Surface modification of magnesium alloys using thermal and solid-state cold spray processes:Challenges and latest progresses

Potential engineering applications of magnesium(Mg)and Mg-based alloys,as the lightest structural metal,have made them a popular subject of study.However,the inferior corrosion and wear characteristics significantly limit their application range.It is widely recognized that surface treatment is the most commonly utilized technique for remarkably improving a substrate’s surface characteristics.Numerous methods have been introduced for the surface treatment of Mg and Mg-based alloys to improve their corrosion behavior and tribological performance.Among these,thermal spray(TS)technology provides several methods for deposition of various functional metallic,ceramic,cermet,or other coatings tailored to particular conditions.Recent researches have shown the tremendous potential for thermal spray coated Mg alloys for biomedical and industrial applications.In this context,the cold spray(CS)method,as a comparatively new TS coating technique,can generate the coating layer using kinetic energy rather than combined thermal and kinetic energies,like the high-velocity oxy-fuel(HVOF)spray method.Moreover,the CS process,as a revolutionary method,is able to repair and refurbish with a faster turnaround time;it also provides solutions that do not require dealing with the thermal stresses that are part of the other repair processes,such as welding or other TS processes using a high-temperature flame.In this review paper,the recently designed coatings that are specifically applied to Mg alloys(primarily for industrial applications)employing various coating processes are reviewed.Because of the increased utilization of CS technology for both 3D printed(additively manufactured)coatings and repair of structurally critical components,the most recent CS methods for the surface treatment,repair,and refurbishment of Mg alloys as well as their benefits and restrictions are then discussed and reviewed in detail.Lastly,the prospects of this field of study are briefly discussed,along with a summary of the presented work.

DROPLETS AND PARTICLES IN SPRAYS: TAILORING PARTICLE PROPERTIES WITHIN SPRAY PROCESSES

Particle generation via atomization and spray processes is a widely applied method for powder production. By means of atomization processes, the relevant particle properties may be tailored to the powder user's need in a wide range. Understanding and control of the main subprocesses of atomization is a key feature for choosing a suitable type of spray process and operation conditions. Tailoring particle properties and extending the applications of particle production beyond the current limits is also possible in this way. This contribution highlights some features of spray processes for powder production, namely the gas- and fluid-dynamic processes involved, the materials-related subprocesses, and the formation of the multiphase flow in the spray. As an example, the production of fibre- or sphere-shaped particles from melt atomization is discussed.

Spray Atomized and Codeposited Al-Li Based Metal-matrix Composites Processing and Properties

In spray atomization and codeposition, a molten stream of metal is disintegrated into a fine dispersion of droplets by high velocity gas jets. The resulting semi-solidified droplets are directed towards a substrate where they impact and collect as rapidly solidified splats. Relatively high rates of solidification are achieved as a result of the thinness of the splats and the rapid heat extraction during flight and upon impacting with the substrate. The processing method uses codeposition of the metallic semi-solidified droplets (metallic matrix) with the injected reinforcement ceramic particles. In the present paper, the microstructures, mechanical properties, interfacial properties, thermal stability and aging behaviour of spray atomized and codeposited Al-Li-X MMC's (injected X=SiC, Al2O3) are reported and correlated to the processing conditions.

An Investigation of Error Sources in Computational Fluid Dynamics Modelling of a Co-current Spray Dryer

The paper is focused on identifying error sources in computational fluid dynamics(CFD) predictions of a spray drying process. Seven groups of drying and atomisation parameters were selected for analysis and 13simulation trials were performed. The theoretical results were compared with experimental data and sensitivity of the simulation results to the analysed factors was determined. The following parameters affecting the accuracy of CFD spray modelling were found: gas turbulence model, particle dispersion, atomising air, initial parameters of atomisation and heat losses to the environment. A major difference in the errors committed during modelling of spray drying process for fine and coarse sprays was observed.

Hot Deformation Behavior and Processing Map of Spray Formed M3∶ 2 High Speed Steel

Hot deformation behavior of a new type of M3∶ 2 high speed steel with niobium addition made by spray forming was investigated based on compression tests in the temperature range of 950-1 150 ℃ and strain rate of 0. 001-10 s^（-1）. A comprehensive constitutive equation was obtained,which could be used to predict the flow stress at different strains. Processing map was developed on the basis of the flow stress data using the principles of dynamic material model. The results showed that the flow curves were in fair agreement with the dynamic recrystallization model. The flow stresses,which were calculated by the comprehensive constitutive equation,agreed well with the test data at low strain rates（ ≤1 s^（-1））. The material constant（ α）,stress exponent（ n） and the hot deformation activation energy（ Q_（HW）） of the new steel were 0. 006 15 MPa^（-1）,4. 81 and 546 kJ·mol^（-1）,respectively. Analysis of the processing map with an observation of microstructures revealed that hot working processes of the steel could be carried out safely in the domain（ T = 1 050-1 150 ℃,ε = 0. 01- 0. 1 s^（-1））with about 33% peak efficiency of power dissipation（ η）. Cracks was expected in two domains at either lower temperatures（ 〈 1 000 ℃） or low strain rates（ 0. 001 s^（-1）） with different cracking mechanisms. Flow localization occurred when the strain rates exceeded 1 s^（-1） at all testing temperatures.

Reaction mechanism of lanthanum nitrate-doped Mo–La material during solid–liquid spray doping processing

At three critical temperatures which were obtained by thermo-gravimetry-differential thermal analysis–differential scanning calorimetry（TG/DTG/DSC）curves of lanthanum nitrate crystal, the air thermal decomposition experiments and solid–liquid spray doping simulation procedures of lanthanum nitrate crystal were carried out, and their products were analyzed by X-ray diffraction（XRD）. Meanwhile, the spray doping processing of Mo O2–50 wt% La（NO3）3composite powder was undergone with lanthanum nitrate solution as the dopant,and doped Mo O2powder was analyzed by XRD. The results demonstrate that during the traditional solid–liquid spray doping processing, lanthanum nitrate, in the form of either crystal or aqueous solution, would be converted into La（NO3）3á4H2O by the dehydration reaction, rather than be decomposed to La2O3and NO or NO2. Therefore, it is inferred that the oxynitride gas produced from the process is attributed to the decomposition of residual HNO3in lanthanum nitrate crystal. The source of HNO3is supported by the chemical composition of lanthanum nitrate crystal.

Study on ultrasonic spray technology for the coating of vascular stent

The ultrasonic spray technology is studied by the method of theoretical derivation, CFD simulation, spray particle diameter detection and analysis, and experimental analysis. And the ultrasonic spray process for the coating of vascular stent is also optimized. Firstly, the ultrasonic atomization physical model is established and the equation of atomization particle diameter is derived. Secondly, the ultrasonic atomization process is simulated by the CFD method, and shows three atomization patterns： incomplete atomization pattern, critical atomization pattern and jet atomization pattem. The critical amplitude and power equation for ultrasonic atomization is derived. Thirdly, experiment is conducted to study the influence of parameters including power, gas pressure, and surface tension. The results show that the spray is stable though few particles are likely to collide each other during spray moving, and the droplet diameter is about 10μm. The Rosin-Rammler distribution equation for ultrasonic spray is created, and the uniform index number is between 7.11 and 11.48. The uniformity of spray particle diameter, the efficiency of adjustment and the energy consumption are better than traditional spray technology. Lastly, the ultrasonic spray process parameters for stent coating are optimized to eliminate the common defects and obtain fine coating.