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Thermal Spray Maps: Material Genomics of Processing Technologies

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Abstract

There is currently no method whereby material properties of thermal spray coatings may be predicted from fundamental processing inputs such as temperature-velocity correlations. The first step in such an important understanding would involve establishing a foundation that consolidates the thermal spray literature so that known relationships could be documented and any trends identified. This paper presents a method to classify and reorder thermal spray data so that relationships and correlations between competing processes and materials can be identified. Extensive data mining of published experimental work was performed to create thermal spray property-performance maps, known as “TS maps” in this work. Six TS maps will be presented. The maps are based on coating characteristics of major importance; i.e., porosity, microhardness, adhesion strength, and the elastic modulus of thermal spray coatings.

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Abbreviations

APS:

Atmospheric plasma spray

ASTM:

American Society for Testing and Materials

CAPS:

Controlled atmosphere plasma spray

CS:

Cold spray

D-Gun® :

Detonation gun spray

FS:

Flame spray

HA:

Hydroxapapite

HRC:

Rockwell hardness C-scale

HVOF:

High-velocity oxygen fuel spray

HVSFS:

High-velocity suspension flame spray

LPPS:

Low pressure plasma spray

PTWA:

Plasma-transferred wire arc spray

RF:

Radio frequency

SOD:

Standoff distance

SPS:

Suspension plasma spray

SPPS:

Solution precursor plasma spray

TAT:

Tensile adhesion test

TBC:

Thermal barrier coating

TS:

Thermal spray

TV:

Flame temperature and particle velocity

TWA:

Twin Wire Arc

VPS:

Vacuum plasma spray

WC:

Tungsten monocarbide

WC-Co:

Tungsten carbide-cobalt

WSP:

Water-stabilized plasma spray

YSZ:

Yttria-stabilized zirconia

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Acknowledgments

This work was supported under a Swinburne University Postgraduate Research Award. We also acknowledge support from the Defence Materials Technology Centre (DMTC).

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Authors and Affiliations

  1. Industrial Research Institute Swinburne, Swinburne University of Technology, H66, P.O. Box 218, Hawthorn, VIC, 3122, Australia

    Andrew Siao Ming Ang, Noppakun Sanpo, Mitchell L. Sesso, Sun Yung Kim & Christopher C. Berndt

  2. Defence Materials Technology Centre (DMTC), Swinburne University of Technology, P.O. Box 218, Hawthorn, VIC, 3122, Australia

    Andrew Siao Ming Ang, Noppakun Sanpo, Mitchell L. Sesso & Christopher C. Berndt

  3. Department of Materials Science and Engineering, Stony Brook University, Stony Brook, NY, 11794, USA

    Christopher C. Berndt

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  1. Andrew Siao Ming Ang
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  2. Noppakun Sanpo
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Correspondence to Andrew Siao Ming Ang.

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Ang, A.S.M., Sanpo, N., Sesso, M.L. et al. Thermal Spray Maps: Material Genomics of Processing Technologies. J Therm Spray Tech 22, 1170–1183 (2013). https://doi.org/10.1007/s11666-013-9970-3

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  • DOI: https://doi.org/10.1007/s11666-013-9970-3

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