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Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings
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Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Thin Films and Interfaces".

Deadline for manuscript submissions: closed (30 June 2023) | Viewed by 23723

Special Issue Editor

Prof. Dr. Cezary Senderowski

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Guest Editor
Departament of Materials and Machinery Technology, University of Warmia and Mazury, Oczapowskiego 11 St., 10-719 Olsztyn, Poland
Interests: intermetallics; microstructure characterization; phase transformation; multiphase nanocomposite intermetallics/ceramics/cermet coatings; multifunctional hybrid coating systems; thermophysical properties; elastic properties characterization up to 1000 °C; thermal stability; residual stresses; adhesive, wear and corrosion properties characterization; D-gun and HVOF ultrasonic metallization spraying; powders metallurgy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Production of intermetallics’ and ceramics’ protective coatings can be simple, beneficial, and highly predictable. However, comprehensive possibilities for the synthesis and application of this type of coatings, also with the use of intermediate layers, are limited by the technological conditions of the synthesis process and coexisting physical phenomena. The physicochemical, thermophysical, and structural properties of the coating materials can frequently be subjected to changes in situ in the synthesis conditions—also with the possibility of formation of new ones phases in relation to the feedstock powder material.

This Special Issue will focus on various conventional synthesis methods of different intermetallics and ceramics coatings with thermal (D-gun, HVOF, ARC and plasma) spraying, cold spraying, PVD, CVD, and additive manufacturing processes (LENS and other). The main subtopics include experimental research on coating production and analysis of physicochemical and thermo-gasokinetic phenomena under various conditions of the synthesis processes relating to a specific method of production.

A unique problem to be considered is analyzing the influence of synthesis conditions on mechanisms of deformation and strengthening of nominally brittle intermetallics and ceramics phases during synthesis processes of the powder particles, especially during the supersonic flow of stream at D-gun spraying and HVOF process. This description includes a comprehensive analysis of the structural transformation of powder particles into elementary grains in the synthesized structure of intermetallic, ceramic. and cermet coatings.

The analysis of the problem can take into account the synthesis conditions (such as the impact of particle velocity, the temperature, and dynamic pressure of the gaseous stream) on the chemical and phase, composition, crystallographic and morphological microtexture, size of the crystallites, and the state of the grain boundaries in the particles and obtained coatings, as well as the degree of superstructure disorder with identification of nano/ultrafine grain and subgrain areas, dislocation, and antiphase domains. In the thermophysical property analysis, both for the feedstock powder material and coatings, other phenomena are subject to consideration (i.e., the exchange of momentum and convective heat transfer, as well as the thermal effects of phase changes after melting of powder particles), including analytical and numerical analysis.

The conducted considerations may also concern the analysis of the feedstock powder properties used in the synthesis process of the coatings, with taking into account the limitations of heat transport efficiency resulting mainly from the conditions of the synthesis process and the structural conditions of the powder particles, which often show an inhomogeneous multiphase structure also involving pores.

It is also important to analyze the functional properties of the produced coatings, including the residual stress, adhesive strength, thermal stability, corrosion resistance, and abrasive wear mechanisms, as well as the geometric structure analysis of the surface layer of the coatings together with fractal characteristics using the root mean square (RMS) method.

Thus, in this Special Issue, it will be possible to make a comprehensive assessment of how specific synthesis conditions using different methods can affect the structure and performance properties of multiphase intermetallic, ceramic, and cermet coatings in terms of their comprehensive use.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Prof. Dr. Cezary Senderowski
Guest Editor

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Keywords

  • multiphase nanocomposite intermetallics
  • ceramics and cermet coatings
  • phase transformation
  • multifunctional hybrid coating systems
  • phase transformation
  • thermophysical properties
  • SEM/ EDS/ EBSD and TEM microstructure analysis
  • residual stresses
  • thermal stability
  • D-gun and HVOF ultrasonic metallization spraying
  • ARC, plasma, and cold spraying
  • PVD and CVD synthesis process
  • additive manufacturing
  • powder characterization

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Published Papers (11 papers)

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Editorial

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4 pages, 207 KiB  
Editorial
Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings
by Cezary Senderowski
Materials 2022, 15(23), 8408; https://doi.org/10.3390/ma15238408 - 25 Nov 2022
Viewed by 1238
Abstract
The production of intermetallic and ceramic protective coatings can be relatively simple, beneficial, and highly predictable [...] Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)

