Modeling and Optimization in Investigating Thermally Sprayed Ni-Based Self-Fluxing Alloy Coatings: A Review

Šimunović, Katica; Havrlišan, Sara; Šarić, Tomislav; Vukelić, Djordje

doi:10.3390/ma13204584

Cited by 21 publications

(9 citation statements)

References 74 publications

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“…However, production in the automotive industry does not only require turbine blades, but other components around the mixture charging of the exhaust side are also under high-temperature stress and require flow-optimized structures [116]. This type of application is also suitable for self-fluxing Ni-based alloy coatings as they are widely used under conditions of wear, corrosion, and high temperatures [117].…”

Section: Automotive Industrymentioning

confidence: 99%

Optimization potentials of laser powder bed fusion: A conceptual approach

Strutz,

Samardžić,

Šimunović

2023

FME Transactions

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Additive manufacturing (AM), more specifically laser powder bed fusion (LPBF), has become increasingly important for the production of complex components. Despite recent improvements, issues with process parameter optimization, multi-material approaches, CAx chain, adaption for automated mass production, automated process planning, and quality control are still major concerns. So far, despite growing interest, the technology has not yet made the leap into everyday and large-scale use. The use of artificial intelligence offers opportunities to solve many of these problems and improve LPBF technology. In this paper, these topics are addressed to give the reader a holistic overview of the potential for optimization. The individual topics are not only explained and supported with example products from various industries but also evaluated in terms of cost-effectiveness and quality improvement. By evaluating the potentials, restrictions, and recommendations, a framework is created for further investigation and practical application of optimization approaches.

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Section: Automotive Industrymentioning

confidence: 99%

Optimization potentials of laser powder bed fusion: A conceptual approach

Strutz,

Samardžić,

Šimunović

2023

FME Transactions

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“…These treatments reduce porosity, homogenize the microstructure, and improve the coating adherence. Also, the use of designed experiments and statistical methods has been widely applied so as to improve the performance of the Ni-based selffluxing alloy coatings that are deposited by flame spraying, high-velocity oxy/air fuel spraying, plasma spraying, plasma-transferred arc welding, and laser cladding processes, as presented in the review of Simunovic et al [31].…”

Section: Introductionmentioning

confidence: 99%

Chemical Composition Effects on the Microstructure and Hot Hardness of NiCrSiFeB Self-Fluxing Alloys Manufactured via Gravity Casting

Niklas,

Santos,

Garcia

et al. 2023

JMMP

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Ni-Cr-Si-Fe-B self-fluxing alloys are commonly used in hardfacing applications; in addition, they are subjected to conditions of wear, corrosion, and high temperatures, but are not used in casting applications. In this work, gravity casting is presented as a potential manufacturing route for these alloys. Three alloys with different chemical compositions were investigated with a focus on microstructure characterization, solidification path, and strengthening mechanisms. Phases and precipitates were characterized using a field emission scanning electron microscope employing energy-dispersive X-ray spectroscopy, wavelength dispersive spectroscopy, and electron backscatter diffraction. Nano- and microhardness indentations were performed at different phases to understand their contribution to the overall hardness of the studied alloys. Hardness measurements were performed at room temperature and high temperature (650 °C). The borides and carbides were the hardest phases in the microstructure, thus contributing significantly to the overall hardness of the alloys. Additional hardening was provided by the presence of hard Ni3B eutectics; however, there was also a small contribution from the solid solution hardening of the γ-Ni dendrites in the high-alloy-grade sample. The amount and size of the different phases and precipitates depended mainly on the contents of the Cr, C, and B of the alloy.

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“…Main processes include spray-fusing, high temperature annealing treatment, laser remelting, and so on. The spray-fusing process was invented along with self-fluxing alloys in the early of last 1950s, applying only to self-fluxing alloys (Ref 1 , 12 , 31 ). Its main features will be mentioned in the later section.…”

Section: Introductionmentioning

confidence: 99%

Recent Research Advances in Plasma Spraying of Bulk-Like Dense Metal Coatings with Metallurgically Bonded Lamellae

Luo

Dong

et al. 2022

J Therm Spray Tech

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Although thermal spray metallic coatings have been widely used for materials protection from wear, corrosion and oxidation, its porous feature limits the full utilization of materials potential. Moreover, the oxidation inherent to thermal spraying in the ambient atmosphere is detrimental to interlamellar bonding formation, which further degrades the performance of thermal spray metal coatings. How to tape out the full potential of spray materials in the form of the coating is a still great challenge to thermal spray coating technology. Facing such challenge, recent efforts have been made to deposit dense metallic coatings with sufficiently bonded lamellae by oxide-free molten droplets through atmospheric plasma spraying. In this paper, the strategies for depositing bulk-like metal coatings will be reviewed. The formation of the bulk-like coating through post-spray treatments is briefly reviewed including post-spray heat treatment and laser remelting following the brief introduction to the features of thermal spray metallic coatings. The effect of the substrate preheating temperature on the splat formation and subsequently the adhesion formation was examined to reveal the dominant limitation of resultant oxide scale. Then, the role of the deposition temperature on the formation of bulk-like metal deposits with neglecting the effect of oxidation during spraying by vacuum plasma spraying practices is shortly presented. The recent progress on the new strategies to develop spread-fusing bonding mechanism and in-situ in-flight deoxidizing mechanism through developing ultra-hot metallic droplets will be introduced. The thermodynamics and kinetics requirements for the in-situ in-flight deoxidizing through deoxidizer elements adding to alloy spray powders for achieving oxide-free molten droplets in the ambient atmosphere are examined. The conditions to develop the spread-fusing mechanism during the spreading of impacting molten metal droplet for metallurgical bonding are presented. It is obvious from this review paper that the realization of two mechanisms depends on both the spray materials design and heating control of in-flight particles. Through the generation of ultra-hot droplets by plasma spraying to achieve oxide-free molten droplets, strategically it will be possible to deposit bulk-like dense metallic coating through spread-fusing of splat surfaces with limited post-spray oxidation. Such strategies will tape out the full potential of coating materials and open up the new application fields for plasma spraying.

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Modeling and Optimization in Investigating Thermally Sprayed Ni-Based Self-Fluxing Alloy Coatings: A Review

Cited by 21 publications

References 74 publications

Optimization potentials of laser powder bed fusion: A conceptual approach

Optimization potentials of laser powder bed fusion: A conceptual approach

Chemical Composition Effects on the Microstructure and Hot Hardness of NiCrSiFeB Self-Fluxing Alloys Manufactured via Gravity Casting

Recent Research Advances in Plasma Spraying of Bulk-Like Dense Metal Coatings with Metallurgically Bonded Lamellae

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