Article
Materials Science, Ceramics
D. Franco, F. Vargas, E. Lopez, H. Ageorges
Summary: Bilayer alumina/mullite and mullite/alumina coatings were applied on silico-aluminous refractory bricks through atmospheric plasma spraying. The wear behavior of these coatings was evaluated under sliding contact conditions up to 1000 degrees C via a ball-on-disk test. Physical and mechanical properties were assessed to correlate with the wear behavior. The results show that both coatings offer higher wear resistances compared to the substrate, potentially providing enhanced protection for nonstructural refractories used in glass and cement production furnaces.
CERAMICS INTERNATIONAL
(2023)
Article
Materials Science, Multidisciplinary
Xueqing Zhang, Xiaojing Li, Tianzhe Shi
Summary: The motion behavior and arrangement of clusters during cold spraying have significant effects on the coating/substrate bonding strength and morphologies. Increasing the normal velocity results in mechanical interlocking failure, while increasing the tangential velocity enhances mechanical interlocking. Moreover, increasing the impact torque around the x-axis improves both mechanical interlocking and metallurgic bonding, while the impact torque around the z-axis only increases metallurgic bonding beyond a certain value. The thermal-softening effect of the first cluster impacting on the substrate contributes more to its own metallurgic bonding and the mechanical interlocking of the latter one for horizontally arranged neighboring clusters, and a smaller velocity difference can greatly enhance metal interlocking and metallurgic bonding for vertically colliding clusters.
Review
Materials Science, Multidisciplinary
Huipeng Wang, Peng Li, Weiling Guo, Guozheng Ma, Haidou Wang
Summary: Copper-based composite coatings have been widely used in important industries due to their excellent properties. The cold spray (CS) technology, characterized by low-temperature deposition, has emerged as the most promising method for preparing Cu-based composite coatings. This paper introduces the principle and deposition mechanism of CS technology, explores the deposition mechanism of Cu-based metal/ceramic composite coatings, summarizes the effects of key CS process parameters on the coating quality, reviews the current research status of cold-sprayed Cu-based composite coatings in different fields, and elaborates on the improvement of coating performance through post-process treatments. Finally, the future development of Cu-based composite coatings and CS technology is discussed.
Article
Automation & Control Systems
Maricruz Hernandez-Hernandez, Rodrigo Gonzalez-Mejia, Victor Hugo Mercado-Lemus, Adriana Gallegos-Melgar, Isabel Pereyra, Juan Munoz-Saldana, Jan Mayen
Summary: Descriptive and inferential statistics were used to analyze data from the LPCS process, studying the relationship between process input variables (nozzle type, standoff distance, and particle velocity) and the output variables (coating porosity, thickness, and deposition efficiency). It was found that the nozzle type had the greatest impact on the final coating properties, with the rectangular nozzle leading to higher particle rebound and increased porosity. The round nozzle was recommended for obtaining coatings with low porosity levels, independent of the standoff distance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Ceramics
Zhiping Pan, Jianzheng Guo, Shuangming Li, Xuguang Li, Hai Zhang
Summary: Silica-based ceramic cores are used in manufacturing turbine blades, but reactions with active metals in superalloys can reduce their quality. Alumina coatings prepared using plasma spraying and sol-gel dipping methods were compared, with the former showing peeling at high temperatures and the latter demonstrating improved performance. The alumina coating effectively prevented interfacial reactions between the superalloy and the silica-based substrate during casting.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Multidisciplinary
Shijie Hu, Hongjun Li, Liying Zhang, Yuzhen Xu
Summary: In this study, the entire trajectories of mixed particles in industrial cold spraying were analyzed using a combination of computational fluid dynamics and a discrete element method. The positions and velocities of each particle were accurately tracked, and a comprehensive simulation of the complete cold spray process was achieved. The numerical model was validated using experimental analysis, and the influence of the mutual collision of copper and aluminum particles on spray deposition was investigated.