Research

Jump to: Editorial

9 pages, 5812 KiB  
Article
Impact of an Aluminization Process on the Microstructure and Texture of Samples of Haynes 282 Nickel Alloy Produced Using the Direct Metal Laser Sintering (DMLS) Technique
by Jarosław Mizera, Bogusława Adamczyk-Cieślak, Piotr Maj, Paweł Wiśniewski, Marcin Drajewicz and Ryszard Sitek
Materials 2023, 16(14), 5108; https://doi.org/10.3390/ma16145108 - 20 Jul 2023
Cited by 4 | Viewed by 1090
Abstract
In this study, we examined the effects of an aluminization process on the microstructure and texture of Haynes 282 nickel samples fabricated using the direct metal laser sintering technique. The aluminization process involved the use of chemical vapor deposition with AlCl3 vapors [...] Read more.
In this study, we examined the effects of an aluminization process on the microstructure and texture of Haynes 282 nickel samples fabricated using the direct metal laser sintering technique. The aluminization process involved the use of chemical vapor deposition with AlCl3 vapors in a hydrogen atmosphere at a temperature of 1040 °C for 8 h. Following the 3D printing and aluminization steps, we analyzed the microstructure of the Haynes 282 nickel alloy samples using light microscopy and scanning electron microscopy. Additionally, we investigated the texture using X-ray diffractometry. A texture analysis revealed that after the process of direct laser sintering of metals, the texture of the Haynes 282 nickel alloy samples developed a texture typical of cast materials. Then, in the aluminization process, the texture was transformed—from foundry-type components to a texture characteristic of recrystallization. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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16 pages, 21052 KiB  
Article
Effect of APS Spraying Parameters on the Microstructure Formation of Fe3Al Intermetallics Coatings Using Mechanochemically Synthesized Nanocrystalline Fe-Al Powders
by Cezary Senderowski, Nataliia Vigilianska, Oleksii Burlachenko, Oleksandr Grishchenko, Anatolii Murashov and Sergiy Stepanyuk
Materials 2023, 16(4), 1669; https://doi.org/10.3390/ma16041669 - 16 Feb 2023
Cited by 3 | Viewed by 1292
Abstract
The present paper presents a study of the behaviour of Fe3Al intermetallic powders particles based on 86Fe-14Al, 86Fe-14(Fe5Mg), and 60.8Fe-39.2(Ti37.5Al) compositions obtained by mechanochemical synthesis at successive stages of the plasma spraying process: during transfer in the volume of the gas [...] Read more.
The present paper presents a study of the behaviour of Fe3Al intermetallic powders particles based on 86Fe-14Al, 86Fe-14(Fe5Mg), and 60.8Fe-39.2(Ti37.5Al) compositions obtained by mechanochemical synthesis at successive stages of the plasma spraying process: during transfer in the volume of the gas stream and deformation at the moment of impact on the substrate. The effect of the change in current on the size of powder particles during their transfer through the high-temperature stream and the degree of particle deformation upon impact with the substrate was determined. It was found that during transfer through the plasma jet, there was an increase in the average size of sputtering products by two–three times compared to the initial effects of mechanochemical synthesis due to the coagulation of some particles. In this case, an increase in current from 400 to 500 A led to a growth in average particle size by 14–47% due to the partial evaporation of fine particles with an increase in their heating degree. An increase in current also led to a 5–10% growth in particle deformation degree upon impact on the substrate due to the rising temperature and velocity of the plasma jet. Based on the research, the parameters of plasma spraying of mechanically synthesized Fe3Al intermetallic-based powders were determined, at which dense coatings with a thin-lamellar structure were formed. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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13 pages, 21819 KiB  
Article
The Effect of Fe/Al Ratio and Substrate Hardness on Microstructure and Deposition Behavior of Cold-Sprayed Fe/Al Coatings
by You Wang, Nan Deng, Zhenfeng Tong and Zhangjian Zhou
Materials 2023, 16(2), 878; https://doi.org/10.3390/ma16020878 - 16 Jan 2023
Cited by 3 | Viewed by 1658
Abstract
Fe/Al composite coatings with compositions of Fe-25 wt.% Al, Fe-50 wt.% Al and Fe-75 wt.% Al were deposited on pure Al and P91 steel plates by a cold spray, respectively. The microstructure of the cross-section of the fabricated coatings was characterized by SEM [...] Read more.
