0000000000069754
AUTHOR
Hanlin Liao
Heterostructured metal oxides-ZnO nanorods films prepared by SPPS route for photodegradation applications
Abstract This work presents the first preparation using the Solution Precursor Plasma Spray process of heterostructured films associating ZnO nanorods (NRs) and various metal oxides (CuO, Fe2O3 and Co3O4) by Solution Precursor Plasma Spray process. These CuO/ZnO, Fe2O3/ZnO and Co3O4/ZnO films exhibit hierarchically chocolate sticks-like, dandelion-like or chrysanthemum-like surface morphologies. These heterostructures were confirmed by SEM, XRD, EDS and Raman analyses. The bandgaps of heterostructured films are narrower than that of pure ZnO. The CuO/ZnO film exhibits the highest photocatalytic activity both under UV and visible light irradiation for the degradation of the Orange II dye due…
Microstructural, mechanical and tribological properties of suspension plasma sprayed YSZ/h-BN composite coating
Abstract Brittleness, relative high friction coefficient and wear rate limit the applications of ceramic coatings as wear-resistant layers. However, because embedding additives with ceramic matrix has demonstrated to be an effective way to improve coating performances, different contents and size of h-BN were added into an YSZ suspension. Afterwards, the YSZ/h-BN composite coatings were manufactured by suspension plasma spray and their tribological analysis indicated that: i) the reduction of the friction coefficient and wear rate can be achieved by incorporating h-BN into YSZ coating. ii) finer h-BN particle is more helpful to enhance the tribological properties of the coating. iii) the op…
Effect of oxidation post treatments on TiO2 coating manufactured using reactive very low-pressure plasma spraying (R-VLPPS)
Abstract TiO2 coatings manufactured using reactive very low-pressure plasma spraying (R-VLPPS) were analyzed in different regions related to their position compared to the plasma flame. For that, a screen was used in order to hide an area of the substrate from the direct plasma flux. The coating morphology changed from quasi lamellar structure to highly vapor structure and coatings exhibited obvious modifications in terms of phases and mechanical properties. The effect of oxidation post treatment on the as sprayed coating was then studied by selecting two methods: in situ oxidation post treatment and classical thermal treatment. The two post treatments provided an increase of the main rutil…
Nanoscale chemistry and atomic-scale microstructure of a bulk Ni3Sn material built using selective laser melting of elemental powder blends
Abstract Cubic specimens of the intermetallic Ni3Sn compound were built using selective laser melting of elemental powder blends. A specimen built at a laser power of 200 W and a scanning speed of 0.5 m/s was determined to have a homogeneous distribution of Ni and Sn on a mesoscopic scale in spite of a 2 at.% Sn deficiency. Characterization of the microstructure using the HAADF-STEM technique reveals a dispersion of ultrafine Ni particles, nanoscale chemical inhomogeneity and the formation of antiphase nanodomains in the matrix of equiaxed Ni3Sn grains. While a mesoscopic homogeneity of the specimen demonstrates a prospect of additive manufacturing of a bulk intermetallic material using sel…
Wear and corrosion resistant performance of thermal-sprayed Fe-based amorphous coatings: A review
Abstract Thermal sprayed Fe-based amorphous coatings exhibit excellent wear and corrosion resistance, and thus have been widely utilized for enhancing the performance of material surfaces. In this paper, important research progresses achieved in regards to deposition technologies and properties of thermal sprayed Fe-based amorphous coatings are reviewed. In particular, the dependence of wear and corrosion resistance of the coatings on processing parameters, e.g., kinetic energy, particle size, gas flow rate, and heat treatment temperature are summarized. Moreover, the utilization of reinforced phases and alloy elements for enhancing the wear and corrosion resistance of the coatings are pres…
Influence of laminated architectures of heterostructured CeO2-ZnO and Fe2O3-ZnO films on photodegradation performances
Abstract The development of photocatalytically active films has gained a great attention in recent years. Herein, new heterostructured films associating ZnO and CeO2 or Fe2O3 and exhibiting various architectures were prepared by the solution precursor thermal spray (SPPS) process. The paper examines the effect of the films laminated architectures on the photodegradation performance. For CeO2-ZnO and Fe2O3-ZnO films, the photodegradation efficiency of the Orange II dye is 100% and 95% after 240 min UV light irradiation and after 360 min visible light irradiation, respectively. The photocatalytic activity of the laminated structures was found to depend on the materials used to construct the h…
