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This paper aims to verify weather atmospheric plasma spray (APS) in situ remelting posttreatment is effective for densifying the porous FeCoCrMoCBY amorphous alloy (FAA) coating and improving the antiabrasion and anticorrosion performances or not.

APS was used to deposit and in situ densify FAA coating on the 40Cr substrate. Scanning electron microscope, X-ray diffractometer, energy dispersive spectroscopy, neutral salt spray, hardness and wear behavior test were used to evaluate the densifying effects.

APS remelting technology can effectively improve the hardness of the coating by reducing the porosity. After remelting at 30 kW power, the hardness of the coating increased by about 260 HV0.2 and the porosity decreased to 2.78%. The amorphous content of the coating is 93.9%, which is about 3.5% lower than original powders. The electrochemical impedance spectrum and neutral salt spray test results show that APS remelting can reduce the corrosion rate by about 62.7%.

APS remelting method is firstly proposed in this work to replace laser remelting or laser cladding methods. APS remelting method can effectively improve the corrosion and abrasion resistance of the FAA coating by increasing the densification with much low recrystallization, which is big progress for application of FAA coatings.

This study aims to review the recent advancements in high entropy alloys (HEAs) called high entropy materials, including high entropy superalloys which are current potential alternatives to nickel superalloys for gas turbine applications. Understandings of the laser surface modification techniques of the HEA are discussed whilst future recommendations and remedies to manufacturing challenges via laser are outlined.

Materials used for high-pressure gas turbine engine applications must be able to withstand severe environmentally induced degradation, mechanical, thermal loads and general extreme conditions caused by hot corrosive gases, high-temperature oxidation and stress. Over the years, Nickel-based superalloys with elevated temperature rupture and creep resistance, excellent lifetime expectancy and solution strengthening L12 and γ´ precipitate used for turbine engine applications. However, the superalloy’s density, low creep strength, poor thermal conductivity, difficulty in machining and low fatigue resistance demands the innovation of new advanced materials.

HEAs is one of the most frequently investigated advanced materials, attributed to their configurational complexity and properties reported to exceed conventional materials. Thus, owing to their characteristic feature of the high entropy effect, several other materials have emerged to become potential solutions for several functional and structural applications in the aerospace industry. In a previous study, research contributions show that defects are associated with conventional manufacturing processes of HEAs; therefore, this study investigates new advances in the laser-based manufacturing and surface modification techniques of HEA.

The AlxCoCrCuFeNi HEA system, particularly the Al0.5CoCrCuFeNi HEA has been extensively studied, attributed to its mechanical and physical properties exceeding that of pure metals for aerospace turbine engine applications and the advances in the fabrication and surface modification processes of the alloy was outlined to show the latest developments focusing only on laser-based manufacturing processing due to its many advantages.

It is evident that high entropy materials are a potential innovative alternative to conventional superalloys for turbine engine applications via laser additive manufacturing.

The purpose of this paper is to investigate the effects of parallel texturing coating on antifriction mechanism of lubricating wear-resistant coating.

A KF301/WS2 lubricating wear-resisting coating was prepared on matrix material GCr15 by applying supersonic plasma spraying technology. On the basis of this sample, the KF301/WS2 modified coating with parallel pit-type texture was prepared by laser re-melting technology and a surface texturing technique. Their friction and wear behaviors were evaluated under ambient temperature, and the antifriction mechanism of two kinds of coatings were discussed.

Results showed that parallel texture has a certain impact on the tribological properties of the coating. When friction and wear reach stable state, the value of the friction coefficient of conventional coating was 0.115, while that of parallel texturing coating was 0.09, the latter decreased by 21 per cent. When the friction and wear time was up to 4 hours, the wear loss of the conventional coating was 0.29 mg, while that of the parallel texturing coating was 0.13 mg, the latter decreased by 55 per cent.

The tribological properties of parallel texturing coating were higher than conventional coating. That is because the change of three-body layer reduces the friction coefficient and the abrasive particles were collected by parallel texture, reducing the effects of debris.

The purpose of this paper is to provide an experimental basis for studying the effects of laser remelting on the surface modification of arc-sprayed Al coating.

A layer of arc-sprayed Al coating on S355 steel was remelted with a CO₂ laser, and the surface-interface morphologies, compositions of chemical elements and phases of Al coating were analyzed with scanning electron microscopy, energy disperse spectroscopy and X-ray diffraction, respectively. The effects of laser remelting on compositions of chemical elements and bonding performance of Al coatings were discussed.

The result shows that there are some pores existing on the Al coating surface after arc spraying, and the combination mode of coating interface is primarily composed of mechanical bonding. The pores on the Al coating reduce after laser remelting, which improves the compact performance, and the mechanical binding mode by arc spraying is changed into metallurgical bonding. The Fe and Al atoms at the coating interface are distributed with gradient, and the stratified enrichment is evident, which improves binding performance of the Al coating. The Al coating exhibits general corrosion before laser remelting and local corrosion after laser remelting, which improves the corrosion resistance of Al coating.

The arc-sprayed Al coating is remelted by CO₂ laser, improving its microstructures and bonding mode with the substrate.