Fe/Al composite coatings with compositions of Fe-25 wt.% Al, Fe-50 wt.% Al and Fe-75 wt.% Al were deposited on pure Al and P91 steel plates by a cold spray, respectively. The microstructure of the cross-section of the fabricated coatings was characterized by SEM and EDX. The bonding strength between the coatings and substrates was measured and analyzed. The effects of the Fe/Al ratios and substrate hardness on the deposition behavior were investigated. It was interesting to find fragmented zones in all fabricated coatings, which were composed of large integrated Al particles and small fragmented Al particles. Meanwhile, the fraction of fragmented zones varied with the fraction of the actual Fe/Al ratio. An Fe/Al ratio of 50/50 appeared to be an optimized ratio for the higher bonding strength of coatings. The in situ hammer effect caused by larger and harder Fe particles played an important role in the cold spray process. The substrate with the higher hardness strengthened the in situ hammer effect and further improved the bonding strength. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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18 pages, 7133 KiB  
Article
Effects of Heat and Momentum Gain Differentiation during Gas Detonation Spraying of FeAl Powder Particles into the Water
by Cezary Senderowski, Andrzej J. Panas, Bartosz Fikus, Dariusz Zasada, Mateusz Kopec and Kostyantyn V. Korytchenko
Materials 2021, 14(23), 7443; https://doi.org/10.3390/ma14237443 - 4 Dec 2021
Cited by 6 | Viewed by 1798
Abstract
In this paper, dynamic interactions between the FeAl particles and the gaseous detonation stream during supersonic D-gun spraying (DGS) conditions into the water are discussed in detail. Analytical and numerical models for the prediction of momentum and complex heat exchange, that includes radiative [...] Read more.
In this paper, dynamic interactions between the FeAl particles and the gaseous detonation stream during supersonic D-gun spraying (DGS) conditions into the water are discussed in detail. Analytical and numerical models for the prediction of momentum and complex heat exchange, that includes radiative effects of heat transfer between the FeAl particle and the D-gun barrel wall and phase transformations due to melting and evaporation of the FeAl phase, are analyzed. Phase transformations identified during the DGS process impose the limit of FeAl grain size, which is required to maintain a solid state of aggregation during a collision with the substrate material. The identification of the characteristic time values for particle acceleration in the supersonic gas detonation flux, their convective heating and heat diffusion enable to assess the aggregation state of FeAl particles sprayed into water under certain DGS conditions. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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13 pages, 8138 KiB  
Article
Nondestructive Methodology for Identification of Local Discontinuities in Aluminide Layer-Coated MAR 247 during Its Fatigue Performance
by Dominik Kukla, Mateusz Kopec, Kehuan Wang, Cezary Senderowski and Zbigniew L. Kowalewski
Materials 2021, 14(14), 3824; https://doi.org/10.3390/ma14143824 - 8 Jul 2021
Cited by 7 | Viewed by 2376
Abstract
In this paper, the fatigue performance of the aluminide layer-coated and as-received MAR 247 nickel superalloy with three different initial microstructures (fine grain, coarse grain and column-structured grain) was monitored using nondestructive, eddy current methods. The aluminide layers of 20 and 40 µm [...] Read more.
In this paper, the fatigue performance of the aluminide layer-coated and as-received MAR 247 nickel superalloy with three different initial microstructures (fine grain, coarse grain and column-structured grain) was monitored using nondestructive, eddy current methods. The aluminide layers of 20 and 40 µm were obtained through the chemical vapor deposition (CVD) process in the hydrogen protective atmosphere for 8 and 12 h at the temperature of 1040 °C and internal pressure of 150 mbar. A microstructure of MAR 247 nickel superalloy and the coating were characterized using light optical microscopy (LOM), scanning electron microscopy (SEM) and X-ray energy dispersive spectroscopy (EDS). It was found that fatigue performance was mainly driven by the initial microstructure of MAR 247 nickel superalloy and the thickness of the aluminide layer. Furthermore, the elaborated methodology allowed in situ eddy current measurements that enabled us to localize the area with potential crack initiation and its propagation during 60,000 loading cycles. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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16 pages, 9561 KiB  
Article
Phase Structure Evolution of the Fe-Al Arc-Sprayed Coating Stimulated by Annealing
by Tomasz Chmielewski, Marcin Chmielewski, Anna Piątkowska, Agnieszka Grabias, Beata Skowrońska and Piotr Siwek
