HVOF-sprayed HAp/S53P4 BG composite coatings on an AZ31 alloy for potential applications in temporary implants

Bioactive thermal spray coatings produced via high-velocity oxygen fuel spray(HVOF)from hydroxyapatite(HAp)and bioactive glasses(BG)have the potential to be employed on temporary implants due to the ability of both HAp and BG to dissolve and promote osseointegration,considering that both phases have different reaction and dissolution rates under in-vitro conditions.In the present work,75%wt.HAp-25%wt.S53P4 bioactive glass powders were HVOF-sprayed to obtain HAp/S53P4 BG composite coatings on a bioresorbable AZ31 alloy.The study is focused on exploring the effect of the stand-off distance and fuel/oxygen ratio variation as HVOF parameters to obtain stable structural coatings and to establish their effect on the phases and microstructure produced in those coatings.Different characterization techniques,such as scanning electron microscopy,X-ray diffraction,and Fourier transform infrared spectroscopy,were employed to characterize relevant structural and microstructural properties of the composite coatings.The results showed that thermal gradients during coating deposition must be managed to avoid delamination due to the high temperature achieved(max 550℃)and the differences in coefficients of thermal expansion.It was also found that both spraying distance and oxygen/fuel ratio allowed to keep the hydroxyapatite as the main phase in the coatings.In addition,in-vitro electrochemical studies were performed on the obtained HAp/S53P4 BG composite coatings and compared against the uncoated AZ31 alloy.The results showed a significant decrease in hydrogen evolution(at least 98%)when the bioactive coating was applied on the Mg alloy during evaluation in simulated body fluid(SBF).

超音速火焰喷涂(HVOF)多相流瞬时演化机理及敏感性分析

以航空煤油为燃料的超音速火焰喷涂(HVOF)技术在制备WC-Co涂层方面具有独特优势。目前对HVOF热喷涂稳态过程的研究无法揭示燃料液滴在燃烧室中的动态燃烧行为。液体燃料进入燃烧室前需要雾化,量化揭示燃料燃烧反应瞬时演化机理是优化喷涂工艺的关键。基于JP5000喷枪建立HVOF热喷涂过程瞬时演化数值模型。将煤油液滴破碎、气化过程、燃烧反应焰流与喷涂粒子直接耦合。采用双向耦合欧拉-拉格朗日方法跟踪连续相和离散相,以realizable k-ε湍流模型、一步反应涡耗散模型(EDM)表述喷涂燃烧焰流特性。通过KHRT(Kelvin-Helmholtz Rayleigh-Taylor)破碎模型描述航空煤油液滴破碎过程。基于可靠性理论,综合分析煤油液滴直径、氧气/燃料比率及反应物质量流量对喷涂粒子飞行行为的影响。结果表明:氧气/燃料比率对粒子温度影响程度最大,煤油液滴直径对粒子速度影响最大。HVOF瞬时演化模型可以直观呈现燃料的动态行为及喷涂粒子的飞行特性,可为优化热喷涂工艺提供参考和理论支撑。

Preparation and Properties of Spray Polyurea Elastomer for Aquaculture Foam Floating Balls

[Objectives] This study was conducted to develop a polyurea elastomer which can be sprayed on the surface of expanded polystyrene (EPS) floating balls, so as to improve the surface strength and service life of the floating balls. [Methods] The effects of the types and amounts of isocyanate, chain extenders and polyether polyols on the gelation rate, adhesion and wear resistance of polyurea elastomer were investigated, and it was finally determined the preparation process of polyurea elastomer using liquid isophorone diisocyanate (IPDI) and amino-terminated polyether (D2000) as the main raw materials, dimethylthiotoluene diamine (E300) as the chain extender and silica as the wear resistance modifier through two-step solution polymerization of prepolymerization and chain extension. [Results] The physical properties and chemical resistance tests of spray polyurea elastomer showed that it had good physical properties and acid and alkali resistance, and could meet the requirements of spraying and protection of EPS floating ball surface in marine environment. [Conclusions] Polyurea elastomer coating can improve the aging resistance, wear resistance and acid and alkali resistance of EPS floating balls, and prevent them from being fragile and floating randomly to form marine floating garbage which results in "white pollution".

