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  • 1.
    Aranke, Omkar
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Algenaid, Wael
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Awe, Samuel
    R and D Department, Automotive Components Floby AB, Floby, 52151, Sweden.
    Joshi, Shrikant V.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW).
    Coatings for automotive gray cast iron brake discs: A review2019Inngår i: Coatings, ISSN 2079-6412, Vol. 9, nr 9, artikkel-id 552Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Gray cast iron (GCI) is a popular automotive brake disc material by virtue of its high melting point as well as excellent heat storage and damping capability. GCI is also attractive because of its good castability and machinability, combined with its cost-effectiveness. Although several lightweight alloys have been explored as alternatives in an attempt to achieve weight reduction, their widespread use has been limited by low melting point and high inherent costs. Therefore, GCI is still the preferred material for brake discs due to its robust performance. However, poor corrosion resistance and excessive wear of brake disc material during service continue to be areas of concern, with the latter leading to brake emissions in the form of dust and particulate matter that have adverse effects on human health. With the exhaust emission norms becoming increasingly stringent, it is important to address the problem of brake disc wear without compromising the braking performance of the material. Surface treatment of GCI brake discs in the form of a suitable coating represents a promising solution to this problem. This paper reviews the different coating technologies and materials that have been traditionally used and examines the prospects of some emergent thermal spray technologies, along with the industrial implications of adopting them for brake disc applications. © 2019 by the authors.

  • 2.
    Curry, Nicholas
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för maskinteknik.
    VanEvery, Kent
    Progressive Surface, Grand Rapids, MI 49512, USA .
    Snyder, Todd
    Progressive Surface, Grand Rapids, MI 49512, USA.
    Markocsan, Nicolaie
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för tillverkningsprocesser.
    Thermal Conductivity Analysis and Lifetime Testing of Suspension Plasma-Sprayed Thermal Barrier Coatings2014Inngår i: Coatings, ISSN 2079-6412, Vol. 4, nr 3, s. 630-650Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Suspension plasma spraying (SPS) has become an interesting method for the production of thermal barrier coatings for gas turbine components. The development of the SPS process has led to structures with segmented vertical cracks or column-like structures that can imitate strain-tolerant air plasma spraying (APS) or electron beam physical vapor deposition (EB-PVD) coatings. Additionally, SPS coatings can have lower thermal conductivity than EB-PVD coatings, while also being easier to produce. The combination of similar or improved properties with a potential for lower production costs makes SPS of great interest to the gas turbine industry. This study compares a number of SPS thermal barrier coatings (TBCs) with vertical cracks or column-like structures with the reference of segmented APS coatings. The primary focus has been on lifetime testing of these new coating systems. Samples were tested in thermo-cyclic fatigue at temperatures of 1100 °C for 1 h cycles. Additional testing was performed to assess thermal shock performance and erosion resistance. Thermal conductivity was also assessed for samples in their as-sprayed state, and the microstructures were investigated using SEM

  • 3.
    Curry, Nicholas
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för tillverkningsprocesser. Treibacher Industrie AG, Althofen 9330, Austria.
    VanEvery, Kent
    Progressive Surface, Grand Rapids, MI 49512, USA.
    Snyder, Todd
    Progressive Surface, Grand Rapids, MI 49512, USA.
    Susnjar, Johann
    Treibacher Industrie AG, Althofen 9330, Austria.
    Björklund, Stefan
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avd för tillverkningsprocesser.
    Performance Testing of Suspension Plasma Sprayed Thermal Barrier Coatings Produced with Varied Suspension Parameters2015Inngår i: Coatings, ISSN 2079-6412, Vol. 5, nr 3, s. 338-356Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Suspension plasma spraying has become an emerging technology for the production of thermal barrier coatings for the gas turbine industry. Presently, though commercial systems for coating production are available, coatings remain in the development stage. Suitable suspension parameters for coating production remain an outstanding question and the influence of suspension properties on the final coatings is not well known. For this study, a number of suspensions were produced with varied solid loadings, powder size distributions and solvents. Suspensions were sprayed onto superalloy substrates coated with high velocity air fuel (HVAF) -sprayed bond coats. Plasma spray parameters were selected to generate columnar structures based on previous experiments and were maintained at constant to discover the influence of the suspension behavior on coating microstructures. Testing of the produced thermal barrier coating (TBC) systems has included thermal cyclic fatigue testing and thermal conductivity analysis. Pore size distribution has been characterized by mercury infiltration porosimetry. Results show a strong influence of suspension viscosity and surface tension on the microstructure of the produced coatings.

  • 4.
    Ganvir, Ashish
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Björklund, Stefan
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Yao, Y.
    Chalmers University of Technology, Department of Industrial and Materials Science, Gothenburg, 41296, Sweden.
    Vadali, S. V. S. S.
    University of Hyderabad, School of Engineering Sciences and Technology, Hyderabad, 500046, India.
    Klement, Uta
    Chalmers University of Technology, Department of Industrial and Materials Science, Gothenburg, 41296, Sweden.
    Joshi, Shrikant V.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW).
    A facile approach to deposit graphenaceous composite coatings by suspension plasma spraying2019Inngår i: Coatings, ISSN 2079-6412, Vol. 9, nr 3, artikkel-id 171Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    This paper demonstrates, for the first time ever, the deposition of graphenaceous composite coatings using an easy, yet robust, suspension plasma spraying (SPS) process. As a case study, a composite coating comprising 8 wt.% of yttria-stabilized-zirconia (8YSZ) and reinforced with graphene oxide (GO) was deposited on a steel substrate. The coatings were sprayed using an 8YSZ-GO mixed suspension with varied plasma spray parameters. Establishing the possibility of retaining the graphene in a ceramic matrix using SPS was of specific interest. Electron microscopy and Raman spectroscopy confirmed the presence of graphenaceous material distributed throughout the coating in the 8YSZ matrix. The experimental results discussed in this work confirm that SPS is an immensely attractive pathway to incorporate a graphenaceous material into virtually any matrix material and can potentially have major implications in enabling the deposition of large-area graphene-containing coatings for diverse functional applications. © 2019 by the authors.