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
Materials Science, Multidisciplinary
Sergey Grigoriev, Eugeniy Gershman, Iosif Gershman, Alexander Mironov
Summary: The study investigated the influence of Cu-Al2O3-Zn powder mixtures on the properties of coatings deposited via cold spraying. Results showed that coatings with different composition ratios displayed varied adhesion, electrical conductivity, and wear resistance. The 60Cu-40Al(2)O(3) coating exhibited superior adhesion and conductivity, while the 40Cu-50Al2O3-10Zn coating was the most wear-resistant.
Article
Materials Science, Coatings & Films
Xingchao Mao, Fangcheng Duan, Fengyi Wang, Chunjin Hang, Hongtao Chen, Mingyu Li
Summary: A solderable coating was formed by low pressure cold spraying Cu-Al2O3 particles on an Al substrate. The metallurgical bonding between the cold sprayed copper layer and the Al substrate was confirmed by FIB-SEM and HR-TEM. Stacking faults, twins, and dislocations were observed near the Cu and Al interfaces due to plastic deformation caused by compressive shock. An atomic diffusion layer of about 100 nm, including ordered lattice structure (AlCu3), severely deformed lattice structure, and amorphous region surrounded by Cu and Al lattices, was discovered.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Materials Science, Coatings & Films
Hongjian Wu, Shaowu Liu, Wenbo Li, Marcel Lewke, Rija-Nirina Raoelison, Alexander List, Frank Gaertner, Hanlin Liao, Thomas Klassen, Sihao Deng
Summary: Applications in thermal and kinetic spraying for coating of complex parts are increasing. Current individual adjustment of robot programming for deposition paths is time-consuming. This work addresses novel strategies for robot programming and post-spray analyses, allowing for fast adaptation and quality control. The proposed method was tested on a complex workpiece and proved to enable fast generation of paths and accurate transfer to spray procedures.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Kai Ma, Qing-Feng Zhang, Hui-Yu Zhang, Chang-Jiu Li, Cheng-Xin Li
Summary: This study investigates the impact of gas preheating temperature on particle impact velocity and temperature using Computational Fluid Dynamics (CFD) simulations, and finds that increasing the gas temperature leads to higher particle impact velocity and better film quality. The experimental results also show improvements in film compactness and electrical properties with gas preheating, and validate the self-adaptive repair mechanism of VCS when depositing metal films on rough substrates.
Review
Electrochemistry
Vicente Albaladejo-Fuentes, Ana Maria Martos, Javier Sanchez, Irene Garcia-Cano
Summary: This review provides an overview of zinc and aluminum coatings for corrosion protection, focusing on the application of thermal spraying techniques and the potential of cold gas spray. Both short-term coating properties and long-term performance in real exposure conditions are discussed, highlighting the need for further development in industrial applications.
Article
Materials Science, Coatings & Films
Junfen Yang, Kai Qu, Jinglin Yang
Summary: The study shows that grit blasting and cold spraying can increase crack length, decrease crack growth rate, and prolong the fatigue life of Q355B steel substrates, with grit blasting followed by cold spraying with Cu achieving a greater improvement effect. Scanning electron microscopy was used to examine the mechanism by which fatigue life is prolonged through these processes.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Chemistry, Physical
Anna Trelka, Wojciech Zorawski, Lukasz Maj, Pawel Petrzak, Dominika Sobon, Anna Goral
Summary: This study investigated the influence of substrate on the microstructure and tribological properties of cold sprayed coatings. The coating deposited on the steel substrate exhibited higher hardness and lower abrasive wear, indicating better durability.
Article
Chemistry, Physical
Daniel Meyer, Lars Schonemann, Nicole Mensching, Volker Uhlenwinkel, Bernhard Karpuschewski
Summary: Cold gas spraying is a solid-state material deposition process that can repair and build samples. The influence of material composition and CS-related properties on milling and deep rolling processes has been investigated, showing that deep rolling does not affect the determined hardness depth profile. Future work will focus on additional analyses to gain further insights on material behavior.