Effect of Spray Rails on Takeoff Performance of Amphibian Aircraft

Amphibian aircraft have seen a rise in popularity in the recreational and utility sectors due to their ability to take off and land on both land and water, thus serving a myriad of purposes, such as aerobatics, surveillance, and firefighting. Such seaplanes must be aerodynamically and hydrodynamically efficient, particularly during the takeoff phase. Naval architects have long employed innovative techniques to optimize the performance of marine vessels, including incorporating spray rails on hulls. This research paper is dedicated to a comprehensive investigation into the potential utilization of spray rails to enhance the takeoff performance of amphibian aircraft. Several spray rail configurations obtained from naval research were simulated on a bare Seamax M22 amphibian hull to observe an approximate 10% - 25% decrease in water resistance at high speeds alongside a 3% reduction in the takeoff time. This study serves as a motivation to improve the design of the reference airplane hull and a platform for detailed investigations in the future to improve modern amphibian design.

Designing an Experimental Device for Swinging Excitation Spray Cooling

In this paper,we introduce the design principle of the oscillating excited spray cooling experimental device.We then designed an oscillating excited spray cooling experimental device.By using the device,the swaying motion can be realized through the control system,and the motion of the droplet under different vibration frequencies can be observed.By measuring the liquid flow rate and pressure,the changes in liquid flow rate,pressure,and temperature with time under different vibration frequencies were studied.The trajectory of the droplet and the temperature distribution of the droplet under different vibration frequencies could be observed.The device has a simple structure,is easy to control,and can achieve continuous observation of the spray cooling process.

稀土改性WC-10Co-4Cr HVOF热喷涂涂层的制备及力学性能

为提高WC-10Co-4Cr热喷涂涂层性能,制备了添加0.2wt.%纳米Pr_(6)O_(11)的WC-10Co-4Cr热喷涂粉末及其高质量涂层,并研究了纳米Pr_(6)O_(11)对WC-10Co-4Cr涂层的影响。采用团聚烧结法制得纳米Pr_(6)O_(11)弥散分布WC-10Co-4Cr热喷涂粉末,并利用JP8000超音速火焰喷涂设备在304不锈钢基体表面制备了Pr_(6)O_(11)改性WC-10Co-4Cr致密涂层,通过ICP-MS、XRD、XPS、SEM和显微硬度计等对热喷涂粉末及其HVOF涂层进行了微观表征和力学性能测试。与未加稀土的空白对照样相比,添加微量纳米Pr_(6)O_(11)的WC-10Co-4Cr(Pr_(6)O_(11))HVOF热喷涂涂层综合力学性能得到有效改善,其平均努氏硬度达到1267.85 HK,平均弹性模量达到363.8 GPa,平均断裂韧性达到4.51 MPa·m^(1/2),这得益于添加纳米Pr_(6)O_(11)使涂层微观组织更加致密、细小、均匀。

Influences of gas flow rates on melting of particles of HVOF sprayed CoCrW coating and coating properties

This paper discussed influences of flow rates of O_2, C_3H_8, and compressedair on the melting degree of particles during HVOF (high velocity oxy-fuel) sprayed CoCrW coating.The O_2 flow rate has the maximal effect on the melting of particles, the C_3H_8 flow rate has thesecond, and the compressed air flow rate has the minimal effect. The bond strength of the HVOFsprayed CoCrW coating is over 54 MPa. The porosity ratio of the HVOF sprayed CoCrW coating afteroptimization of gas flow rates is less than 2%. The average microhardness of the coating is up toHV_(0.1) 545. The oxidation amount per unit area of the HVOF sprayed CoCrW coating increases withthe holding time increasing at 800℃. In the same way, the oxidation amount of the coating increasesas the temperature increases. Particularly, the oxidation of the coating drastically increases over850℃.

