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A Comprehensive Review of Design and Development of Advanced Tailored Material on Sustainability Aspects
Published in Sarbjeet Kaushal, Ishbir Singh, Satnam Singh, Ankit Gupta, Sustainable Advanced Manufacturing and Materials Processing, 2023
Saurabh Rai, Subodh Kumar, Ankit Gupta
Plasma spraying is a thermal spraying procedure that melts and accelerates small particles onto a prepared surface using a high-energy heat source (Łatka et al. 2020). These molten particles (droplets) cool and solidify quickly upon impact due to heat transmission to the underlying substrate, forming a lamellae-like covering through accumulation. Flame spraying, plasma spraying, high-velocity oxygen fuel (HVOF), vacuum plasma spraying, arc metallization, and detonation gun spraying are the most common thermal spraying procedures. The process has been successfully used to manufacture bioactive bioceramic coatings on metal substrates, and flame spraying, HVOF spraying, and plasma spraying (Heimann 2007).
AN EXPERIMENTAL STUDY TO FIND THE SUITABILITY OF D-GUN BASED COATINGS FOR SILT AFFECTED UNDERWATER HYDEL COMPONENTS
Published in C.V.J. Varma, B.S.K. Naidu, A.R.G. Rao, Silting Problems in Hydro Power Plants, 2020
D. MAHESHWAR REDDY, S.R. RATHORE
Thermal spraying is a widely used technique for a variety of applications to combat wear, erosion and corrosion. In this paper the Detonation Gun (D-Gum) was chosen as a spray technique because of its novelty in providing impressive and smooth coatings with extremely high bond strength between coating and substrate. In view of these advantages, post coating heat treatment often followed for conventional thermal spray coating technique can be avoided, thereby making the process simple and cost effective. In view of this advantage the D-gun technique has been adopted to combat silt erosion problem existing in hydel components. In the present work D-gun based coatings were applied on test coupons and subjected to microstructure evaluation, micro hardness and XRD analysis. Coating performance was evaluated by subjecting the coupon to simulated silt erosion conditions. The D-gun coating of WC-12 Co materials show superior performance compared to the corresponding base material i.e. 13 Cr-4Ni steel used normally for hydel under water components.
Introduction to Friction Surfacing
Published in B. Ratna Sunil, Surface Engineering by Friction-Assisted Processes, 2019
Due to the adhesion, inter-diffusion and mechanical interlocking, a sound coating is developed. These kinds of coatings are different from the spray atomization and behave similar to that of overlay coatings. Coating material can be used in the form of powder, wire or rod. However, depending on the type of coating material, the material feed mechanism is altered. The level of dilution is minimum or completely eliminated, and therefore, the substrate is unaffected. Wide variety of materials (metals, non-metals, plastics, and ceramics) can be coated. Usual thickness that can be obtained from thermal spraying ranges from 0.1 to 1 mm. Thermal barrier coatings, abrasive resistance coatings, restoration of dimensions and surface coatings in medical applications are a few examples Where thermal spraying play vital role. Flame spraying, ceramic rod spraying, electric arc spraying, plasma spraying, detonation gun spraying and high-velocity oxy-fuel (HVOF) spraying are a few best known thermal spraying processes.
Characteristics of Thermally Sprayed Alumina-Titania Ceramic Coatings obtained from Conventional and Nanostructured Powders - A Review
Published in Australian Journal of Mechanical Engineering, 2023
Mohammed Thalib Basha G, Venkateshwarlu Bolleddu
In thermal spraying, the consumables in wire or powder form are typically introduced into a high temperature and high-velocity gas jet which melts and sprays the feedstock onto the substrate. Flame, electric arc, plasma gas, and high-velocity oxy-fuel (HVOF) spraying processes constitute some of the widely used thermal spray processes. Importantly, almost any material including metals, ceramics, and polymers can be thermally sprayed as long as it melts upon heating without extensive degradation or vaporisation (Little)(Little 1979), (Longo)(Longo 1985), (Budinski K.G)(Budinski 1988). In addition, the low substrate temperatures ensure that thermal stresses induced distortions are not much significant. Thermal spraying processes were also used extensively in hi-tech industries like aerospace, nuclear energy as well as conventional industries like textiles, chemicals, plastics, and paper industries. Materials commonly deposited using APS as well as HVOF processes and their corresponding applications are listed in Table 2. The comparison of different parameters for various types of thermal spraying process are shown in Table 3.
Performance of thermal-sprayed coatings to combat hot corrosion of coal-fired boiler tube and effect of process parameters and post-coating heat treatment on coating performance: a review
Published in Surface Engineering, 2021
Santosh Kumar, Amit Handa, Vikas Chawla, Neel Kanth Grover, Rakesh Kumar
Thermal spraying can be utilized to provide resistance against hot corrosion, oxidation, erosion, wear, bacteria, chemicals, etc. However, certain thermal spray techniques (cold spray) can be used as an additive manufacturing method to restore damaged parts or to fabricate standing-free parts. Owing to these advantages, thermal spray coatings are widely utilized in energy (thermal /nuclear power plant), aerospace, medical, automotive and marine industries [36]. These processes used distinct coating materials such as metals, ceramics, carbides, nano-structured powders, polymers, metal matrix composites and non-metallic substrates [37]. A brief summary of the materials system for thermal-sprayed coatings (especially cold spray) along with their application and merits is given in Table 9.
FeCrNiMnAl high-entropy alloy coating by spray deposition and thermite reaction
Published in Surface Engineering, 2019
Gang Chen, Lihua Zhu, Shucheng Shen, Chengshang Zhou
The current preparation methods for HEA coatings are laser cladding [8,9], magnetron sputtering [10,11] and thermal spraying [12,13]. Laser cladding technology has fairly good prospects in applications such as surface repair and protection of turbine blades [14], marine propellers [15] and hydraulic turbines [16], owing to a fast cooling rate which leads to high bonding strength and fine crystal grain size. Magnetron sputtering as a method of preparation of ultrathin HEA films provides unique advantages, such as a reduced temperature spike of the substrate and uniform structure of the coating [17,18]. Thermal spraying is a process with good adaptability and high efficiency. Coatings developed by thermal spraying have the advantages of high temperature resistance and wear resistance. However, these methods generally require considerable investment in equipment and high energy consumption, and result in low yields.