  • 5.
    Ganvir, Ashish
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Markocsan, Nicolaie
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Joshi, Shrikant V.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW).
    Influence of Isothermal Heat Treatment on Porosity and Crystallite Size in Axial Suspension Plasma Sprayed Thermal Barrier Coatings for Gas Turbine Applications2017Inngår i: Coatings, ISSN 2079-6412, Vol. 7, nr 1, s. 1-14, artikkel-id 4Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    xial suspension plasma spraying (ASPS) is an advanced thermal spraying technique, which enables the creation of specific microstructures in thermal barrier coatings (TBCs) used for gas turbine applications. However, the widely varying dimensional scale of pores, ranging from a few nanometers to a few tenths of micrometers, makes it difficult to experimentally measure and analyze porosity in SPS coatings and correlate it with thermal conductivity or other functional characteristics of the TBCs. In this work, an image analysis technique carried out at two distinct magnifications, i.e., low (500×) and high (10,000×), was adopted to analyze the wide range of porosity. Isothermal heat treatment of five different coatings was performed at 1150 °C for 200 h under a controlled atmosphere. Significant microstructural changes, such as inter-columnar spacing widening or coalescence of pores (pore coarsening), closure or densification of pores (sintering) and crystallite size growth, were noticed in all the coatings. The noted changes in thermal conductivity of the coatings following isothermal heat treatment are attributable to sintering, crystallite size growth and pore coarsening

  • 6.
    Sadeghimeresht, Esmaeil
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Markocsan, Nicolaie
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Electrochemical Behavior of Bilayer Thermal-Spray Coatings in Low-Temperature Corrosion Protection2017Inngår i: Coatings, ISSN 2079-6412, Vol. 7, nr 10, s. 1-13, artikkel-id 162Artikkel i tidsskrift (Fagfellevurdert)
    Abstract [en]

    Cr3C2-NiCr coatings are greatly used to protect critical components in corrosive environments and to extend their lifetime and/or improve functional performance. However, the pores formed during spraying restrict the coating’s applicability area for many corrosion protection applications. To overcome this technical challenge, bilayer coatings have been developed, in which an additional layer (the so-called intermediate layer) is deposited on the substrate before spraying the Cr3C2-NiCr coating (the so-called top layer). The corrosion behavior of the bilayer coating depends on the composition and microstructure of each layer. In the present work, different single-layer coatings (i.e., Cr3C2-NiCr, Fe- and Ni-based coatings) were initially sprayed by a high-velocity air fuel (HVAF) process. Microstructure analysis, as well as electrochemical tests, for example, open-circuit potential (OCP) and polarization tests, were performed. The potential difference (Delta E) had a great influence on galvanic corrosion between the top and intermediate layers, and thus, the coatings were ranked based on the OCP values (from high to low) as follows: NiCoCrAlY > NiCr > Cr3C2-NiCr > NiAl > Fe-based coatings (alloyed with Cr) > pure Ni. The Ni-based coatings were chosen to be further used as intermediate layers with the Cr3C2-NiCr top layer due to their capabilities to show high OCP. The corrosion resistance (R-p) of the bilayer coatings was ranked (from high to low) as follows: NiCoCrAlY/Cr3C2-NiCr > NiCr/Cr3C2-NiCr > NiAl/Cr3C2-NiCr > Ni/Cr3C2-NiCr. It was shown that splat boundaries and interconnected pores are detrimental for corrosion resistance, however, a sufficient reservoir of protective scale-forming elements (such as Cr or/and Al) in the intermediate layer can significantly improve the corrosion resistance.

  • 7.
    Sadeghimeresht, Esmaeil
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Amirkabir University of Tehran, Tarbiat Modares University of Tehran.
    Markocsan, Nicolaie
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Nylén, Per
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW).
    A Comparative Study of Corrosion Resistance for HVAF-Sprayed Fe- and Co-Based Coatings2016Inngår i: Coatings, ISSN 2079-6412, Vol. 6, nr 2, s. 1-15Artikkel, forskningsoversikt (Fagfellevurdert)
    Abstract [en]

    There is an increasing demand to replace Co-based coatings with cheap and environmentally friendly Fe-based coatings in corrosive environments. The main objective of this work was to evaluate whether Fe-based coatings could present a better corrosion performance than Co-based coatings. Therefore, two types of Fe-based and one type of Co-based coatings with chemical compositions (in wt %) of Fe-28Cr-16Ni-1.85C (FeNiCrC), Fe-17Cr-12Ni (FeNiCr), andCo-28Cr-1C (CoCrC) were produced by High Velocity Air Fuel (HVAF) spraying. The corrosion behavior of the coatings was studied comparatively by electrochemical tests in 3.5 wt % NaCl solutionat 25 C. The polarization test results showed that the FeCrNiC coating protected the underlying substrate better than the CoCrC coating, while the FeCrNi coating failed to hinder the penetration of corrosive ions. Electrochemical impedance spectroscopy (EIS) measurements revealed that thesolution penetrated into the coating through defects, however the corrosion process slowed down due to clogging of the interconnected defects by corrosion products. Increasing the in-flight average particle temperature from 1400 C to 1500 C led to a denser coating with fewer defects which seemed to improve the corrosion resistance of the FeCrNiC coating. The high-alloyed Fe-based coatings had the best corrosion protection performance and can thus be recommended as a potential alternative toCo-based coatings.

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