Electrochemical characteristics of HVOF spray coated layer with WC-27NiCr and WC-10Co4Cr for Al bronze

Among the environmentally friendly marine energies,tidal current power plants require low cost because they do not need to construct a large dam.Tidal power is particularly reliable energy source because the power generation capacity is predictable regardless of weather or season.Composite materials or stainless steel have been used as materials of blades for current power plant.However,their strength and welding performance generated many problems in field application.Copper alloys with excellent cavitation resistance and corrosion resistance were applied as blade materials to improve the durability of copper alloys.They were coated with WC-27NiCr and WC-10Co4Cr using the high velocity oxy-fuel (HVOF) method.The metal spray coating technology has the advantage in terms of the selection of materials for cost effectiveness and environmental effects of corrosion because the properties of the coat layer can be controlled intentionally.Coating with WC-27NiCr and WC-10Co4Cr by HVOF,WC-27NiCr shows better corrosion resistance overall.The reason for this seems to be that corrosion resistance improves and a stable passive film forms due to the effects of Ni and Cr.

Dynamic analysis of particle temperaturein HVOF spray

Based on “Gas Dynamics”, “Thermodynamics”, “Fluid Dynamics of Multiphase Systems” and other theories, dynamic analyses of the particle temperature in a HVOF spray have been accomplished. The relationship between the temperature of the particle and the heated time has been proposed in this paper. Meanwhile, the influences of the temperature of the hot gas of a HVOF gun and the particle size on the temperature of a particle for depositing have been discussed in detail. It is evident that the velocity of a particle heated in the hot gas of a HVOF gun is very high, and the maximum theoretic temperature of a particle heated is mostly equivalent to the temperature of the hot gas.

Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings

Flow based Erosion e corrosion problems are very common in fluid handling equipments such as propellers, impellers, pumps in warships, submarine. Though there are many coating materials available to combat erosionecorrosion damage in the above components, iron based amorphous coatings are considered to be more effective to combat erosionecorrosion problems. High velocity oxy-fuel(HVOF)spray process is considered to be a better process to coat the iron based amorphous powders. In this investigation, iron based amorphous metallic coating was developed on 316 stainless steel substrate using HVOF spray technique. Empirical relationships were developed to predict the porosity and micro hardness of iron based amorphous coating incorporating HVOF spray parameters such as oxygen flow rate, fuel flow rate, powder feed rate, carrier gas flow rate, and spray distance. Response surface methodology(RSM) was used to identify the optimal HVOF spray parameters to attain coating with minimum porosity and maximum hardness.

Investigation on Interface Structure and Wear-resistant Properties of HVOF Sprayed Carbides Coating onto Copper Substrate

In this paper, we deposited carbides on copper substrate by High velocity oxy-fuel (HVOF) spraying. The structure of the coating and microstructure of the substrate-coating interface have been investigated by means of scanning electron microscope (SEM) and transmission electron microscopy (TEM). We observed the worn surface of the coating and investigated the wear mechanism. The results show that the microstructure of the interface between HVOF sprayed coating and substrate which consists of the amorphous layers, nanocrystalls in the coating and dislocation cells in copper substrate, etc. is complex. The amorphous layers are formed from heated adhesion after rapidly cooling, while the nanocrystalls come from the fragmentation of half-molten carbides. At the same time we found that the wear-resistant properties of the WC-Co coating is better than that of Cr3C2-NiCr coating at room temperature. The early wear-resistance of the HVOF sprayed coating is poor because of the roughness of its surface or bad bond of hard composite particles. The high velocity of molten droplets is propitious to fill up the interspaces between carbides, so as to make the coating more compact and reduce its porosities, thus the wear-resistance of carbides coatings is improved.

