Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat
A new approach is proposed to achieve an in-depth understanding of crystallisation, residual stress and adhesion in epitaxial splats obtained by Combustion Flame Spray. Modelling of the fundamental process mechanisms is achieved with the help of experimental observations providing details with a sub...
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| Format: | Article |
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Elsevier
2018
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| Online Access: | https://eprints.nottingham.ac.uk/52163/ |
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| author | Fanicchia, F. Maeder, X. Ast, J. Taylor, A.A. Guo, Y. Polyakov, M.N. Michler, J. Axinte, D.A. |
| author_facet | Fanicchia, F. Maeder, X. Ast, J. Taylor, A.A. Guo, Y. Polyakov, M.N. Michler, J. Axinte, D.A. |
| author_sort | Fanicchia, F. |
| building | Nottingham Research Data Repository |
| collection | Online Access |
| description | A new approach is proposed to achieve an in-depth understanding of crystallisation, residual stress and adhesion in epitaxial splats obtained by Combustion Flame Spray. Modelling of the fundamental process mechanisms is achieved with the help of experimental observations providing details with a sub-micrometre spatial resolution. At this scope, High Angular Resolution Electron Backscatter Diffraction and Transmission Electron Microscopy analysis are employed to provide insights into crystallisation and residual stress levels, while FIB-milled microcantilever beam bending is used for fracture strength measurements in the case of single splats. A comparison to fully-developed coatings is achieved by employing the X-ray Diffraction technique and pull-off methods for residual stress and fracture strength, respectively. The methodology is applied to metallic CoNiCrAlY material sprayed onto a Ni-based superalloy substrate. The establishment of different crystallisation regions: epitaxial and polycrystalline, is the result of variations in the heat flux direction at the solidification front. Significant dislocation density is also reported, indicating the relevance of impact dynamics and plastic deformation mechanisms. The comparison with fully-developed coatings suggests a reduction in inter-splat bonding at splat overlapping. |
| first_indexed | 2025-11-14T20:23:20Z |
| format | Article |
| id | nottingham-52163 |
| institution | University of Nottingham Malaysia Campus |
| institution_category | Local University |
| last_indexed | 2025-11-14T20:23:20Z |
| publishDate | 2018 |
| publisher | Elsevier |
| recordtype | eprints |
| repository_type | Digital Repository |
| spelling | nottingham-521632020-05-04T19:49:05Z https://eprints.nottingham.ac.uk/52163/ Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat Fanicchia, F. Maeder, X. Ast, J. Taylor, A.A. Guo, Y. Polyakov, M.N. Michler, J. Axinte, D.A. A new approach is proposed to achieve an in-depth understanding of crystallisation, residual stress and adhesion in epitaxial splats obtained by Combustion Flame Spray. Modelling of the fundamental process mechanisms is achieved with the help of experimental observations providing details with a sub-micrometre spatial resolution. At this scope, High Angular Resolution Electron Backscatter Diffraction and Transmission Electron Microscopy analysis are employed to provide insights into crystallisation and residual stress levels, while FIB-milled microcantilever beam bending is used for fracture strength measurements in the case of single splats. A comparison to fully-developed coatings is achieved by employing the X-ray Diffraction technique and pull-off methods for residual stress and fracture strength, respectively. The methodology is applied to metallic CoNiCrAlY material sprayed onto a Ni-based superalloy substrate. The establishment of different crystallisation regions: epitaxial and polycrystalline, is the result of variations in the heat flux direction at the solidification front. Significant dislocation density is also reported, indicating the relevance of impact dynamics and plastic deformation mechanisms. The comparison with fully-developed coatings suggests a reduction in inter-splat bonding at splat overlapping. Elsevier 2018-09-05 Article PeerReviewed Fanicchia, F., Maeder, X., Ast, J., Taylor, A.A., Guo, Y., Polyakov, M.N., Michler, J. and Axinte, D.A. (2018) Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat. Materials & Design, 153 . pp. 36-46. ISSN 0264-1275 Thermal spray Splat Crystallisation Epitaxial growth Residual stress Solidification microstructure Fracture mechanism Plastic deformation https://www.sciencedirect.com/science/article/pii/S0264127518303101 doi:10.1016/j.matdes.2018.04.040 doi:10.1016/j.matdes.2018.04.040 |
| spellingShingle | Thermal spray Splat Crystallisation Epitaxial growth Residual stress Solidification microstructure Fracture mechanism Plastic deformation Fanicchia, F. Maeder, X. Ast, J. Taylor, A.A. Guo, Y. Polyakov, M.N. Michler, J. Axinte, D.A. Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title | Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title_full | Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title_fullStr | Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title_full_unstemmed | Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title_short | Residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial CoNiCrAlY single splat |
| title_sort | residual stress and adhesion of thermal spray coatings: microscopic view by solidification and crystallisation analysis in the epitaxial conicraly single splat |
| topic | Thermal spray Splat Crystallisation Epitaxial growth Residual stress Solidification microstructure Fracture mechanism Plastic deformation |
| url | https://eprints.nottingham.ac.uk/52163/ https://eprints.nottingham.ac.uk/52163/ https://eprints.nottingham.ac.uk/52163/ |