THERMAL SPRAY R&D

TOPICS	2003	2004	2005	2006	2008	2009
Cold Spray	20	17	40	57	68	61
Nanostructured Coatings	14	20	24	28	32	22
Suspension & Solution Spray	6	12	6	14	31	28
Solid Oxide Fuel Cells	2	5	4	13	20	9
Thermal Barrier Coatings	42	44	30	52	62	41

I have compiled the above table, showing the number of proceedings papers and journal articles on selected topics as found in the International Thermal Spray Conference proceedings and two of the top thermal spray related publications between 2003 and 2009, excluding 2007.  The journal data, which was collected using SCOPUS, and the ITSC proceedings papers provide a rough gauge of activities in various areas of thermal spray research. 

As the table shows, publications dealing with cold spray almost tripled those dealing with nanostructured coatings, and had a combined publication total of approximately 60 in 2009.  Publications relating to TBCs have been steady with an average annual publication total of about 45 during the past few years.  The increase in publication rate was highest for suspension and solution spray activities.  This topic has seen a large increase in R&D publications during the past two years, totaling approximately 30 combined publications for each of 2008 and 2009. 

With recent advancements in lower-cost, higher production rate processing of nanostructured metal powders, there may be an increase in research related to the cold spray processing of nanostructured metal-base coatings.  The low-temperature and high velocity of the cold spray process seems to be a near-perfect match for what is required to deposit a dense, oxide-limited, nanostructure deposit.  Preliminary results from cold spraying nanostructured metal deposits [1-4] show promising results.

Thermal spraying of nanostructured coatings has also been explored recently for both the top and bond coat layers of TBC systems.  Suspension and solution spraying of nanostructured YPSZ top coats [5, 6] and HVOF application of nanostructured MCrAlYs [7, 8] have yielded promising results with respect to enhancements in thermal cycling performance.

Among the thermal spray topics that have attracted much research interest in the past few years, suspension and solution sprayed coatings have seen the greatest increase.  The solution precursor plasma spray approach was first introduced by Berndt et al. in the late 1990’s [9-11].  Suspension plasma spray was introduced around 2005 and shares many attributes with the solution approach, as compared to powder feed thermal spray methods.  The attributes include:

• Easier to handle feedstock material
• Lower feedstock cost
• Greater flexibility in feedstock and deposit chemistry
• Wider variations in physical characteristics of deposits, i.e., low and high porosity, sub- or nano-structure, high and low relative thicknesses, etc.
• Easier means of forming functionally graded deposits
• Ability to attain metastable deposits

Current research efforts related to suspension and solution sprayed coatings are focused primarily on SOFCs and TBCs, although some research also involves hard coatings, biomedical implants, catalyst supports, optical devices, sensors, luminescent and magnetic materials [12, 13].  They have also been used to produce nanostructured powders.

1.         Kim H-J, Lee C-H, Hwang S-Y, “Superhard nano WC-12%Co coating by cold spray deposition”, Materials science & engineering. A, 2005, vol. 391, n^o1-2, pp. 243-248

2.         Tetyana Shmyreva, James Knapp, Victor Sedov, “Nano- and microcrystalline cold spray coatings”, ITSC 2005, p 192-192

3.         P. Richer, B. Jodoin, E. Sansoucy, L. Ajdelsztajn, G.E. Kim, “Properties of Cold Spray Nickel Based Coatings”, proceedings of the International Thermal Spray Conference, Seattle, USA, May 15-18, 2006.

4.         L. Ajdelsztajn, J. Schoenung, B. Jodoin, G.E. Kim, “Cold spray deposition of nanocrystalline aluminum alloys”, Metallurgical and Materials Transactions A, Volume 36, Number 3, March 2005, pp. 657-666(10 

5.         Xinqing Ma, Fang Wu, Jeff Roth, Maurice Gell, Eric H. Jordan, “Low thermal conductivity thermal barrier coating deposited by the solution plasma spray process”, Surface and Coatings Technology, Volume 201, Issue 7, 20 December 2006, Pages 4447-4452

6.         Xinqing Ma, Jeff Roth, T. D. Xiao, L. D. Xie, M. Gell, E. H. Jordan, N. P. Padture, “Solution Precursor Plasma Spray: A Promising New Technique for Forming Functional Nanostructured Films and Coatings”, 28th International Conference on Advanced Ceramics and Composites B: Ceramic Engineering and Science Proceedings, Volume 25, Issue 4, 2008

7.         G.E. Kim, M. Brochu, A. Moran, T. Addona, “Enhanced TBC Performance with Nanostructured Bond Coats”, proceedings of the International Thermal Spray Conference, Las Vegas, Nevada, USA, May 4-7, 2009

8.         G.E. Kim, T. Addona, P. Richer, B. Jodoin, A. Al-Mathami, M. Brochu, “Characterization and Evaluation of Nanostructured Bond Coats from Non-cryogenically Milled Feedstock”, proceedings of the International Thermal Spray Conference, Beijing, China, May 14-16, 2007

9.         Karthikeyan J.,Berndt C.C., Tikkanen J., Wang J.Y., King A.H., Herman H, "Preparation of Nanophase Materials by Thermal Spray Processing of Liquid Precursors", Nanostructured Materials, 9(1), 1997, p 137-140

10.      Karthikeyan J.,Berndt C.C., Tikkanen J., Wang J.Y., King A.H., Herman H, "Nanomaterial Powders and Deposits Prepared by Flame Spray Processing of Liquid Precursors", 8(1), 1997, p 61-74

11.      Jeganathan Karthikeyan, Christopher C. Berndt, Sri Reddy, Jenn-Yue Wang, Alexander H. King, and Herbert Herman, "Nanomaterial Deposits Formed by DC Plasma Spraying of Liquid Feedstocks", Journal of the American Ceramic Society, 81, 1998, p 121-128

12.      B.G. Ravi, S. Sampath, R. Gambino, P.S. Devi, and J.B. Parise, “Plasma Spray Synthesis from Precursors: Progress, Issues, and Considerations”, Journal of Thermal Spray Technology Volume 15(4) December 2006, p 701-707

13.      Lech Pawlowski, “Suspension and solution thermal spray coatings”, Surface & Coatings Technology, 203 (2009) 2807–2829

George E. Kim, Ph.D.

F.W. Gartner

Perpetual Technologies, Inc.

email: gkim@perpetualtech.ca

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