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Recent Advances in Thermal Spraying Technology
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Recent Advances in Thermal Spraying Technology

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 February 2023) | Viewed by 5250

Special Issue Editor

Dr. Pawel Sokolowski

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, 50-370 Wroclaw, Poland
Interests: thermal spraying; powders; liquid feedstocks; thermal barrier coatings; hardfacing; additive manufacturing; mechanical properties; thermophysical properties

Special Issue Information

Dear Colleagues,

Thermal spraying of liquid feedstocks (SPS, SPPS, S-HVOF) has recently garnered considerable interest in depositing different coating materials due to the interesting functional properties of the obtained ceramic, polymer, and cermet coatings. The material coatings sprayed using liquid feedstocks could have many potential applications in the biomedical field, high temperature environment, and as anti-microbial, photocatalytic and corrosion-resistnat coatings etc. This Special Issue shall cover the recent research works in the field of liquid feedstocks thermal spraying of functional coating materials. The topics of the Special Issue include but are not limited to:

  • Novel feedstock materials, including: multi-material feedstocks, hybrid feedstocks, tailor-made compositions, nano-feedstocks etc.
  • Recent advances and applications of liquid feedstocks thermal spraying such as:
  • Bioactive and functionaly graded coatings
  • Anti-microbial coatings
  • Photocatalytic coatings
  • Hyrophobic and super-hydrophobic coatings
  • Thermal barrier coatings, Environmental barrier coatings
  • Anti-corrosion or corrosion-resistant coatings
  • Anti-wear coatings
  • Others
  • Numerical or simulation studies of liquid feedstocks thermal spray processes
  • Recent advances in characterizations of microstructure and properties of liquid feedstocks thermal sprayed coatings
  • Recent advances in the diagnostic analysis in the: droplet-thermal (jet) interactions, droplet-substrate interactions etc.

Dr. Pawel Sokolowski
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Published Papers (3 papers)

