Plasma-Sprayed Al Alloy Coating with Enhanced Lamellar Bonding Through Novel Self-Bonding Strategy

Rashid, Haroon; Dong, Xiaoxin; Wang, Jun; Liao, Xian-Jin; Wei, Ying-Kang; Luo, Xiao-Tao; Li, Chang‐Jiu

doi:10.1007/s11837-020-04394-z

Cited by 3 publications

(11 citation statements)

References 34 publications

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“…For pure Al, the simulation shows that when Al droplet temperature is higher than 1800 o C the substrate surface temperature intact with molten Al thin layer can be heated to over its melting point (Fig. 6) [14]. [11].…”

Section: Self-bonding In Al Coating With a Low Melting Pointmentioning

confidence: 99%

“…Figure6: Effect of molten Al droplet temperature on the interface temperature evolution between molten splat and solid substrate[14].…”

mentioning

confidence: 99%

“…Figure7: Change of Al in-flight spray particle temperature in plasma jet against spray distance[14].…”

mentioning

confidence: 99%

“…Figure 8: Morphology of Al splat deposited on a polished flat Al alloy substrate at a low magnification (a), showing flat reference surface profile (b), and showing wavy interface between splat and substrate with an evident contrast[14].…”

mentioning

confidence: 99%

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Novel Strategy for Developing Bulk-Like Dense Metallic Coatings by Plasma Spraying

Dong

Zhang

et al. 2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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Thermal spray coatings are widely used to protect materials from corrosion, wear, and oxidation, but they have yet to reach their full potential because of porosity limitations and the detrimental effects of oxidation on interlamellar bonding. This paper investigates an atmospheric plasma spraying process that deposits oxide-free dense metallic coatings with well bonded lamellae. The process produces ultrahigh temperature metallic droplets, up to 2650 °C, using specially designed powders that are deoxidized in-flight through the evaporation or gasification of oxides. The impact of these oxide-free ultrahigh temperature droplets has a spreading-fusing, self-metallurgical bonding effect resulting in fully dense bulk-like metallic coatings. Various coating materials, including NiCrMo, 304SS-Mo, NiCrBSi, and Al, are investigated, demonstrating the versatility of the new technique.

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Section: Self-bonding In Al Coating With a Low Melting Pointmentioning

confidence: 99%

“…Figure6: Effect of molten Al droplet temperature on the interface temperature evolution between molten splat and solid substrate[14].…”

mentioning

confidence: 99%

“…Figure7: Change of Al in-flight spray particle temperature in plasma jet against spray distance[14].…”

mentioning

confidence: 99%

mentioning

confidence: 99%

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Novel Strategy for Developing Bulk-Like Dense Metallic Coatings by Plasma Spraying

Dong

Zhang

et al. 2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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“…For pure Al, the simulation shows that when the droplet temperature is higher than 1800 °C the Al substrate surface can be heated to a temperature higher than its melting point by Al molten droplets (Fig. 5 ) (Ref 98 ). The measurement of Al particle temperatures during plasma spraying reveals that most Al particles are heated to a temperature higher than 1800 °C (Fig.…”

Section: Strategy For Developing Bulk-like Metal Coating By Spread-fusing Effect Through Creating Ultra-high Temperature Dropletsmentioning

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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Long-Term Corrosion Behavior of Flame Sprayed Al-Based Coatings After Nano-alumina Sealing Treatment

et al. 2023

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Plasma-Sprayed Al Alloy Coating with Enhanced Lamellar Bonding Through Novel Self-Bonding Strategy

Cited by 3 publications

References 34 publications

Novel Strategy for Developing Bulk-Like Dense Metallic Coatings by Plasma Spraying

Novel Strategy for Developing Bulk-Like Dense Metallic Coatings by Plasma Spraying

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

Long-Term Corrosion Behavior of Flame Sprayed Al-Based Coatings After Nano-alumina Sealing Treatment

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