Stable layer-building strategy to enhance cold-spray-based additive manufacturing
Abstract Cold spray (CS) has recently become one of the popular additive manufacturing (AM) processes for its advantages: high-forming efficiency, low temperature, and no phase changing of materials. These advantages may make CS able to form large volume objects and possibly directly iterate with material-removing processes to become a hybrid AM process. Current research proposes using a bulk-based volume-forming strategy (e.g. a tessellation-based method) for volume building. Although it can form 3D volumes, the control of the process is difficult and it has limitations in forming complex 3D near-net-shapes with acceptable accuracy. This also conflicts with the basic principle of AM, where…
Tunable morphologies of ZnO films via the solution precursor plasma spray process for improved photocatalytic degradation performance
Abstract The Solution Precursor Plasma Spray (SPPS) process is a novel, versatile and one-step route for building photocatalytic films. Herein, the influence of the precursor solution composition on the microstructure and on the properties of ZnO films prepared via the SPPS process was studied. Nanostructured ZnO particles (i.e. nanorods (NRs) and nanowires (NWs)) were obtained by using a solution of pure Zn(OAc)2 rather than pure Zn(NO3)2. Upon adding urea to the Zn(NO3)2 solution, NRs structured ZnO films were formed as well. The addition of acetic acid into the Zn(OAc)2 solution led to a damage of the nanostructured morphologies likely due to the inhibition of the zinc-containing cluster…
Evaluation of nano/submicro pores in suspension plasma sprayed YSZ coatings
Abstract Nano-submicro pores could considerably influence the coating performances and thus should be properly designed for the intended applications. However, it is challenging to characterize accurately such small pores in coatings. In this study, YSZ coatings were firstly manufactured by suspension plasma spray (SPS) and the nano-submicro pores in as-prepared coatings were investigated using Ultra-small-angle X-ray scattering (USAXS). Afterwards, a multivariate analysis on the effect of five different process parameters was carried out. The two main results showed that: 1) the nano-submicro pores content in coatings has a negative correlation with suspension mass load and powder size, an…
Development of photocatalytically active heterostructured MnO/ZnO and CuO/ZnO films via solution precursor plasma spray process
Abstract Heterostructured ZnO photocatalysts for the degradation of organic pollutant are mainly synthesized by conventional chemical methods, suffering from long duration, multi-steps, and post-treatment of the powder-formed catalysts after usage. In this paper, Solution Precursor Plasma Spray (SPPS) process is demonstrated to be a fast and efficient method for the one-step preparation of MnO/ZnO and CuO/ZnO heterostructured films for photocatalytic applications. The ratios between MnO or CuO and ZnO materials in the films were easily adjusted by varying the molar ratio of Mn(OAc)2 or Cu(OAc)2 relative to Zn(OAc)2 during the SPPS synthesis. To optimize the microstructure of selected CuO/Zn…
Bonding behavior of Bi-metal-deposits produced by hybrid cold spray additive manufacturing
Abstract Cold spraying (CS) is one of the most recently used additive manufacturing (AM) processes that allow forming large 3D objects efficiently without severe thermal effects. However, due to some limitations of the CSAM process, it is difficult to achieve the desired geometry with high precision. As a potential solution to this issue, CSAM process coupled machining, that is, hybrid addition and subtraction manufacturing, is proposed to achieve desired accuracy and reliable shape. Therefore, it is necessary to assess the mechanical reliability of multilayer deposits deposited by CSAM + machining processes before that. In this work, different bi-deposits were obtained via hybrid CSAM. The…
Deposition of hollow sphere In2O3 coatings by liquid flame spray
Hollow sphere In(OH)3 coatings were deposited by a simple liquid flame spray with hollow sphere In(OH)3 suspension, which was synthesized by improved soft template methods. The morphology of the In...
