Article
Materials Science, Coatings & Films
Laurent Aubanel, Francesco Delloro
Summary: This study investigates a composite coating obtained by cold spray for its potential application in automotive internal combustion engines. The coating consists of a 410 L matrix and M2 tool steel reinforcements. The study examines the microstructure, mechanical properties, topography, and tribological behavior of the coatings and proposes the use of surface textures with protuberances for lubricated contacts.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Yutao Yan, Lifeng Lu, Yuqiu Huo, Yong Zhao
Summary: Electrodeposition technique is an effective method for preparing functional coatings with improved tribological behavior. Ni-MoS2, Ni-SiC, and Ni-MoS2/SiC composite coatings were successfully prepared on 2218 aluminum alloy, showing enhanced friction reduction and wear resistance. However, the specific performance varied among the different composite coatings.
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
Materials Science, Coatings & Films
Avneesh Kumar, Ravi Kant, Harpreet Singh
Summary: This study investigates the tribological behavior and performance of Titanium/Baghdadite cold sprayed composite coatings for artificial human joints in dry and simulated body fluid environments. The coatings are found to effectively protect biomedical grade steel from wear in different environments, with three-body abrasion wear and adhesive wear as the dominant mechanisms observed. The coatings exhibit good adhesion with the substrate, and their hydrophilicity improves with an increase in Baghdadite content.
SURFACE & COATINGS TECHNOLOGY
(2021)
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
Chemistry, Physical
Peng Han, Wen Wang, Zhihao Liu, Ting Zhang, Qiang Liu, Xiaohu Guan, Ke Qiao, Dongming Ye, Jun Cai, Yingchun Xie, Kuaishe Wang
Summary: In this study, a novel Al matrix composite reinforced by CoCrFeNi HEA particles was fabricated for the first time using cold spray and subsequent friction stir processing. The microstructure and mechanical properties of the composites were examined, and the results showed that the FSPed samples exhibited improved properties compared to the CSed samples, with refined particle size, optimized grain size, and enhanced interfacial bonding.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
Article
Chemistry, Multidisciplinary
Wei Zhang, Zhichao Ma, Dongni Liu, Junming Xiong, Hongwei Zhao, Luquan Ren
Summary: In this study, graphene oxide (GO) reinforced high-entropy alloy (HEA) composites with different GO contents were synthesized and their surface hardness and wear resistance were comparatively investigated. The results showed that an appropriate amount of GO significantly improved the surface hardness and wear resistance of the materials, but excessive GO content resulted in decreased hardness and increased friction coefficient.
Article
Materials Science, Multidisciplinary
Abreeza Manap, N. F. Afandi, Savisha Mahalingam, Siti Nurul Akmal Yusof, Zulkifli Mohd. Rosli
Summary: The study investigated the mechanical and tribological properties of Al coatings deposited using high-pressure cold-spray (HPCS) and low-pressure cold-spray (LPCS) techniques. The results showed that Al coatings produced by LPCS process exhibited higher micro-hardness, lower friction coefficients, and lower specific wear rate compared to those produced by HPCS process.
Article
Materials Science, Multidisciplinary
Dmitry Dzhurinskiy, Abhishek Babu, Stanislav Dautov, Anil Lama, Mayuribala Mangrulkar
Summary: An innovative hybrid process combining cold spray and friction stir processing techniques was proposed to refine the microstructure of Cu-Al-Ni-Al2O3 composite coating material. The results showed that the processed coatings exhibited improved microstructure and mechanical properties, with a slight reduction in wear rate compared to the as-sprayed coatings. Among all the test coatings, the friction stir processed S1 coating showed the lowest wear rate.
Article
Materials Science, Ceramics
Wenlong Song, Lei An, Yang Lu, Xuan Zhang, Shoujun Wang
Summary: The use of MoS2/PTFE lubricating coatings can effectively improve the dry friction behavior of traditional hard coatings, reducing the friction coefficient, increasing surface hardness, and reducing wear forms such as abrasion wear and coating delamination.
CERAMICS INTERNATIONAL
(2021)
Article
Polymer Science
Yiren Pan, Yihui Chen, Yi Pan, Junxiu Xue, Wenwen Han, Huiguang Bian
Summary: This study compared the use of carbon matrix composite (CMC) wear-resistant plate and common wear-resistant (CWR) plate in replacing silica in rubber formula. The results showed that CMC wear-resistant plate exhibited a high friction coefficient and low wear rate in the mixing process of silica compound, while the opposite trend was observed for carbon black compound. The experimental results suggested that CMC wear-resistant plate is more suitable for a silica mixing process, and its increasing friction coefficient with decreasing wear rate can improve the importance of effective friction in mixing and prolong the service life of wear-resistant plate.
Article
Materials Science, Multidisciplinary
Armin Seynstahl, Sebastian Krauss, Erik Bitzek, Bernd Meyer, Benoit Merle, Stephan Tremmel
Summary: Depositing MoS2 coatings for industrial applications involves rotating the samples during the PVD magnetron sputtering process, with excessive substrate rotation introducing porosity that affects mechanical properties and wear behavior.
Article
Materials Science, Multidisciplinary
Ashokkumar Mohankumar, Thirumalaikumarasamy Duraisamy, Ramachandran Chidambaramseshadri, Thirumal Pattabi, Sathiyamoorthy Ranganathan, Murugan Kaliyamoorthy, Guruprasad Balachandran, Deepak Sampathkumar, Pradeep Raj Rajendran
Summary: Al alloy/alumina metal matrix composite coatings were formed by low pressure cold spraying and post-friction stir processing to enhance the corrosion resistance of Mg alloy. The corrosion performance of the coatings was improved after the friction stir processing, especially at the second run. The enhanced surface state is the primary mechanism for improving the electrochemical properties of the friction stir-processed coatings.
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
F. Venturi, A. Rincon Romero, T. Hussain
Summary: A novel setup for injecting liquid-based feedstock in a liquid-fuelled high velocity oxy-fuel (HVOLF) thermal spray torch is proposed in this study. The new setup uses a Hybrid Nozzle to inject suspension radially and protect the thermal spray flame from environmental oxygen. SiC/YAG composite coatings with 85 wt% SiC content were successfully deposited using this new setup, demonstrating good wear performance.
SURFACE & COATINGS TECHNOLOGY
(2023)
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.
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)
Article
Engineering, Mechanical
Steven A. Policastro, J. Michael Shockley, Matthew J. Strom, Christopher R. So, Derek J. Horton, Kathryn J. Wahl
Summary: The wear-assisted corrosion response of a super-duplex stainless-steel from a single asperity contact was studied using atomic force microscopy (AFM). The results showed that the stress fields induced damage in the protective oxide and disrupted other oxide-formation processes, leading to slower repassivation.
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)