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Alloy 625 is a Ni-based superalloy which is often a good solution to surface engineering problems involving high temperature corrosion, wear, and thermal degradation. Coatings of alloy 625 can be efficiently deposited by thermal spray methods such as Air Plasma Spraying. As in all thermal spray processes, the final properties of the coatings are determined by the spraying parameters. In the present study, a D-optimal experimental design was used to characterize the effects of the APS process parameters on in-flight particle temperature and velocity, and on the oxide content and porosity in the coatings. These results were used to create an empirical model to predict the optimum deposition conditions. A second set of coatings was then deposited to test the model predictions. The optimum spraying conditions produced a coating with less than 4% oxide and less than 2.5% porosity. The process parameters which exhibited the most important effects directly on the oxide content in the coating were particle size, spray distance, and Ar flow rate. The parameters with the largest effects directly on porosity were spray distance, particle size, and current. The particle size, current, and Ar flow rate have an influence on particle velocity and temperature but spray distance did not have a significant effect on either of those characteristics. Thus, knowledge of the in-flight particle characteristics alone was not sufficient to control the final microstructure. The oxidation index and the melting index incorporate all the parameters that were found to be significant in the statistical analyses and correlate well with the measured oxide content and porosity in the coatings.

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Climbing lizards display numerous advanced features in their locomotion, notably a method to quickly switch between a state of low and high adhesive force capacity. Inspired by the gecko's adhesive switching, a method of mechanically switching between low and high adhesive states is reported. In particular, the first switching of an adhesive system using only a change in system compliance is demonstrated. Mechanical clamping and a novel magnetic clamping system are used to switch an iron/PDMS composite adhesive between a soft and rigid state. The switch in compliance directly influences the maximum load of the adhesive as meas-ured in lap-shear. Notably, contact area and the contact chemistry remain unaltered despite significant changes in force capacity. The demonstration of a compliance-only switching mechanism has broad implications for understanding natural adhesive systems-especially in organisms that can dynamically alter their rigidity (e.g. cells).

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Metallic coatings using thermal spraying techniques are widely applied to structural steels to protect infrastructure against corrosion and improve durability of the associated structures for longer service life. The thermal sprayed metallic coatings consisting of various metals, although have higher corrosion resistance, will still corrode in a long run and may also subject to corrosion induced damages such as cracks. Corrosion and the induced damages on the metallic coatings will reduce the effectiveness of the coatings for protection of the structures. Timely repair on these damaged metallic coatings will significantly improve the reliability of protected structures again deterioration. In this paper, an inline detection system for corrosion and crack detection was developed using fiber Bragg (FBG) grating sensors. Experimental results from laboratory accelerated corrosion tests showed that the developed sensing system can quantitatively detect corrosion rate of the coating, corrosion propagations, and cracks initialized in the metallic coating in real time. The developed system can be used for real-time corrosion detection of coated metal structures in field.

In this article, a recently proposed long-period fiber grating sensor coated with a thin layer of polyurethane and nano iron/silica particles is further developed and applied to monitor the corrosion process of deformed steel bars. Once calibrated, one coated long-period fiber grating sensor and one uncoated long-period fiber grating sensor for environmental compensation were attached to each of three steel bar samples that were tested in 3.5 wt% NaCl solution for 512 h. The resonant wavelength in long-period fiber grating spectra increased exponentially with immersion time due to corrosion of iron particles and thus reduction in coating thickness. The mass loss rate of steel bar #1 at the completion of corrosion tests (512 h of corrosion time) was correlated with that of sparse iron particles on long-period fiber grating sensor #1 after 130.5 h of immersion. The corrosion rates of long-period fiber grating sensors #2 and #3 were evaluated at 130.5 h and then used as a prediction of the corrosion rates of steel bars #2 and #3. The predicted corrosion rates by the long-period fiber grating sensors #2 and #3 were finally compared with those by potentiodynamic tests. The maximum mass loss prediction error by the long-period fiber grating sensors #2 and #3 is 26%. The coefficients of variation of three corrosion rate measurements are 0.049 by the long-period fiber grating sensors and 0.115 by the potentiodynamic tests, indicating more consistent and reliable measurements with the proposed technology.