A new approach to simulate coating thickness in cold spray
Abstract In the process of cold spray on complex components, the coating thickness is an important indicator to monitor and control. Current methods such as destructive tests or direct mechanical measurements can only be performed after spraying. Besides, these methods lead to production shutdown and additional costs . This article presents a novel approach predicting coating thickness for components with complex curved surfaces, especially in the case of shadow effects. Firstly, a three-dimensional geometric model of the coating profile based on Gaussian distribution was developed. In addition, the relative deposition efficiency (RDE) resulting from the different robot kinematic parameters…
Deposition of binder-free oxygen-vacancies NiCo2O4 based films with hollow microspheres via solution precursor thermal spray for supercapacitors
Abstract Hollow micro-/nanostructures and oxygen vacancies are highly desirable for supercapacitors due to high active surface area and outstanding electrochemical properties. In order to benefiting from the both effect, binder-free oxygen-vacancies NiCo2O4 based films with hollow microspheres were pioneering directly deposited via one kind thermal spray technology, named solution precursor thermal spray (SPTS) process. To our best knowledge, the rapid one-step SPTS route was firstly employed to synthesize and deposit NiCo2O4 films for supercapacitor applications. The CV data clearly demonstrated that the specific capacitances of more oxygen-deficient NiCo2O4 electrodes with hollow microsph…
Solution precursor plasma spray process as an alternative rapid one-step route for the development of hierarchical ZnO films for improved photocatalytic degradation
Abstract The development of efficient photocatalytic hierarchical coral-like ZnO films via a relatively simple, efficient, rapid and single-step process is essential for industrial development. Herein, we report a novel method for directly synthesizing well-shaped ZnO nanorods (NRs) by Solution Precursor Plasma Spray (SPPS) process rather than conventional spherical/ellipsoidal particles. In the prepared ZnO-NRs films, the ZnO NRs display an average diameter of 190 nm, and exhibit a preferential orientation growth along (002) plane compared to a reference ZnO films (called ZnO-P) containing spherical/ellipsoidal particles. ZnO-NRs films exhibit relative narrower bandgap (3.02 eV) probably d…
Influence of spray trajectories on characteristics of cold-sprayed copper deposits
Abstract Industrial robots are widely used in cold spray (CS) as well as thermal spray to produce various coatings by precisely controlling kinematic parameters during the process. However, the robot trajectory and its effect on the characteristics of CS deposits are important, but not fully studied. This article introduces four typical spray trajectories, including zigzag path, cross path, parallel path, and spiral path, to elaborate thick CS Cu deposits, and characterizes the corresponding Cu deposits, respectively. The experimental results revealed that the spray trajectories have a major influence on the associated thermal history and the residual stress distribution. However, no signif…
Microstructure and electric properties of low-pressure plasma sprayed β-FeSi 2 based coatings
Abstract Thermoelectric material β-FeSi 2 based coating was fabricated by the technique low-pressure plasma spray (LPPS) on the Al 2 O 3 substrate from different alloy powders. During the process LPPS, the phase transformation had occurred through the peritectoid, eutectoid reaction and their inverse reaction. The grain size of the as-sprayed β-FeSi 2 doped Co coatings was reduced comparing with the original feedstock powders, which implied the thermal conductivity could effectively decreased by the LPPS process. The room temperature electrical conductivity showed metal and semiconductor properties on the as-sprayed and annealed coatings. This method and the results could solve the problems…
Porous architecture and thermal properties of thermal barrier coatings deposited by suspension plasma spray
Abstract Besides the intrinsic low heat transfer capability of material, the thermal insulation property of thermal barrier coatings (TBCs) also relies on their microstructures. For better understanding the relationship between process parameters, porous architecture, and thermal properties of coatings, YSZ coatings were firstly manufactured by suspension plasma spray (SPS). Afterwards their total porosities were characterized by using the technique of X-ray transmission, the nano/submicro pores in those coatings were detected with Ultra-Small Angle X-ray Scattering (USAXS), and the thermal properties of coatings were measured using the laser flash method. The results indicated that: i) the…
Oxygen-deficient Co3O4 submicron porous sphere films as highly active supsercapacitor electrodes
Abstract Herein, we report Co3O4 films with different content of oxygen vacancies and shapes of particles for supercapacitor electrodes. Under the similar area ratio of OII peak in the XPS spectrum of oxygen elements, the specific capacitance of electrode films with hollow spongy-like particles (963 F/g under a scan rate of 5 mV/s) is 1.6 times higher than that of the electrodes with solid irregular particles (596 F/g), indicating the effect of particle shapes on electrochemical properties. The films composed of submicron porous spheres and containing highest content of oxygen vacancies exhibited the specific capacitances as high as 1700 F/g under the scan rate of 5 mV/s. By contrast, after…
Laser densification of organic coating: Effects of laser wavelength, operating parameters and substrate properties