Materials 2021, 14(12), 3210; https://doi.org/10.3390/ma14123210 - 10 Jun 2021
Cited by 11 | Viewed by 2089
Abstract
The article presents the results of research on the structural evolution of the composite Fe-Al-based coating deposited by arc spray with initial low participation of in situ intermetallic phases. The arc spraying process was carried out by simultaneously melting two different electrode wires, [...] Read more.
The article presents the results of research on the structural evolution of the composite Fe-Al-based coating deposited by arc spray with initial low participation of in situ intermetallic phases. The arc spraying process was carried out by simultaneously melting two different electrode wires, aluminum and low alloy steel (98.6 wt.% of Fe). The aim of the research was to reach protective coatings with a composite structure consisting of a significant participation of FexAly as intermetallic phases reinforcement. Initially, synthesis of intermetallic phases took place in situ during the spraying process. In the next step, participation of FexAly fraction was increased through the annealing process, with three temperature values, 700 °C, 800 °C, and 900 °C. Phase structure evolution of the Fe-Al arc-sprayed coating, stimulated by annealing, has been described by means of SEM images taken with a QBSD backscattered electron detector and by XRD and conversion electron Mössbauer spectroscopy (CEMS) investigations. Microhardness distribution of the investigated annealed coatings has been presented. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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17 pages, 3216 KiB  
Article
A Proposal for a Composite with Temperature-Independent Thermophysical Properties: HfV2–HfV2O7
by Philipp Keuter, Anna L. Ravensburg, Marcus Hans, Soheil Karimi Aghda, Damian M. Holzapfel, Daniel Primetzhofer and Jochen M. Schneider
Materials 2020, 13(21), 5021; https://doi.org/10.3390/ma13215021 - 7 Nov 2020
Cited by 5 | Viewed by 2655
Abstract
The HfV2–HfV2O7 composite is proposed as a material with potentially temperature-independent thermophysical properties due to the combination of anomalously increasing thermoelastic constants of HfV2 with the negative thermal expansion of HfV2O7. Based on [...] Read more.
The HfV2–HfV2O7 composite is proposed as a material with potentially temperature-independent thermophysical properties due to the combination of anomalously increasing thermoelastic constants of HfV2 with the negative thermal expansion of HfV2O7. Based on literature data, the coexistence of both a near-zero temperature coefficient of elasticity and a coefficient of thermal expansion is suggested for a composite with a phase fraction of approximately 30 vol.% HfV2 and 70 vol.% HfV2O7. To produce HfV2–HfV2O7 composites, two synthesis pathways were investigated: (1) annealing of sputtered HfV2 films in air to form HfV2O7 oxide on the surface and (2) sputtering of HfV2O7/HfV2 bilayers. The high oxygen mobility in HfV2 is suggested to inhibit the formation of crystalline HfV2–HfV2O7 composites by annealing HfV2 in air due to oxygen-incorporation-induced amorphization of HfV2. Reducing the formation temperature of crystalline HfV2O7 from 550 °C, as obtained upon annealing, to 300 °C using reactive sputtering enables the synthesis of crystalline bilayered HfV2–HfV2O7. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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11 pages, 10400 KiB  
Article
Thermal Barrier Stability and Wear Behavior of CVD Deposited Aluminide Coatings for MAR 247 Nickel Superalloy
by Dominik Kukla, Mateusz Kopec, Zbigniew L. Kowalewski, Denis J. Politis, Stanisław Jóźwiak and Cezary Senderowski
Materials 2020, 13(17), 3863; https://doi.org/10.3390/ma13173863 - 1 Sep 2020
Cited by 16 | Viewed by 3146
Abstract
In this paper, aluminide coatings of various thicknesses and microstructural uniformity obtained using chemical vapor deposition (CVD) were studied in detail. The optimized CVD process parameters of 1040 °C for 12 h in a protective hydrogen atmosphere enabled the production of high density [...] Read more.
In this paper, aluminide coatings of various thicknesses and microstructural uniformity obtained using chemical vapor deposition (CVD) were studied in detail. The optimized CVD process parameters of 1040 °C for 12 h in a protective hydrogen atmosphere enabled the production of high density and porosity-free aluminide coatings. These coatings were characterized by beneficial mechanical features including thermal stability, wear resistance and good adhesion strength to MAR 247 nickel superalloy substrate. The microstructure of the coating was characterized through scanning electron microscopy (SEM), X-ray energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) analysis. Mechanical properties and wear resistance of aluminide coatings were examined using microhardness, scratch test and standardized wear tests, respectively. Intermetallic phases from the Ni-Al system at specific thicknesses (20–30 µm), and the chemical and phase composition were successfully evaluated at optimized CVD process parameters. The optimization of the CVD process was verified to offer high performance coating properties including improved heat, adhesion and abrasion resistance. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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17 pages, 5162 KiB  