Article
Materials Science, Coatings & Films
Bahman Daneshian, Frank Gaertner, Hamid Assadi, Daniel Hoeche, Wolfgang Weber, Thomas Klassen
Summary: The impact behavior of ceramic particles in aerosol deposition is influenced by particle sizes, with particles of 25-75 nm exhibiting three different impact behaviors and larger particles not exhibiting bonding behavior. The bonding of particles to the substrate is caused by localized inelastic deformation and shear localization. Heat diffusion at small scales depends on particle size, with larger particles generating localized heat which supports deformation and the formation of dense layers in aerosol deposition.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Sara Bagherifard, Jan Kondas, Stefano Monti, Jan Cizek, Fabrizio Perego, Ondrej Kovarik, Frantisek Lukac, Frank Gaertner, Mario Guagliano
Summary: Cold spraying technology has gained attention in additive manufacturing due to its low working temperature and high deposition rates. By adjusting spray parameters and post-treatments, high-performance deposits can be obtained, with studies showing that using N2 as process gas can achieve high-quality stainless steel deposits.
MATERIALS & DESIGN
(2021)
Review
Materials Science, Coatings & Films
Michel Hauer, Frank Gaertner, Sebastian Krebs, Thomas Klassen, Makoto Watanabe, Seiji Kuroda, Werner Kroemmer, Knuth-Michael Henkel
Summary: This study compares prerequisites for cavitation-resistant bronzes production by different coating techniques, aiming to help select the right technology for best cavitation protection. Results show that high-pressure warm spraying, cold spraying, HVOF spraying, and arc spraying can achieve properties similar to cast nickel aluminum bronze, with superior performance compared to shipbuilding steel.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Nanoscience & Nanotechnology
C. Borchers, J. Arlt, C. Nowak, F. Gartner, M. Hammerschmidt, H. Kreye, C. A. Volkert, R. Kirchheim
Summary: The investigation of a melt pocket in the bonding zone of medium carbon steel bonded on low-carbon steel by explosive welding using laser assisted atom probe tomography revealed a nanocrystalline structure with carbon-enriched (sub-) grain boundaries. The high hardness values in the melt pocket are attributed to a combination of (sub-) grain size and carbon distribution.
SCRIPTA MATERIALIA
(2021)
Article
Materials Science, Multidisciplinary
Chunjie Huang, Mariia Arseenko, Lv Zhao, Yingchun Xie, Andreas Elsenberg, Wenya Li, Frank Gartner, Aude Simar, Thomas Klassen
Summary: By appropriately annealing metallic deposits manufactured by cold spraying, the strength and fracture strain can be significantly improved. Copper has been identified as a reliable material for cold spraying, and assessing the strength of copper powder can help correlate deposit strength with process parameters and material properties. In-situ observations during tensile testing can provide insights into crack initiation, growth, and final fracture, revealing failure mechanisms and allowing for the identification of solutions for improving cold-sprayed deposits.
MATERIALS & DESIGN
(2021)
Review
Metallurgy & Metallurgical Engineering
Yuanyuan Shang, Claudio Pistidda, Goekhan Gizera, Thomas Klassen, Martin Dornheim
Summary: Magnesium and magnesium based compounds have been extensively studied as potential hydrogen and thermal energy storage materials due to their abundance and high storage densities. Efforts have been made by the scientific community to improve their properties while maintaining high hydrogen storage capacity.
JOURNAL OF MAGNESIUM AND ALLOYS
(2021)
Article
Materials Science, Coatings & Films
Bahman Daneshian, Frank Gaertner, Hamid Assadi, Maria Villa Vidaller, Daniel Hoeche, Thomas Klassen
Summary: The deformation and bonding of ceramic particles in aerosol deposition (AD) were studied, showing the existence of dislocation-based plasticity within a certain velocity range that coincides with the bonding velocity range in AD. Simulation results and analytical models provide a deposition window for AD.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Clarissa Abetz, Prokopios Georgopanos, Claudio Pistidda, Thomas Klassen, Volker Abetz
Summary: Hydrogen is crucial for the transition to a sustainable future without CO2 emissions. It can be produced from renewable energy sources like solar and wind power and used to buffer energy fluctuations in all sectors. Safe and efficient storage options, such as metal hydride materials, are essential for hydrogen technology implementation.
