A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

Currently, most thermal spray coating service providers expect original equipment manufacturers (OEMs) to suggest the coating recipe, comprising of the right coating equipment, starting process parameters, type of inert gases, and robot program. The microstructure and mechanical properties may not comply in the first few runs. Feedback from a competent material testing service provider forms the initial step to adjust the parameters in the development journey, toward identifying the processing parameters required to obtain an acceptable coating. With the surge of interest in sustainable manufacturing, the time spent on trials in the future will shrink, and a more rigorous process needs to be applied to achieve the “right-first-time manufacturing” approach in thermal spraying. However, a framework for the systematic development of thermal spray parameter optimisation is lacking. This article provides a framework, based on a logical acumen, in selecting the right process parameters, using available data and prior knowledge about the thermal spraying process. To that end, the article summarises the extant developmental journey of thermal spray process parameters, by covering the aspects of equipment choice, robot and spray parameters, and how to minimise iterations, using diagnostic tools to get to the end solution most efficiently. This article, in its current form, will serve as a good guide for early career engineers and scientists or workers, to minimise the time processing window, by avoiding endless iterations to deposit a certain type of coating using thermal spraying. Besides, this work is also aimed at transforming academic research innovations to a robust and repeatable industrial manufacturing process

Structure zone diagram and particle incorporation of nickel brush plated composite coatings

This work studies the deposition of aluminium-incorporated nickel coatings by brush electroplating, focusing on the electroplating setup and processing parameters. The setup was optimised in order to increase the volume of particle incorporation. The optimised design focused on increasing the plating solution flow to avoid sedimentation, and as a result the particle transport experienced a three-fold increase when compared with the traditional setup. The influence of bath load, current density and the brush material used was investigated. Both current density and brush material have a significant impact on the morphology and composition of the coatings. Higher current densities and non-abrasive brushes produce rough, particle-rich samples. Different combinations of these two parameters influence the surface characteristics differently, as illustrated in a Structure Zone Diagram. Finally, surfaces featuring crevices and peaks incorporate between 3.5 and 20 times more particles than smoother coatings. The presence of such features has been quantified using average surface roughness Ra and Abbott-Firestone curves. The combination of optimised setup and rough surface increased the particle content of the composite to 28 at.%

Particle distribution, film formation and wear performance of brush plated Ni/WC

Nickel-matrix composite coatings with tungsten carbide particles were produced by brush electroplating using different current densities and materials of the brush. Non-abrasive materials and high current densities produce coatings with high particle content and non-uniform dispersion. Abrasive wear testing showed premature coating failure in areas with high particle concentrations (>21.3 at.% of W). Changes to the solution flow direction were undertaken to decrease ‘solution pooling’, as it was related to areas with excessive particle content. This, together with the use of abrasive brushes at lower current densities, gives Ni/WC coatings with a low and narrow composition range (from 13.2 ± 4.8 to 2.8 ± 0.8 at.% of W). Such optimized coatings minimized premature coating failure and improved the wear resistance to 1.8–4.4 times that of the original nickel matrix, achieving values similar to hard chrome coatings tested under the same conditions. Unlike other brush plated composite coatings, changes in coating morphology are not heavily influenced by processing parameters, but are sensitive to the presence of WC particles

Comparative Surface and Nano-Tribological Characteristics of Nanocomposite Diamond-Like Carbon Thin Films Doped by

Abstract In this study we have deposited silver-containing hydrogenated and hydrogen-free diamondlike carbon (DLC) nanocomposite thin films by plasma immersion ion implantation-deposition methods. The surface and nano-tribological characteristics were studied by x-ray photoelectron spectroscopy (XPS), atomic force microscopy (AFM) and nano-scratching experiments. The silver doping was found to have no measurable effect on sp 2 -sp 3 hybridization of the hydrogenated DLC matrix and only a slight effect on the hydrogen-free DLC matrix. The surface topography was analyzed by surface imaging. High-and low-order roughness determined by AFM characterization was correlated to the DLC growth mechanism and revealed the smoothing effect of silver. The nano-tribological characteristics were explained in terms of friction mechanisms and mechanical properties in correlation to the surface characteristics. It was discovered that the adhesion friction was the dominant friction mechanism; the adhesion force between the scratching tip and DLC surface was decreased by hydrogenation and increased by silver doping

Functional evaluation and testing of a newly developed Teleost’s Fish Otolith derived biocomposite coating for healthcare

Polymers such as polycaprolactone (PCL) possess biodegradability, biocompatibility and affinity with other organic media that makes them suitable for biomedical applications. In this work, a novel biocomposite coating was synthesised by mixing PCL with layers of calcium phosphate (hydroxyapatite, brushite and monetite) from a biomineral called otolith extracted from Teleost fish (Plagioscion Squamosissimus) and multiwalled carbon nanotubes in different concentrations (0.5, 1.0 and 1.5 g/L). The biocomposite coating was deposited on an osteosynthesis material Ti6Al4V by spin coating and various tests such as Fourier transformation infrared spectroscopy (FTIR), Raman spectroscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), scratch tests, MTT reduction cytotoxicity, HOS cell bioactivity (human osteosarcoma) by alkaline phosphatase (ALP) and fluorescence microscopy were performed to comprehensively evaluate the newly developed biocoating. It was found that an increase in the concentration of carbon nanotube induced microstructural phase changes of calcium phosphate (CP) leading to the formation of brushite, monetite and hydroxyapatite. While we discovered that an increase in the concentration of carbon nanotube generally improves the adhesion of the coating with the substrate, a certain threshold exists such that the best deposition surfaces were obtained as PCL/CP/CNT 0.0 g/L and PCL/CP/CNT 0.5 g/L