Microstructure and Sliding Wear Behaviour of Ni(Cr)-TiB_2 Coatings Deposited by HVOF Spraying of SHS Powders

This work reports research concerning the microstructure and sliding wear behaviour of cermet coatings deposited by high velocity oxy-fuel (HVOF) spraying. Two cermets were prepared with the following target compositions namely, Ni (Cr)-65 wt.% TiB2 and Ni (Cr)-40 wt.% TiB2. Coating microstructures were investigated by scanning electron microscopy (SEM) and X-ray diffraction (XRD), whilst microhardness and sliding wear tests were performed on the coatings to evaluate their performance. The HVOF sprayed deposits had layered, splat-like morphologies typical of thermally sprayed cermets. Coatings consisted primarily of TiB2 particles in a nickel-based binder phase. Other minor peaks in the XRD patterns belong to TiB, Ni2B, NiTiO3 and Ti2Oj. The coatings exhibit an amorphous halo in the diffraction pattern between 2 values of 40° and 50°. Sliding wear behaviour was examined using a conventional ball-on-disc apparatus. A sintered ceramic ball (A12O3) was employed as the counterface. The Ni (Cr)-65 wt.% TiB2 coating had a lower wear rate than Ni (Cr)-40 wt.% TiB2 coating. This may be related to the larger sizes of borides. Wear scar morphologies, on both coatings were examined by using SEM and EDAX detecting in order to establish the wear mechanism. Wear is proposed to proceed by subsurface cracking in these coatings.

F92阀芯件表面HVOF制备NiCr-Cr_(3)C_(2)涂层高温摩擦磨损性能研究

采用超音速火焰喷涂技术(HVOF)在F92阀芯材料表面制备NiCr-Cr_(3)C_(2)单层和NiCr+NiCr-Cr_(3)C_(2)双层涂层。通过扫描电镜(SEM)、X射线衍射仪(XRD)、维氏硬度计、高温摩擦试验机等探究了两类涂层的显微形貌、相结构、力学及高温摩擦学性能。结果表明:两种涂层成分均匀、结构致密。其中,单层涂层的表面硬度较低(810.19±22.74 HV),且摩擦系数范围由低温的0.4~0.9到高温的0.3~0.7,磨损率从3.19×10^(-6)mm^(3)/(N•m)到3.06×10^(-5)mm^(3)/(N•m),单层涂层在高温下(630℃)表现出更为优异的耐磨性能;双层涂层具有较高的表面硬度(869.68±44.12 HV),且摩擦系数受摩擦往复频率影响在0.4~0.8波动,磨损率维持在2.5×10^(-5)mm^(3)/(N•m)左右,受磨损频率因素影响较小,更能适用于频率频繁变换(1 Hz~5 Hz)的服役环境中。C析出生成的Cr7C3与高温氧化生成的Cr2O3之间的协同作用能够提高涂层的高温摩擦磨损性能,磨损机理分析表明:两种涂层的高温摩擦磨损形式相似,整个磨损过程由磨粒磨损、黏着磨损构成。

Microstructure and properties of HVOF sprayed Ni-based submicron WS_2/CaF_2 self-lubricating composite coating

Ni-based submicron WS2/CaF2 self-lubricating composite coatings were produced on carbon steel substrate by high velocity oxygen fuel(HVOF) spray processing, and the microstructure and mechanical properties of the coatings were investigated. Non-uniform microstructure characterized by some pores and microcracks is observed in the produced composite coatings, which leads to low microhardness value, low adhesive strength and low frictional coefficient. For Ni45-5%CaF2-10%WS2 (mass fraction) and Ni45-10%CaF2-5%WS2 (mass fraction) coatings, under the test condition of load 40 N and speed 2 m/s, the friction coefficients obtained at room temperature are in the range of 0.35-0.48 and 0.31-0.41, respectively. The friction coefficients of two kinds of coatings increase to 0.4-0.63 and 0.35-0.46, respectively, at the test speed of 1 m/s. And the Ni45-10%CaF2-5%WS2 coating presents the minimum friction coefficient of 0.32-0.38 and good anti-wear properties at 400 ℃.

