mild steel substrate using high-velocity oxygen fuel (HVOF) spraying. The microstructure and distribution of Laves phases in the coatings were investigated. It was found that Co3Mo2Si and Co3Mo were the main constituents of the intermetallic Laves phases in the sprayed coatings. The volume fraction of Laves phases in the coatings was significantly lower compared to similar alloys due to high cooling rate and solidification in HVOF. The Laves-free solid solution exhibited a nano-crystalline microstructure with similar local hardness to the Laves phases.
JOURNAL OF MATERIALS SCIENCE
(2022)