Bactericidal Surfaces: An Emerging 21st Century Ultra-Precision Manufacturing and Materials Puzzle

Progress made by materials scientists in recent years has greatly helped the field of ultra-precision manufacturing. Ranging from healthcare to electronics components, phenomena such as twinning, dislocation nucleation, and high-pressure phase transformation have helped to exploit plasticity across a wide range of metallic and semiconductor materials. One current problem at the forefront of the healthcare sector that can benefit from these advances is that of bacterial infections in implanted prosthetic devices. The treatment of implant infections is often complicated by the growth of bacterial biofilms on implant surfaces, which form a barrier that effectively protects the infecting organisms from host immune defenses and exogenous antibiotics. Further surgery is usually required to disrupt the biofilm, or to remove the implant altogether to permit antibiotics to clear the infection, incurring considerable cost and healthcare burdens. In this review, we focus on elucidating aspects of bactericidal surfaces inspired by the biological world to inform the design of implant surface treatments that will suppress bacterial colonization. Alongside manufacturing and materials related challenges, the review identifies the most promising natural bactericidal surfaces and provides representative models of their structure, highlighting the importance of the critical slope presented by these surfaces. The scalable production of these complex hierarchical structures on freeform metallic implant surfaces has remained a scientific challenge to date and, as identified by this review, is one of the many 21st-century puzzles to be addressed by the field of applied physics

Probe geometry and surface roughness effects in microscale impact testing of WC-Co

Depth-sensing repetitive microimpact tests have been performed on cemented carbide cutting tool inserts with spheroconical diamond probes with end radii of 8, 20 and 100 µm. Results were strongly dependent on the probe radius and applied load. At higher load, there was a transition to a faster damage rate marking the onset of more variability in rate and in the residual depth of the impact crater when using 8 and 20 µm probes. SEM images show the breakup of the WC skeleton at the periphery of the contact zone. Lower surface roughness slowed the initial damage rate at a higher load but did not significantly influence the final crater depth. The load-dependent fatigue mechanism displayed by the cemented carbide also has implications for the study and optimization of coatings when these are deposite

Wear-resistant nickel-matrix composite coatings incorporating hard chromium carbide particles

This work evaluates the influence of plating variables on the morphology, composition homogeneity, and abrasive wear resistance of metal matrix composite coatings. A set of Ni/Cr3C2 coatings were brush plated onto steel coupons modifying two key variables: particle size and brush material. Compositional maps of unprecedented detail have been produced and analysed statistically to enhance understanding of composition distribution. The use of Abbott-Firestone curves to analyse surface morphology enabled the evaluation of valley and peak features. The coating differences highlighted by previous analyses have been compared with their behaviour in abrasive environments, simulated using Taber testing. Moreover, coupling Taber testing with partial compositional maps at different wear stages enabled monitoring of coating wear evolution. This methodology has revealed the importance of particle sedimentation during plating, which increased particle incorporation in the composite coating but also increased composition heterogeneity. The smaller 1.7 μm carbides and abrasive brushes produced coatings with more homogeneous morphologies, higher particle content, and increased resistance against abrasive wear, with a 60% reduction in material loss in comparison to the standard nickel coatings

Functionalization of Hydrogen-free Diamond-like Carbon Films using Open-air Dielectric Barrier Discharge Atmospheric Plasma Treatments

A dielectric barrier discharge (DBD) technique has been employed to produce uniform atmospheric plasmas of He and N2 gas mixtures in open air in order to functionalize the surface of filtered-arc deposited hydrogen-free diamond-like carbon (DLC) films. XPS measurements were carried out on both untreated and He/N2 DBD plasma treated DLC surfaces. Chemical states of the C 1s and N 1s peaks were collected and used to characterize the surface bonds. Contact angle measurements were also used to record the short- and long-term variations in wettability of treated and untreated DLC. In addition, cell viability tests were performed to determine the influence of various He/N2 atmospheric plasma treatments on the attachment of osteoblast MC3T3 cells. Current evidence shows the feasibility of atmospheric plasmas in producing long-lasting variations in the surface bonding and surface energy of hydrogen-free DLC and consequently the potential for this technique in the functionalization of DLC coated devices

Characterization of surface Ag nanoparticles in nanocomposite a-C:Ag coatings by grazing incidence X-ray diffraction at sub-critical angles of incidence

Silver diffusion within nanocomposite films and/or toward the film surface is often observed during annealing of the silver-based nanocomposite films. In order to control and/or minimize this process, it is crucial to characterize the aggregated silver nanoparticles on the films surface. In this paper grazing incidence X-ray diffraction (GIXRD) with both sub-critical and supra-critical angles of incidence is used to characterize the Ag nanoparticles distribution, shape and structure both inside the matrix and on the nanocomposite film surface. The nanocomposite carbon coating containing Ag nanoparticles (a-C:Ag) was deposited by dc magnetron sputtering. The coatings were analyzed by GIXRD using fixed incident angles both below and above the critical angle for total reflection. By using sub-critical angles it was possible to eliminate diffraction from the bulk material allowing to estimate the size distribution of the nanoparticles sitting on the surface. The results obtained by GIXRD analysis were checked through comparison with the observations made by both TEM and SEM analysis. The proposed methodology can be used to characterized nanoparticles deposition on a surface and/or island formation during film growth as long an adequate substrate with high critical angle for total reflection is used.We gratefully acknowledge the financial support provided by the FCT—Fundação para a Ciência e Tecnologia and FSE for the grant SFRH/BD/82472/2011. This research is sponsored by the FEDER funds through the program COMPETE—Programa Operacional Factores de Competitividade and by the national funds through FCT—Fundação para a Ciência e Tecnologia in the framework of the Strategic Projects PEST C/EME/UIO0285/2011