渗氮处理对HVOF喷涂Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)高熵合金涂层组织结构和磨损性能的影响

为了研究渗氮处理对HVOF喷涂Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)高熵合金涂层组织结构和磨损性能的影响,采用HVOF技术在35CrMo钢基体上制备Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)高熵合金涂层,然后对其进行渗氮处理。利用SEM、XRD、三维白光干涉仪以及EDS等表征手段研究了渗氮处理对HVOF喷涂Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)高熵合金涂层组织结构和磨损性能的影响。结果表明:渗氮处理后的Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)高熵合金涂层组织结构致密,具有典型的热喷涂层状结构,厚度约为300~350μm,氮化层厚度约为10μm,氮化层相结构为FCC相和AlN、CrN等氮化物相,氮化层的显微硬度分别为981 HV_(2 N)(x=0)、1090 HV_(2 N)(x=0.125)和1194 HV_(2 N)(x=0.250),和未经渗氮处理过的高熵合金涂层的显微硬度479 HV_(2 N)(x=0)、506 HV_(2 N)(x=0.125)、548 HV_(2 N)(x=0.250)相比有着显著的提升;并且随着Ti含量的增加,氮化层的耐磨性增加,其中Al_(0.750)CoCrFeNiTi_(0.250)氮化层具有最优异的耐磨性能(2.17×10^(-6)mm^(3)·N^(-1)·m^(-1))。Al_(1-x)CoCrFeNiTi_(x)(x=0,0.125,0.250)氮化层的磨损失效机理主要是磨粒磨损、氧化磨损和黏着磨损。

Effect of Salt Spray Corrosion on Tribological Properties of HVOF Sprayed NiCr-Cr3C2 Coating with Intermediate Layer

The objective of the present work was to determine the influence of the neutral salt spray corrosion on the wear resistance of HVOF sprayed NiCr-Cr3C2 coating with intermediate layer. Ni-Zn-Al2O3 coatings as interlayers were prepared by low pressure cold spray（LPCS） between NiCr-Cr3C2 cermet coatings to form a sandwich structure to enhance the corrosion resistance properties. The tribological properties were examined using the UMT-3 fricition and wear tester by line-contact reciprocating sliding under dry and salt spray one week corrosion. The morphology, element distribution, and phase compositions of the coating and worn sufaces were analyzed by using scanning electron microscopy, energy dispersive spectrometry, and X-ray diffraction respectively. The corrosion behavior of the coating was studied by the open-circuit potential, the electrochemical impedance spectroscopy, potentiodynamic polarization, and salt spray corrosion methods. It is found that the sandwich structured coating has better corrosion resistance than the single layer coating. The results show that under dry wear conditions, the wear mechanism is abrasive and adhesive wear, whereas under salt spray corrosion conditions it becomes corrosion wear. The friction coefficient of the sandwich structured coating after salt spray corrosion is slightly lower than the dry friction coefficient, but the weight of the wear loss is lower than that under dry condition.

Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni–22Cr–10Al–1Y and Ni–22Cr–10Al–1Y–SiC(N) coatings on ASTM-SA213-T22 steel

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel(HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y(80 wt%;microsized)–silicon carbide(SiC)(20 wt%;nano(N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na2SO4–60 wt%V2O5 molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction,field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y–20 wt%SiC(N) composite coating was more effective than the Ni–22Cr–10Al–1Y coating against corrosion in the high-temperature fluxing process.

