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Powders for Cold Spray Coatings
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Powders for Cold Spray Coatings

A special issue of Powders (ISSN 2674-0516).

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 6961

Special Issue Editor

Prof. Dr. Pasquale Cavaliere

E-Mail Website
Guest Editor
Department of Innovation Engineering, University of Salento, Via per Arnesano 73100 Lecce, Italy
Interests: thermal spray coatings; powder metallurgy; severe plastic deformation; ironmaking and steelmaking
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The main issue related to the quality of coating produced via cold spray is related to powder properties. For many alloys and composites, the intrinsic powder properties influencing coating performance are still scientifically and technologically unknown or not completely clarified. As a matter of fact, by modifying one or more powder characteristics, the employed processing conditions must also be varied, with various consequences on coating performance. As this involves cold spray coating formation processes due to severe plastic deformation of splatting particles, there are several aspects regarding their initial microstructure and strength and deformation mode that need to be clarified. Thus, deformation behavior (e.g., potential adiabatic shear) is also still under debate. In a more complex vision, all these issues related to the composite powders’ behavior open many and broad fields of investigation.

This Special Issue aims to focus on powder properties related to optimal cold spray coatings in order to shed a light on the multiple aspects awaiting clarification.

Prof. Dr. Pasquale Cavaliere
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Powders is an international peer-reviewed open access quarterly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1000 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • cold spray
  • powders
  • processing parameters
  • severe plastic deformation
  • coatings
  • microstructure
  • mechanical properties
  • alloys
  • composites

Published Papers (4 papers)

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Research

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16 pages, 4538 KiB  
Article
Multiple-Instance Regression for Metal Powder Hall Flow Rate Prediction Using Augmented Particle Size and Shape Data
by Ashley Schuliger, Stephen Price, Bryer C. Sousa, Danielle L. Cote and Rodica Neamtu
Powders 2023, 2(1), 189-204; https://doi.org/10.3390/powders2010013 - 14 Mar 2023
Cited by 1 | Viewed by 1180
Abstract
This study investigates the relationship between metallic powders and their flowability behavior (captured in terms of Hall flow rates using Hall flowmeters). Due to the many trait dependencies of powder flowability, which have made the formulation of a physical and mechanistic generalizable model [...] Read more.
This study investigates the relationship between metallic powders and their flowability behavior (captured in terms of Hall flow rates using Hall flowmeters). Due to the many trait dependencies of powder flowability, which have made the formulation of a physical and mechanistic generalizable model difficult to resolve, this study seeks to develop an alternative data-driven framework based on powder size and shape characteristics for Hall-flow-rate predictions. A multiple-instance regression framework was both developed for processing multiple-instance powder data and compared with standard machine learning models. Data augmentation was found to improve the overall performance of the framework, although the limited dataset was a constraint. Still, the study contributes to ongoing efforts to identify traditional, associative, and generalizable patterns between powder properties and resultant flowability behaviors. The findings show promise for real-world applications with a larger dataset, such that this initial application of multiple instance regression frameworks for metal powder Hall-flow-rate predictions as a function of powder particle size and shape data can be scrutinized in full. Full article
(This article belongs to the Special Issue Powders for Cold Spray Coatings)
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18 pages, 5603 KiB  
Article
An Attempt to Understand Stainless 316 Powders for Cold-Spray Deposition
by Neeraj S. Karmarkar, Vikram V. Varadaraajan, Pravansu S. Mohanty and Sharan Kumar Nagendiran
Powders 2023, 2(1), 151-168; https://doi.org/10.3390/powders2010011 - 07 Mar 2023
Cited by 1 | Viewed by 1407
Abstract
Cold gas dynamic spray (CS) is a unique technique for depositing material using high-strain-rate solid-state deformation. A major challenge for this technique is its dependence on the powder’s properties, and another is the lack of standards for assessing them between lots and manufacturers. [...] Read more.
Cold gas dynamic spray (CS) is a unique technique for depositing material using high-strain-rate solid-state deformation. A major challenge for this technique is its dependence on the powder’s properties, and another is the lack of standards for assessing them between lots and manufacturers. The motivation of this research was to understand the variability in powder atomization techniques for stainless steel powders and their subsequent properties for their corresponding impacts on CS. A drastic difference (~30%) was observed in the deposition efficiencies (DEs) of unaltered, spherical and similar sized stainless steel (316) powders produced using centrifugal (C.A) and traditional gas atomization (G.A) techniques. The study highlights more the differences on a precursor level. Using recent advancements in large scale statistical measurements, such as laser diffraction shape analysis and µCT scanning; and traditional methods, such as EBSD and nanoindentation, an attempt was made to understand the powder’s properties. Insights on powder size and shape were documented. Significant differences were observed between C.A and G.A powders in terms of grain size, fraction of high-angle grain boundaries (HAGBs) and nanohardness. The outcomes of this study should be helpful for understanding the commercialization of the cold-spray process for bulk manufacturing of powder precursors. Full article
(This article belongs to the Special Issue Powders for Cold Spray Coatings)
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13 pages, 6879 KiB  
Article
Crack Initiation and Growth Behavior of HVOF Stellite-6 Coatings under Bending Loading
by Behzad Sadeghi, Pasquale Cavaliere, Angelo Perrone and Alessio Silvello
Powders 2022, 1(2), 62-74; https://doi.org/10.3390/powders1020006 - 24 Mar 2022
Cited by 1 | Viewed by 1866
Abstract
Stellite-6 powders were sprayed on Ni-Al bronze in order to produce coatings via high-velocity oxygen fuel (HVOF). The microstructural observations revealed the main mechanisms taking place for the substrate–coating adhesion. It was revealed that tungsten-rich particles are very active in improving the coating [...] Read more.
Stellite-6 powders were sprayed on Ni-Al bronze in order to produce coatings via high-velocity oxygen fuel (HVOF). The microstructural observations revealed the main mechanisms taking place for the substrate–coating adhesion. It was revealed that tungsten-rich particles are very active in improving the coating adhesion as well as the mechanical properties. The X-ray diffraction analysis of the coating material showed pronounced peak broadening, revealing high residual stresses related to excellent bonding to the substrate. As expected, the coating procedure led to an increase in surface hardness. The surface properties of the coatings were evaluated through cyclic three-point bending tests at different maximum loads. It was demonstrated that the main part of the fatigue life is spent in the crack initiation stage, with a short propagation stage. Obviously, this behavior decreases as the maximum cyclic stress increases. The micro-mechanisms taking place during cyclic loading were evaluated through fracture surface observations via scanning electron microscopy. Full article
(This article belongs to the Special Issue Powders for Cold Spray Coatings)
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Review