International audience; Mechanical bonding and interface behaviour play a key role for any materials deposited on different substrates. Usually, a post-spray heat treatment is required to improve the coating morphology and to enhance mechanical properties of thermal-sprayed polymeric coating. The effects of YAG, CO2 and diode laser radiations on as-sprayed PEEK coating deposited on stainless steel and aluminum substrates were investigated. The results revealed a good coating densification and interface behavior. A correlation between coating and substrate absorption coefficients, their thermophysical properties and laser operating parameters was shown. Besides, the finite element modeling b…
One-step synthesis and deposition of ZnFe2O4 related composite films via SPPS route for photodegradation application
Binary spinel-type metal oxides (AB2O4) related materials, including ferrites (AFe2O4), are attractive photocatalysts thanks to their excellent visible light response for the photodegradation of organic pollutants. Currently, these materials are synthesized via conventional chemical routes suffering from long preparation duration and multistep. Moreover, the photocatalysts are obtained as nano-powders from conventional chemical routes would introduce another drawback for their recycling and reuse. From an industrial perspective, it is desirable to develop an efficient and facile synthesis process to produce photocatalysts in a non-dispersible form. Herein, we demonstrate that the solution p…
Improvement of flame spraying PEEK coating characteristics using lasers
Flame spraying is frequently used for PEEK coatings elaboration on metallic surfaces. However, this process has a certain number of limitations particularly considering the quality of the coatings like high porosity or low interfacial adherence. For that reason a thermal post-processing is often necessary. From all of the processes which can be used (flame, oven, etc.), laser can be an interesting technology. Then, the aim of this study is to analyse the dependence of the morphological structure (compactness) and the adherence of the flame sprayed PEEK coatings to the stainless steel (304L) and aluminium alloy (AA2017) substrates on laser parameters. Moreover, the influence of the laser bea…
Numerical Reconstruction of Porous Architecture for Suspension Plasma Sprayed Coatings
Abstract The porous architecture of coatings has a significant influence on the coating performances and thus should be properly designed for the intended applications. For simulating the coating properties, it is necessary to determine the numerical representation of the coating microstructure. In this study, YSZ coatings were manufactured by suspension plasma spray (SPS). Afterwards, the porous architecture of as-prepared coatings was investigated by the combination of three techniques, imaging analysis, Ultra Small Angle X-ray Scattering (USAXS), and X-ray transmission. A microstructural model for reconstructing the porous architecture of the SPS coating was subsequently computed accordi…
Cold gas dynamic spray additive manufacturing today: Deposit possibilities, technological solutions and viable applications
This paper reports the current potentials of cold gas dynamic spraying (CGDS). CGDS has been significantly developed to produce several functional solutions categorized as follows: deposits with a single powder nature, composites-based deposits, nanotechnological deposits and hybrid coating/substrate assemblies. CGDS process has improved in proficiency and is still gaining attention from scientists and industry. Covering a wide range of materials, both standard and advanced, this additive manufacturing process offers substantial applications for surface functionalization, structural or dimensional restoration, bulk production providing specific material properties, and art/decoration. Progr…
Prediction and analysis of high velocity oxy fuel (HVOF) sprayed coating using artificial neural network
Abstract Thermal spray comprises a group of coating processes for coating manufacturing in which metallic or nonmetallic materials are deposited in a molten or semi-molten condition. Most often, the coating properties are significantly influenced by the operating parameters. However, obtaining a comprehensive modeling or analytical analysis of the thermal spray process is too difficult to be practical due to the complex chemical and thermodynamic reactions. Accordingly, the present study aims at applying an artificial neural network (ANN) model to predict the HVOF sprayed Cr3C2−25NiCr coatings and analyze the influence of operating parameters regardless of the intermediate process. The proce…
Oxygen-defective ZnO films with various nanostructures prepared via a rapid one-step process and corresponding photocatalytic degradation applications.
Abstract The deposition of oxygen-defective ZnO films exhibiting varied nanostructures via Solution Precursor Plasma Spray (SPPS) route, a one-step, minute-scaled duration and large scale method, is reported. The in situ formation of oxygen vacancies in ZnO films was confirmed by UV–Visible, Raman and photoluminescence (PL) spectroscopy and the as-prepared samples exhibit a bandgap as low as 3.02 eV. Density functional theory (DFT) simulation demonstrates that the polarization of ZnO is enhanced by the created oxygen vacancies, leading to substantially improved photocatalytic activity. The comparative experiments also revealed that forming and preserving appropriate ZnO precursor clusters i…
Method for Identifying In-Flight Particles based on Digital Image Technologies in Thermal Spraying
Abstract In thermal spray processes, the characteristics of in-flight particles (velocity and temperature) have a significant effect on coating performance. Although many imaging systems and algorithms have been developed for identifying and tracking in-flight particles, most are limited in terms of accuracy. One key to solving the tracking problem is to get an algorithm that can distinguish different particles in each image frame. As the study showed, when noise and interference are treated, particles are more readily identified in the background, leading to more accurate size and position measurements with respect to time. This approach is demonstrated and the results discussed.