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4,311 papers
Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

Andrew Ang, Thibaut Archer, Farzam Arhami, Mettupalayam Balachander et al.

Abstract Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most …

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Hastelloy C276-NbC Composite Coatings: Outlining Their Features from a Macro- to Microscale

Alex Pizzatto, Gabriel Schimunda Gawlak, Emilly Rossi Parizoto, Moisés Felipe Teixeira et al.

Abstract The synthesis of composite coatings by laser cladding has been extensively researched, although it still has some inherent challenges, such as the non-uniform distribution of reinforcement particles and microstructure predictability. This work focused on a macro- and microscale evaluation of Hastelloy C276 TM reinforced with 10, 30, and 50% NbC. The characterization…

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Corrosion Behavior of Cold-Sprayed 316L Coatings: Effects of Deposition Temperature and Surface Condition

Brenda Juliet Martins Freitas, Vinicius Gustavo da Cruz, Alexandre Romão Costa Nascimento, Luc Pouliot et al.

Abstract The passivation behavior of cold-sprayed 316L stainless steel coatings deposited onto SAE 1020 carbon steel was investigated with particular emphasis on the influence of surface condition and deposition temperature. Coatings produced at gas temperatures of 650-825 °C exhibited thicknesses of ~ 450-520 µ m and porosity levels of ~ 5-7 vol.%, with microstructures charact…

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Nozzle Geometry Optimization for Aerosol Deposition by 3D Computational Fluid Dynamics Simulations

Julio Gutiérrez de Frutos, Andreas Elsenberg, Luca Bachnick, Frank Gärtner et al.

Abstract In aerosol deposition, fine ceramic powders in sizes of less than typically 5 μm are deposited as a coating at room temperature. Aerosol deposition must be performed under a vacuum to apply such fine powders and avoid bow shock effects. According to experimental results, coating formation by aerosol deposition only occurs if particle velocities exceed a material-specif…

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Numerical Model of a Hydrogen-Fueled HVOF Thermal Spray Process

Benedikt Biller, Alexander Bußmann, Olivier Messe, Marcus Giglmaier et al.

Abstract The present study introduces and validates a comprehensive numerical model for hydrogen-fueled high-velocity oxygen-fuel (HVOF) spraying of tungsten carbide-cobalt-chromium (WC-Co-Cr) powder. We conduct three-dimensional (3D), two-way coupled simulations of the reactive, particle-laden flow within the DJ2600 thermal spray gun and its supersonic exhaust jet. The model i…

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Validation of a Digital Twin for Cold Spray Supersonic Deposition: A Literature-Based Case Study for Melt-less Additive Manufacture of IN718

Muhammad Faizan-Ur-Rab, Saden H. Zahiri

Abstract Cold spray is a coating process as well as rapidly emerging and scalable solid-state robotic additive manufacturing technology. Its high deposition rates (+10 kg/hr) allow for manufacturing of near net shape large metal and composite structures. For example, it is possible to additive manufacture near net shape IN718 parts directly from powder in addition to coating an…

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