Measurement and analysis of adhesion strength for thermally sprayed coatings

Lin, Chung Kwei; Berndt, C. C.

doi:10.1007/bf02649003

Cited by 105 publications

(39 citation statements)

References 70 publications

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“…The expression above allows for the estimation of required particle acceleration velocity for more moderate heating of particles to prevent undesirable physicochemical transformations. The development of plasma spraying and supersonic flame spraying of coatings has been reported ( Ref 11,[31][32][33][34][35][36]39,[41][42][43][44][45][46][47][48][49][50][51][52][53], and the properties of the coatings produced by these methods are comparable with those of detonation coatings. The HVOF processes similar to the D-gun spraying are based on high-pressure combustion.…”

Section: Introductionmentioning

confidence: 77%

Influence of Detonation Gun Spraying Conditions on the Quality of Fe-Al Intermetallic Protective Coatings in the Presence of NiAl and NiCr Interlayers

Senderowski

Bojar

2009

J Therm Spray Tech

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The paper presents results of detailed research of the application of detonation gun (D-gun) spraying process for deposition of Fe-Al intermetallic coatings in the presence of NiAl and NiCr interlayers. A number of D-gun experiments have been carried out with significant changes in spraying parameters which define the process energy levels (changes in volumes of the working and fuel gases, and the distance and frequency of spraying). These changes directly influenced the quality of the coatings. The initial results underlay the choice of the process parameters with the view to obtain the most advantageous of geometric and physical-mechanical properties of the coating material, interlayer and substrate. The metallurgical quality of the coatings was considered by taking into account grain morphology, the inhomogeneity of chemical content and phase structure, the cohesive porosity in the coating volume, and adhesive porosity in the substrate/interlayer/coating boundaries. The surface roughness level was also considered. It was found that the D-gun sprayed coatings are in all cases built with flat lamellar splats. The splats develop from powder particles which are D-gun transformed in their plasticity and geometry. A significant result of the optimization of D-gun spraying parameters is the lack of signs of melting of the material (even in microareas) while the geometry of the subsequently deposited grains is considerably changed and the adhesivity and cohesion of the layers proves to be high. This is considered as an undeniable proof of high plasticity of the D-gun formed Fe-Al intermetallic coating.

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Section: Introductionmentioning

confidence: 77%

Influence of Detonation Gun Spraying Conditions on the Quality of Fe-Al Intermetallic Protective Coatings in the Presence of NiAl and NiCr Interlayers

Senderowski

Bojar

2009

J Therm Spray Tech

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“…Attempts were also made to measure the indentation fracture toughness of thermal spray coatings using the indentation technique [9]. A surprising result was that these HVOF (JP5000) coatings did not crack at indentation loads as high as 4.9 N (500p).…”

Section: Microhardness Measurementsmentioning

confidence: 99%

“…not normally comparable for various techniques. Readers are referred to Lin and Berndt [9] for a detailed comparison of various available techniques. However, a qualitative comparison between APS and JP5000 (HVOF) coatings can be made by comparing Fig.…”

Section: Microhardness Measurementsmentioning

confidence: 99%

Contact fatigue failure modes of HVOF coatings

Ahmed

2002

Wear

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The objective of this experimental study was to investigate the influence of coating thickness and contact stress fields on the performance and fatigue failure modes of thermal spray (WC-12%Co) HVOF coatings. Results of this study indicate that a non-dimensional coating thickness parameter (∆ = ξ/Ψ ), where ξ is the coating thickness and Ψ the depth of maximum shear stress, can be used as a useful index to optimise coating delamination resistance during Hertzian contact loading. Apart from the detection of a new failure mode (termed spalling), which is a rare failure mode in thermal spray coatings, results indicate that by appropriate control of coating thickness, and tribological conditions, it is possible to achieve a fatigue life in excess of 70 million stress cycles, without failure. This improvement in coating performance was attributed to improved fracture toughness of liquid fuel HVOF (JP5000) coatings. Coating failure was attributed to micro-and macrocracking within the coating microstructure. Thermal spray coatings were deposited by a JP5000 system in three different thicknesses on the surface of 440-C steel substrate cones to vary the depth of shear stress within the Hertzian stress field. Rolling contact fatigue (RCF) tests were conducted using a modified four-ball machine under various tribological conditions of contact stress, configuration and lubrication. Surface observations were made using scanning electron microscope (SEM), surface interferometry and light microscopy, whereas subsurface observations were made using die penetrant investigations.

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“…To ensure the performance of the thermal sprayed coatings for corrosion and damage protection, non-destructive testing can be applied for coating quality evaluation on requests such as electrochemical method, guided wave, acoustic, ultrasonic, and microwave techniques [19][20][21][22][23][24][25][26]. The application of these techniques requires accessing the structures which may not be the case for some off-shore or marine structures.…”

Section: Introductionmentioning

confidence: 99%

Pitted Corrosion Detection of Thermal Sprayed Metallic Coatings Using Fiber Bragg Grating Sensors

et al. 2017

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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.

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Measurement and analysis of adhesion strength for thermally sprayed coatings

Cited by 105 publications

References 70 publications

Influence of Detonation Gun Spraying Conditions on the Quality of Fe-Al Intermetallic Protective Coatings in the Presence of NiAl and NiCr Interlayers

Influence of Detonation Gun Spraying Conditions on the Quality of Fe-Al Intermetallic Protective Coatings in the Presence of NiAl and NiCr Interlayers

Contact fatigue failure modes of HVOF coatings

Pitted Corrosion Detection of Thermal Sprayed Metallic Coatings Using Fiber Bragg Grating Sensors

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