Gildersleeve Edward J, Vaßen Robert
Institute of Energy and Climate Research, Materials Synthesis and Processing (IEK-1), Forschungszentrum Jülich GmbH, 52425 Jülich, Germany.
J Therm Spray Technol. 2023;32(4):778-817. doi: 10.1007/s11666-023-01587-1. Epub 2023 Apr 27.
Thermal spray coatings are material systems with unique structures and properties that have enabled the growth and evolution of key modern technologies (i.e., gas turbines, structurally integrated components, etc.). The inherent nature of these sprayed coatings, such as their distinctive thermal and mechanical properties, has been a driving force for maintaining industrial interest. Despite these benefits and proven success in several fields, the adoption of thermal spray technology in new applications (i.e., clean energy conversion, semiconductor thermally sprayed materials, biomedical applications, etc.) at times, however, has been hindered. One possible cause could be the difficulty in concurrently maintaining coating design considerations while overcoming the complexities of the coatings and their fabrication. For instance, a coating designer must consider inherent property anisotropy, in-flight decomposition of molten material (i.e., loss of stoichiometry), and occasionally the formation of amorphous materials during deposition. It is surmisable for these challenges to increase the risk of adoption of thermal spray technology in new fields. Nevertheless, industries other than those already mentioned have benefited from taking on the risk of implementing thermal spray coatings in their infrastructure. Benefits can be quantified, for example, based on reduced manufacturing cost or enhanced component performance. In this overview paper, a historical presentation of the technological development of thermal spray coatings in several of these industries is presented. Additionally, emerging industries that have not yet attained this level of thermal spray maturation will also be discussed. Finally, where applicable, the utility and benefits of multilayer functional thermal spray coating designs will be demonstrated.
热喷涂涂层是具有独特结构和性能的材料体系，推动了关键现代技术（如燃气轮机、结构集成部件等）的发展与演进。这些喷涂涂层的固有特性，如独特的热性能和机械性能，一直是维持工业关注度的驱动力。尽管热喷涂涂层在多个领域具有这些优势且已取得成功，但在新应用（如清洁能源转换、半导体热喷涂材料、生物医学应用等）中采用热喷涂技术有时仍受到阻碍。一个可能的原因是，在克服涂层及其制造的复杂性的同时，难以兼顾涂层设计考量。例如，涂层设计师必须考虑固有性能各向异性、熔融材料的飞行中分解（即化学计量比的损失），以及沉积过程中偶尔形成的非晶态材料。可以推测，这些挑战增加了热喷涂技术在新领域应用的风险。然而，除上述行业外，其他行业也已从在其基础设施中采用热喷涂涂层所承担的风险中受益。例如，可以基于降低的制造成本或增强的部件性能来量化这些益处。在这篇综述文章中，将介绍热喷涂涂层在其中几个行业的技术发展历程。此外，还将讨论尚未达到热喷涂成熟水平的新兴行业。最后，在适用的情况下，将展示多层功能热喷涂涂层设计的实用性和益处。