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26 pages, 15999 KiB  
Review
Microstructural and Micromechanical Characterization of Feedstock for Cold Spray Additive Manufacturing and Processing
by Bryer C. Sousa, Kyle Tsaknopoulos and Danielle L. Cote
Powders 2022, 1(3), 129-154; https://doi.org/10.3390/powders1030010 - 29 Jul 2022
Cited by 1 | Viewed by 1634
Abstract
Due to the processes solid-state nature, cold gas-dynamic spray metal additive manufacturing may be considered microstructurally and micromechanically retentive, such that properties of the feedstock material are refined and partially retained, influencing component performance. As a result, cold spray processing enables unique freedoms [...] Read more.
Due to the processes solid-state nature, cold gas-dynamic spray metal additive manufacturing may be considered microstructurally and micromechanically retentive, such that properties of the feedstock material are refined and partially retained, influencing component performance. As a result, cold spray processing enables unique freedoms regarding feedstock, which can be pre-processed using chemical, thermal, and mechanical treatments to produce powder properties that achieve finely controlled consolidations with application-specific behaviors. Given such features of the cold spray process, the present review article is concerned with the through-process integration of mechanically and microstructurally characterized feedstocks for optimizable cold spray metal additive manufacturing. Therefore, in this paper, we consider how nanoindentation (dynamic, static, and quasi-static) was coupled with microstructural characterization for experimental feedstock evaluation, testing, and characterization. Atomized aluminum alloys, atomized stainless steel, and copper feedstocks, among others, were considered. Accordingly, the review validates how microparticle feedstock pre-processing and characterization in cold spray metal additive manufacturing and processing lead to controllable component performance and properties. Full article
(This article belongs to the Special Issue Powders for Cold Spray Coatings)
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