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Metals
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Modern Cold Spray Technique (Volume II)
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Modern Cold Spray Technique (Volume II)

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 January 2024) | Viewed by 2334

Special Issue Editor

Dr. Alessio Silvello

E-Mail Website
Guest Editor
CPT—Centro de Proyección Térmica (Thermal Spray Center), Universitat de Barcelona, Barcelona, Spain
Interests: cold spray; HEAs, additive manufacturing; stainless steel; Ni-based superalloy; thermal spray process; mechanical properties; fatigue behavior; corrosion; wear
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Cold spray is becoming more and more prominent among thermal spray processes. The possibility to produce thick coatings with low porosity, as well as the absence of any phase transformation during the deposition process, is of great interest to the scientific community. Furthermore, we should not forget the possibility of spraying any type of materials, from steel to Ti and Ni superalloys, and many more. Not only the microstructural and mechanical properties of the coatings, but also the deposition efficiency and geometrical accuracy are key factors for the future success of the process. On these premises, it is no doubt true that cold spray will be the process of the future not only for depositing coatings, but also for producing additive manufactured parts. Consequently, this Special Issue aims to investigate and address the future challenges of cold spray in terms of understanding, improving, modeling, and applying the process in different advanced industrial sectors. Original research articles as well as review papers on the state of the art of the cold spray process are welcome.

Dr. Alessio Silvello
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. Metals is an international peer-reviewed open access monthly 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.

Keywords

  • cold spray
  • powder metallurgy
  • coatings
  • additive manufacturing
  • High-Entropy Alloys (HEAs)
  • wear
  • corrosion
  • fatigue
  • maintenance
  • repair

Published Papers (2 papers)

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Research

15 pages, 2455 KiB  
Article
A Comparative Study of the Life Cycle Inventory of Thermally Sprayed WC-12Co Coatings
by Edwin Rúa Ramirez, Alessio Silvello, Edwin Torres Diaz, Rodolpho Fernando Vaz and Irene Garcia Cano
Metals 2024, 14(4), 431; https://doi.org/10.3390/met14040431 - 6 Apr 2024
Viewed by 1033
Abstract
In this research, a life cycle inventory (LCI) is developed for tungsten carbide–cobalt (WC-Co) coatings deposited via atmospheric plasma spray (APS), high-velocity oxy-fuel (HVOF), and cold gas spray (CGS) techniques. For the APS process, a mixture of Ar/H2 was used, while the [...] Read more.
In this research, a life cycle inventory (LCI) is developed for tungsten carbide–cobalt (WC-Co) coatings deposited via atmospheric plasma spray (APS), high-velocity oxy-fuel (HVOF), and cold gas spray (CGS) techniques. For the APS process, a mixture of Ar/H2 was used, while the HVOF process was fueled by H2. The carrier gas for CGS was N2. This study aims to determine and quantify the inputs (consumption of inputs and materials) and outputs (emissions to air, soil, water, and waste generation) that could be used in the life cycle analysis (LCA) of these processes. The dataset produced will allow users to estimate the environmental impacts of these processes using WC-Co feedstock powder. To obtain a complete and detailed LCI, measurements of electrical energy, gas, WC-CO powder, and alumina powder consumption were performed (the use of alumina was for sandblasting). Furthermore, emissions like carbon dioxide (CO2), carbon monoxide (CO), and noise were also measured. This practice allowed us to determine the input/output process quantities. For the first time, it was possible to obtain LCI data for the APS, HVOF, and CGS deposition processes using WC-12Co as a feedstock powder, allowing access to the LCI data to a broader audience. Comparisons were made between APS, HVOF, and CGS processes in terms of consumption and emissions. It was determined that the APS process consumes more electrical energy and that its deposition efficiency is higher than the other processes, while the HVOF process consumes a large amount of H2, which makes the process costlier. CGS has comparatively low electricity consumption, high N2 consumption, and low deposition efficiency. The APS, HVOF, and CGS processes analyzed in this study do not emit CO, and CO2 emissions are negligible. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique (Volume II))
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18 pages, 68697 KiB  
Article
Understanding the Effect of Substrate Preheating Temperature and Track Spacing on Laser Assisted Cold Spraying of Ti6Al4V
by Dibakor Boruah, Philip McNutt, Deepak Sharma, Henry Begg and Xiang Zhang
Metals 2023, 13(10), 1640; https://doi.org/10.3390/met13101640 - 25 Sep 2023
Cited by 2 | Viewed by 1046
Abstract
In this study, laser-assisted cold spray (LACS) of titanium alloy Ti6Al4V onto Ti6Al4V substrates has been investigated in two phases: (i) single-track deposits on substrates preheated to 400 °C, 600 °C, and 800 °C, respectively, and (ii) single-layer (multi-track) deposits on substrates preheated [...] Read more.
In this study, laser-assisted cold spray (LACS) of titanium alloy Ti6Al4V onto Ti6Al4V substrates has been investigated in two phases: (i) single-track deposits on substrates preheated to 400 °C, 600 °C, and 800 °C, respectively, and (ii) single-layer (multi-track) deposits on substrates preheated to 600 °C with three different track spacings (1 mm, 2 mm, and 3 mm). Cross-sectional microstructures of the single-track deposits showed intimate contact at the interfaces, especially extensive interfacial mixing for specimens with substrate preheating at 600 °C and 800 °C. Cross-sectional area porosity content in single layer LACS coatings was found to be around 0.4%, which is significantly lower than the standard or conventional cold spray (CS) process having ~2.3% porosity. The microstructure reveals that the LACS process has improved the adhesion and cohesion of the deposits, in addition to the other advantages of the CS process. The average microhardness values of LACS deposits were found to be in the range of 388–403 HV (the highest hardness with the lowest track spacing), which is approximately 6–10% lower than that of the CS deposits without laser substrate preheating. Tensile residual stresses were found in all three LACS coatings, which was due to elevated process gas temperature along with high heat input during laser preheating of the substrate. It was observed that the higher the track spacing, the higher the stress magnitude, i.e., 31 MPa, 135 MPa, and 191 MPa in the longitudinal direction when deposited with 1 mm, 2 mm, and 3 mm track spacings, respectively. Heat treatments induced varied microstructures in LACS coatings, encompassing fully equiaxed or lamellar α-phase within the β-phase, or a bimodal microstructure, with characteristics linked to track spacing variations. Key contributions of this study include enhanced coating-substrate adhesion through extensive interfacial mixing, a substantial reduction in cross-sectional area porosity compared to CS, insights into the effects of residual stresses, and, ultimately, advancing the comprehension of LACS and its potential advantages over conventional CS process. Full article
(This article belongs to the Special Issue Modern Cold Spray Technique (Volume II))
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