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Research

16 pages, 16075 KiB  
Article
Solution Precursor Plasma Spraying of TiO2 Coatings Using a Catalyst-Free Precursor
by Key Simfroso, Shena Ramyr Cabo, Romnick Unabia, Angelito Britos, Paweł Sokołowski and Rolando Candidato, Jr.
Materials 2023, 16(4), 1515; https://doi.org/10.3390/ma16041515 - 11 Feb 2023
Cited by 1 | Viewed by 1667
Abstract
The microstructural characteristics and phase composition of solution precursor plasma-sprayed (SPPS) titania-based coatings using a catalyst-free precursor are reported in this work. An ethanol-based solution containing titanium isopropoxide was used to deposit TiO2 coatings. The thermal behavior of the solution precursor changed [...] Read more.
The microstructural characteristics and phase composition of solution precursor plasma-sprayed (SPPS) titania-based coatings using a catalyst-free precursor are reported in this work. An ethanol-based solution containing titanium isopropoxide was used to deposit TiO2 coatings. The thermal behavior of the solution precursor changed as its phase transformation temperature increased when the molar concentration was increased from 0.3 M to 0.6 M. Scanning electron micrographs showed that the surface of the coatings was composed of nano- and submicron-sized spherical particles (<1 μm) with sintered and melted particles. The cross-sections showed a porous structure using lower concentrations and dense coating formation with micropores using higher concentrations, with thicknesses of about 5 µm–8 µm. Moreover, the coatings when the number of spray passes was increased were 16 µm–20 µm thick, giving an average layer thickness of 0.6 µm deposited per spray pass in all cases. Phase analysis revealed the presence of both the anatase and rutile phases of TiO2 in coatings sprayed with various concentrations at various stand-off distances. More detailed discussion is presented with respect to the effects of the solution concentration, stand-off distance, and number of spray passes on the coating’s phase composition and microstructure. Full article
(This article belongs to the Special Issue Recent Advances in Thermal Spraying Technology)
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12 pages, 4453 KiB  
Article
Condition Monitoring of a Three-Cathode Cascaded Plasma Spray Torch Regarding Process Reliability
by Georg Mauer, Frank Kurze, Karl-Heinz Rauwald and Robert Vaßen
Materials 2022, 15(18), 6203; https://doi.org/10.3390/ma15186203 - 6 Sep 2022
Cited by 1 | Viewed by 1112
Abstract
The TriplexPro™-210 plasma spray torch (Oerlikon Metco) is a three-cathode plasma generator. It became a kind of workhorse for the wide range of tasks handled at the Jülich Thermal Spray Center (JTSC). Compared to conventional single-cathode torches, the cascaded design of the nozzle [...] Read more.
The TriplexPro™-210 plasma spray torch (Oerlikon Metco) is a three-cathode plasma generator. It became a kind of workhorse for the wide range of tasks handled at the Jülich Thermal Spray Center (JTSC). Compared to conventional single-cathode torches, the cascaded design of the nozzle suggests low fluctuations of the arc and thus high stability. However, after a certain time, degradation sets in even with such a torch, impairing the reliability of the process. It is therefore important to detect indications of performance loss in time and not only during the inspection of the deposited layer. In this study, standard samples of YSZ thermal barrier coatings were sprayed regularly over a period of two years. Operational data and feedstock characteristics were collected and correlated with the area-specific mass deposition. It turned out that the measured substrate surface temperature showed a distinct correlation. Searching for the reasons for the temperature variations, several process parameters could be ruled out as they are monitored by calibrated sensors, controlled, and their time course is recorded by the control unit. Moreover, there are other parameters, which can have a considerable impact such as the robot alignment or the substrate cooling conditions. However, the purposeful experimental variation of such variables resulted in a variability of the mass deposition being considerably smaller than observed over the two years. Thus, it can be concluded that torch degradation had a pronounced effect, too. The substrate surface temperature can be used as indicator for the torch status and the reliability of the spray process. Full article
(This article belongs to the Special Issue Recent Advances in Thermal Spraying Technology)
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10 pages, 13733 KiB  
Article
Application of Copper Thermal Spraying for Electrical Joints between Superconducting Nb3Sn Cables
by Vincenzo D’Auria, Pierluigi Bruzzone, Mickael Sebastian Meyer, Enrique Rodriguez Castro and Stefano Sgobba
Materials 2022, 15(1), 125; https://doi.org/10.3390/ma15010125 - 24 Dec 2021
Cited by 2 | Viewed by 2010
Abstract
This manuscript reports on the application of copper thermal spraying in the manufacturing process of an electrical connection between Nb3Sn cables for superconducting magnets of fusion reactors. The joint is realized through diffusion bonding of the sprayed coating of the two [...] Read more.
This manuscript reports on the application of copper thermal spraying in the manufacturing process of an electrical connection between Nb3Sn cables for superconducting magnets of fusion reactors. The joint is realized through diffusion bonding of the sprayed coating of the two cables. The main requirement for such a connection is its electrical resistance, which must be below 1 nΩ at B = 8 T, I = 63.3 kA and T = 4.5 K. Micrographs of the joint prototype were taken to relate the joint resistance with its microstructure and to provide feedback on the manufacturing process. Optical microscopy (OM) was used to evaluate the grain size of the coating, presence of oxide phases and to analyze the jointed surfaces. Scanning electron microscopy (SEM) and, in particular, energy-dispersive X-ray spectroscopy (EDX) were used to confirm the elemental composition of specimens extracted from the prototype. It is shown that the copper coating has an oxide concentration of 40%. Despite this, the resistance of the prototype is 0.48 nΩ in operating conditions, as the oxides are in globular form. The contact ratio between the jointed surfaces is about 95%. In addition, residual resistivity ratio (RRR) measurements were carried out to quantify the electrical quality of the Cu coating. Full article
(This article belongs to the Special Issue Recent Advances in Thermal Spraying Technology)
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