ADVANCED MATERIALS TECHNOLOGIES
(2022)
Article
Chemistry, Physical
Carmen Tenholt, Daniel Hoeche, Mauricio Schieda, Thomas Klassen
Summary: Most research on photo-electrochemical (PEC) cells for water splitting has been based on simulations and experiments on laboratory scales. This study investigates the effects of stepwise upscaling of PEC cells and develops a computer-aided reference model to predict their behavior on different scales. Machine learning via Bayesian optimization is employed to optimize the simulation model input parameters, resulting in good agreement with measured current-voltage curves.
SUSTAINABLE ENERGY & FUELS
(2022)
Article
Materials Science, Multidisciplinary
Chunjie Huang, Alexander List, Junjun Shen, Banglong Fu, Shuo Yin, Ting Chen, Benjamin Klusemann, Frank Gaertner, Thomas Klassen
Summary: This study investigates the influence of powder strength on the performance and deposit quality in cold spraying of atomized Al-alloy powders. The results demonstrate that annealing can reduce powder strength, leading to improved adhesion, electrical conductivity, and tensile strength of deposits.
MATERIALS & DESIGN
(2022)
Article
Biochemistry & Molecular Biology
Ou Jin, Yuanyuan Shang, Xiaohui Huang, Dorothee Vinga Szabo, Thi Thu Le, Stefan Wagner, Thomas Klassen, Christian Kuebel, Claudio Pistidda, Astrid Pundt
Summary: The addition of 3TiCl(3)center dot AlCl3 is found to improve the dehydrogenation kinetics of the reactive hydride composite LiBH4-MgH2. The growth process of MgB2 is studied, and it is observed that MgB2 prefers to form on TiB2 nanoparticles due to the creation of an interface that reduces the elastic strain energy density. The kinetics of MgB2 growth is described by the JMAK equation, and it is suggested that the nucleation center change from Mg to TiB2 leads to a transition from interface- to diffusion-controlled growth, resulting in a change in MgB2 morphology.
Article
Chemistry, Physical
Archa Santhosh, ShinYoung Kang, Nathan Keilbart, Brandon C. Wood, Thomas Klassen, Paul Jerabek, Martin Dornheim
Summary: This study investigates the growth and nature of oxide films on the surface of TiFe intermetallic compound using first-principles methods. Different structures and temperature effects of oxide phases are studied in detail. The interaction between the oxidized surface and hydrogen is evaluated, providing important insights for the design of activation methods for TiFe and related materials as hydrogen storage materials.
JOURNAL OF MATERIALS CHEMISTRY A
(2023)
Article
Chemistry, Multidisciplinary
Yuanyuan Shang, Claudio Pistidda, Chiara Milanese, Alessandro Girella, Alexander Schokel, Thi Thu Le, Annbritt Hagenah, Oliver Metz, Thomas Klassen, Martin Dornheim
Summary: This manuscript proposes a method for obtaining high-quality NaAlH4 from automotive recycled alloy, and comprehensively explores its hydrogen storage properties using various experimental techniques. The results show that NaAlH4 with comparable properties to high-purity commercial NaAlH4 was successfully synthesized.
Article
Materials Science, Coatings & Films
Andreas Elsenberg, Marco Busato, Frank Gartner, Alexander List, Alessia Bruera, Giovanni Bolelli, Luca Lusvarghi, Thomas Klassen
Summary: Cold gas spraying is a solid-state deposition technique that can retain material properties in coatings but may not be suitable for building up coatings of brittle materials. MAX phase ceramics exhibit partial deformability in certain lattice directions, making them potentially suitable for cold spraying. The influence of material properties and deposition conditions on coating microstructure and quality is significant, with different MAX phases showing varying deposition behavior and mechanical properties.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
Article
Materials Science, Coatings & Films
Charline Wolpert, Thomas Emmler, Maria Villa Vidaller, Andreas Elsenberg, Kentaro Shinoda, Mauricio Schieda, Frank Gartner, Jun Akedo, Thomas Klassen
Summary: The study indicates that hydrogen generation from renewable energy sources plays a crucial role in mitigating climate change, with photoelectrochemical water splitting cells being a promising and eco-friendly technology. By using the aerosol deposition method to form bismuth vanadate thin films, the research explores a novel approach to fabricate photoactive coatings without the need for binders or sintering processes, with significant influences on the photoelectrochemical performance.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2021)