The purpose of this paper is to evaluate the salt spray corrosion (SSC) and electrochemical corrosion performances of CrNi, TiAlN/NiCr and CrNi–Al₂O₃–TiO₂ coatings on H13 steel, which improved the corrosion resistance of H13 hot work mold.

CrNi, TiAlN/NiCr and CrNi–Al₂O₃–TiO₂ coatings were fabricated on H13 hot work mold steel using a laser cladding and cathodic arc ion plating. The SSC and electrochemical performances of obtained coatings were investigated using a corrosion test chamber and electrochemical workstation, respectively. The corrosion morphologies, microstructure and phases were analyzed using an electron scanning microscope, optical microscope and X-ray diffraction, respectively, and the mechanisms of corrosion resistance were also discussed.

The CrNi coating is penetrated by corrosion media, producing the oxide of Fe₃O₄ on the coating surface; and the TiAlN coating is corroded to enter into the CrNi coating, forming the oxides of TiO and NiO, the mechanism is pitting corrosion, whereas the CrNi–Al₂O₃–TiO₂ coating is not penetrated, with no oxides, showing the highest SSC resistance among the three kinds of coatings. The corrosion potential of CrNi coating, TiAlN/CrNi and CrNi–Al₂O₃–TiO₂ coatings was –0.444, –0.481 and –0.334 V, respectively, and the corresponding polarization resistances were 3,074, 2,425 and 86,648 cm², respectively. The electrochemical corrosion resistance of CrNi–Al₂O₃–TiO₂ coating is the highest, which is enhanced by the additions of Al₂O₃ and TiO₂.

The CrNi, TiAlN/CrNi and CrNi–Al₂O₃–TiO₂ coatings on H13 hot work mold were firstly evaluated by the SSC and electrochemical performances.

The purpose of this paper is to predict and control the composition during laser additive manufacturing, since composition control is important for parts manufactured by laser additive manufacturing. Aluminum and steel functionally graded material (FGM) were manufactured by laser metal deposition, and the composition was analyzed by means of spectral analysis simultaneously.

The laser metal deposition process was carried out on a 5 mm thick 316L plate. Spectral line intensity ratio and plasma temperature were chosen as two main spectroscopic diagnosis parameters to predict the compositional variation. Single-trace single-layer experiments and single-trace multi-layer experiments were done, respectively, to test the feasibility of the spectral diagnosis method.

Experiment results showed that with the composition of metal powder changing from steel to aluminum, the spectral intensity ratio of the characteristic spectral line is proportional to the elemental content in the plasma. When the composition of deposition layers changed, the characteristic spectrum line intensity ratio changed obviously. And the linear chemical composition analysis results confirmed the gradient composition variation of the additive manufacturing parts. The results verified the feasibility of composition analysis based on spectral information in the laser additive manufacturing process.

The composition content of aluminum and steel FGM was diagnosed by spectral information during laser metal deposition, and the relationship between spectral intensity and composition was established.

The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed.

Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes.

The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants.

This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

A two‐dimensional laser surface remelting problem is numerically simulated. The mathematical formulation of this multiphase problem is obtained using a continuum model, constructed from classical mixture theory. This formulation permits the construction of a set of continuum conservation equations for pure or binary, solid‐liquid phase change systems. The numerical resolution of this set of coupled partial differential equations is performed using a finite volume method associated with a PISO algorithm. The numerical results show the modifications caused by an increase of the free surface shear stress (represented by the Reynolds number R_e) upon the stability of the thermocapillary flow in the melting pool. The solutions exhibit a symmetry‐breaking flow transition, oscillatory behaviour at higher values of R_e. Spectral analysis of temperature and velocity signals for particular points situated in the melted pool, show that these oscillations are at first mono‐periodic them new frequencies appear generating a quasi‐periodic behaviour. These oscillations of the flow in the melted pool could induce the deformation of the free surface which in turn could explain the formation of surface ripples observed during laser surface treatments (surface remelting, cladding) or laser welding.

In last month's “Corrosion Commentary” we gave brief details of the new Hy‐Pac process from Plasma Coatings Ltd. to produce non‐porous thermally sprayed coatings. We have now received the following further information.

The purpose of this paper is to determine conditions under which good metallurgical bonding was achieved in 3D objects formed by depositing tin droplets layer by layer.

Molten tin droplets (0.18‐0.75 mm diameter) were deposited using a pneumatic droplet generator on an aluminum substrate. The primary parameters varied in experiments were those found to most affect bonding between droplets on different layers: droplet temperature (varied from 250 to 325°C) and substrate temperature (varied from 100 to 190°C). Droplet generation frequency was kept low enough (1‐10 Hz) that each layer of droplets solidified and cooled down before another molten droplet impinged on it.

In this paper, a one dimensional heat transfer model was used to predict the minimum droplet and substrate temperatures required to remelt a thin layer of the substrate and ensure good bonding of impinging droplets. Cross‐sections through samples confirmed that increasing either the droplet temperature or the substrate temperature to the predicted remelting region produces good bonding between deposition layers.

This paper used a practical model to provide reasonable prediction of conditions for droplet fusion which is essential to droplet‐based manufacturing. The feasibility of fabricating 3D metal objects by deposition of molten metal droplets has been well demonstrated.