Corrosion Behaviour of Modified HVOF Sprayed WC Based Cermet Coatings on Stainless Steel

WC based cermet coatings have been considered as alternative replacements to the more traditional hard chrome plating for improved surface properties of aircraft landing gear. While these coatings are used in engineering applications requiring superior hardness and improved wear resistance, little is known about the corrosion resistance. In this study, three WC based composite coatings were deposited onto ferritic stainless steel substrates using high velocity oxy fuel (HVOF) technology. Salt spray testing and potentiodynamic scanning studies in a saline environment were conducted on the coatings. Characterisation of the coating structure, composition and morphology, was carried out, prior to and after corrosion testing, using optical microscopy, scanning electron microscopy and EDX elemental analysis. The results showed that poor corrosion performance was exhibited by all three coatings. This was attributed to the high levels of porosity and the presence of micro-cracks within the coatings, resulting in attack of the substrate directly by the saline environment and possible galvanic coupling effects between the substrate and the coating. Dissolution and / or erosion of specific phases within the coating, resulting in the formation of micro-channels and increased number / size of voids may have accelerated corrosion of the system.

Corrosion behavior of NiCrBSi coatings deposited by HVOF spraying

The corrosion resistance of NiCrBSi coating deposited on steel substrate by HVOF was examined using electrochemical tests and immersion tests so as to offer an experimental basis to expand a promising applied field of HVOF in aqueous medium, comparing with those of coatings deposited by oxyacetylene flame spraying and flame cladding. The results show that the general corrosion rate of HVOF sprayed coatings is quite bigger than that of clad coatings, but it is less sensitive to local corrosion. There is less and smaller porosity in the coatings deposited by HVOF than that in flame sprayed coatings. The effects of porosity on the corrosion current density was indistinctive, but the existence of large amount of defects in the coatings damaged the cohesion of the coatings, causing the metallic particles drop off from the coatings under the influence of corrosive medium. Improving the quality and reducing the porosity of coatings is the key to get the coatings with high corrosion resistance.

喷涂距离对内孔HVOF喷涂纳米WC-10Co4Cr涂层组织及抗泥沙冲蚀性能的影响

利用内孔氧-丙烷超音速火焰喷涂技术在ZG0Cr13Ni5Mo不锈钢基材表面制备纳米WC-10Co4Cr涂层,分别通过45°和90°两种内孔喷枪研究了喷涂距离对涂层宏/微观组织及抗泥沙冲蚀性能的影响。采用X射线衍射仪(XRD)测试分析了涂层的物相成分,利用扫描电子显微镜(SEM)观察了涂层截面的微观形貌,并结合金相显微镜分析了孔隙率;通过维氏硬度计测试了涂层的显微硬度,利用粗糙度仪和光学轮廓仪表征了涂层表面的粗糙度及三维形貌;采用泥沙冲蚀磨损试验机对比研究了涂层与不锈钢基材的抗泥沙冲蚀性能,并结合SEM分析了冲蚀磨损机理。研究发现,45°和90°两种内孔喷枪所制备纳米WC-10Co4Cr涂层主要物相成分均为WC、W_(2)C和非晶态CoCr合金相,未受到喷涂距离的影响。短喷涂距离会导致涂层孔隙缺陷的产生,孔隙率随着喷涂距离的增大先下降后上升。喷涂距离对90°喷枪所制备涂层显微硬度的影响较小,而45°喷枪在喷涂距离增大到150 mm以后涂层硬度有下降趋势,两者最高硬度分别为1343.1 HV0.2和1275.4 HV0.2;对于两种喷枪,短喷涂距离会导致涂层表面产生凸起团聚颗粒,粗糙度随着喷涂距离的增大而降低。涂层抗泥沙冲蚀性能随喷涂距离的增大先升高而后逐渐下降,45°和90°内孔喷枪喷距分别为200 mm和250 mm时所制备涂层的抗泥沙冲蚀性能达到最高,分别是基材的7.03倍和8.05倍。WC-10Co4Cr涂层的泥沙冲蚀磨损机制主要是交变应力下的疲劳剥落,基材则为均匀的泥沙微切削。