Article
Influence of Anodization Temperature on Geometrical and Optical Properties of Porous Anodic Alumina(PAA)-Based Photonic Structures
by Ewelina Białek, Maksymilian Włodarski and Małgorzata Norek
Materials 2020, 13(14), 3185; https://doi.org/10.3390/ma13143185 - 16 Jul 2020
Cited by 15 | Viewed by 2726
Abstract
In this work, the influence of a wide range anodizing temperature (5–30 °C) on the growth and optical properties of PAA-based distributed Bragg reflector (DBR) was studied. It was demonstrated that above 10 °C both structural and photonic properties of the DBRs strongly [...] Read more.
In this work, the influence of a wide range anodizing temperature (5–30 °C) on the growth and optical properties of PAA-based distributed Bragg reflector (DBR) was studied. It was demonstrated that above 10 °C both structural and photonic properties of the DBRs strongly deteriorates: the photonic stop bands (PSBs) decay, broaden, and split, which is accompanied by the red shift of the PSBs. However, at 30 °C, new bands in transmission spectra appear including one strong and symmetric peak in the mid-infrared (MIR) spectral region. The PSB in the MIR region is further improved by a small modification of the pulse sequence which smoothen and sharpen the interfaces between consecutive low and high refractive index layers. This is a first report on PAA-based DBR with a good quality PSB in MIR. Moreover, it was shown that in designing good quality DBRs a steady current recovery after subsequent application of high potential (UH) pulses is more important than large contrast between low and high potential pulses (UH-UL contrast). Smaller UH-UL contrast helps to better control the current evolution during pulse anodization. Furthermore, the lower PSB intensity owing to the smaller UH-UL contrast can be partially compensated by the higher anodizing temperature. Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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11 pages, 3745 KiB  
Communication
A Novel Microstructural Evolution Model for Growth of Ultra-Fine Al2O3 Oxides from SiO2 Silica Ceramic Decomposition during Self-Propagated High-Temperature Synthesis
by Mateusz Kopec, Stanisław Jóźwiak and Zbigniew L. Kowalewski
Materials 2020, 13(12), 2821; https://doi.org/10.3390/ma13122821 - 23 Jun 2020
Cited by 3 | Viewed by 2343
Abstract
In this paper, experimental verification of the microstructural evolution model during sintering of aluminum, iron and particulate mullite ceramic powders using self-propagated high-temperature synthesis (SHS) was performed. The powder mixture with 20% wt. content of reinforcing ceramic was investigated throughout this research. The [...] Read more.
In this paper, experimental verification of the microstructural evolution model during sintering of aluminum, iron and particulate mullite ceramic powders using self-propagated high-temperature synthesis (SHS) was performed. The powder mixture with 20% wt. content of reinforcing ceramic was investigated throughout this research. The mixed powders were cold pressed and sintered in a vacuum at 1030 °C. The SHS reaction between sintered feed powders resulted in a rapid temperature increase from the heat generated. The temperature increase led to the melting of an aluminum-based metallic liquid. The metallic liquid infiltrated the porous SiO2 ceramics. Silicon atoms were transited into the intermetallic iron–aluminum matrix. Subsequently, a ternary matrix from the Fe–Al–Si system was formed, and synthesis of the oxygen and aluminum occurred. Synthesis of both these elements resulted in formation of new, fine Al2O3 precipitates in the volume of matrix. The proposed microstructural evolution model for growth of ultra-fine Al2O3 oxides from SiO2 silica ceramic decomposition during SHS was successfully verified through scanning electron microscopy (SEM), X-ray energy-dispersive spectroscopy (EDS) analysis and X-ray diffraction (XRD). Full article
(This article belongs to the Special Issue Synthesis, Properties and Applications of Intermetallics, Ceramic and Cermet Coatings)
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