Crystalline and amorphous PEO based ceramic coatings on AA6061: Nanoindentation and corrosion studies

Present study reports the detailed nanomechanical and corrosion behaviours of crystalline and amorphous plasma electrolytic oxidation (PEO) coatings developed on Aluminium alloy-6061. The concentration of sodium silicate in the electrolyte is tailored to achieve crystalline and amorphous natures of the PEO coatings. X-ray diffraction (XRD), scanning electron microscopy (SEM) and nanoprofilometry techniques are utilized to investigate microstructural and morphological properties of the PEO coatings. XRD studies confirmed that crystalline ceramic phases are obtained at lower silicate concentration while amorphous nature occurred for comparatively higher concentration of silicate in the electrolyte. Nanoindentation technique is utilized to study the mechanical properties such as hardness (H) and Young's modulus (E) of the PEO coatings. The scatter of the data is treated with well-established Weibull statistical method. Finally, in depth corrosion behaviour of the coatings are investigated by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization techniques. Amorphous coatings exhibited superior mechanical properties compared to the crystalline coatings. This is possibly linked with the presence of aluminosilicate phases and difference in silicon content in the coatings. However, as expected crystalline PEO coatings offer better corrosion resistance than the amorphous coatings and this behaviour is explained in terms of porosity contents of the coatings.     

Determination of Thermal Spray Coating Property with Curvature Measurements

Real-time curvature measurement of a coating-substrate system during deposition has facilitated the monitoring of coating stresses and provided additional insights into thermal spray deposition mechanisms. However, the non-equilibrium state of coating formation along with harsh spray booth environment introduces complexity not only in data interpretation but also in the coating properties estimation. In this paper, a new procedure is proposed to estimate the elastic modulus of thermal sprayed ceramic coatings using in situ curvature and temperature measurements. In order to correlate the measurable parameters to coating elastic modulus, a systematic study is conducted to develop a suitable methodology. First, various finite element model analyses are carried out to formulate suitable relations between the measurements and elastic modulus. Subsequently, experiments are conducted to validate the procedure to estimate coating moduli. The results are compared with more accurate measurements obtained from post-deposition characterization technique under low temperature thermal cycles. The comparison suggests that the moduli estimated using the proposed procedure are in good agreements with those obtained from the post-deposition technique. Further, the nonlinear response of coatings are evaluated from the estimated moduli during deposition and cool down, which offer additional information on the characteristics of thermal spray coatings.     

Mechanical Behavior of Spray-Coated Metallic Laminates

Thermal spray (TS) coatings have been extensively utilized for various surface modifications such as enhancing wear/erosion resistance and thermal protection. In the present study, a new function of TS material is explored by studying its load-carrying capability. Due to the inherent microstructures containing voids and interfaces, it has been presumed TS materials were not suitable to bear loads. However, the recent advances in TS technology to manufacture near fully dense TS coatings have expanded their potential applications. In the current experiments, TS nickel coatings are deposited onto metallic substrates, and their mechanical behaviors are closely examined. Based on the measured data, the estimated elastic modulus of TS Ni is about 130 GPa (35% less than bulk value), and the maximum tensile strength is about 500 MPa (comparable to bulk value). It was found that such a high value is attainable because the coating is deposited onto a substrate, enabling a load-transfer mechanism and preventing coating failure at a much lower stress level. Three distinct deformation stages are identified to describe this behavior. Such a clarification is critical for enabling TS process to restore structural parts as well as to additively manufacture load-bearing components.     

The 2016 Thermal Spray Roadmap

Considerable progress has been made over the last decades in thermal spray technologies, practices and applications. However, like other technologies, they have to continuously evolve to meet new problems and market requirements. This article aims to identify the current challenges limiting the evolution of these technologies and to propose research directions and priorities to meet these challenges. It was prepared on the basis of a collection of short articles written by experts in thermal spray who were asked to present a snapshot of the current state of their specific field, give their views on current challenges faced by the field and provide some guidance as to the R&D required to meet these challenges. The article is divided in three sections that deal with the emerging thermal spray processes, coating properties and function, and biomedical, electronic, aerospace and energy generation applications.     

Combinatorial-designed multifunctional polymeric nanosystems for tumor-targeted therapeutic delivery

By definition, multifunctional nanosystems include several features within a single construct so that these devices can target tumors or other disease tissue, facilitate in vivo imaging, and deliver a therapeutic agent. Investigations of these nanosystems are rapidly progressing and provide new opportunities in the management of cancer. Tumor-targeted nanosystems are currently designed based primarily on the intrinsic physico-chemical properties of off-the-shelf polymers. Following fabrication, the surfaces of these nanoscale structures are functionalized for passive or active targeted delivery to the tumors. In this Account, we describe a novel approach for the construction of multifunctional polymeric nanosystems based on combinatorial design principles. Combinatorial approaches offer several advantages over conventional methods because they allow for the integration of multiple components with varied properties into a nanosystem via self-assembly or chemical conjugation. High-throughput synthesis and screening is required in polymer design because polymer composition directly affects properties including drug loading, retention in circulation, and targeting of the nanosystems. The first approach relies on the self-assembly of macromolecular building blocks with specific functionalities in aqueous media to yield a large variety of nanoparticle systems. These self-assembled nanosystems with diverse functionalities can then be rapidly screened in a high-throughput fashion for selection of ideal formulations, or hits, which are further evaluated for safety and efficacy. In another approach, a library of a large number of polymeric materials is synthesized using different monomers. Each of the formed polymers is screened for the selection of the best candidates for nanoparticle fabrication. The combinatorial design principles allow for the selection of those nanosystems with the most favorable properties based on the type of payload, route of administration, and the desired target for imaging and delivery.     

Mechanical,thermal, tribological,and flammability properties of polybutylene terephthalate composites: Comparing the effects of synthetic wollastonite nanofibers,natural wollastonite,and graphene oxide

Polybutylene terephthalate (PBT) composites were prepared with 1.0 phr synthetic wollastonite nanofibers (SWN), natural wollastonite (NW) and graphene oxide (GO) to study the effect of different fillers on mechanical, thermal, tribological, and flammability properties. The properties of PBT composites are related to the size, structure, and interfacial adhesion of the fillers in PBT matrix. PBT/SWN demonstrated the highest tensile strength and Young's modulus (6% and 9% increment), followed by PBT/NW (1.3% and 7% increment) and PBT/GO (2% decrement and 4% increment). PBT/SWN gave the highest degradation temperature (409°C), followed by PBT/GO (404.7°C). The maximum enhancement in wear resistance (73%) by PBT/SWN and anti-friction performance (26%) by PBT/GO evinced the excellent load-bearing ability of SWN and the great lubricating effect of GO. PBT/NW had the lowest peak heat release rate, smoke, and carbon dioxide production rate. This study shows that PBT composites have great potential in different automotive applications.     

On the Interplay Between Adhesion Strength and Tensile Properties of Thermal Spray Coated Laminates—Part I: High Velocity Thermal Spray Coatings

Adhesion of thermal spray (TS) coatings is an important system level property in coating design and application. Adhesive-based pull testing (ASTM C633) has long been used to evaluate coating/substrate bonding. However, this approach is not always suitable for high velocity spray coatings, for example, where adhesion strengths are routinely greater than the strength of the adhesive bonding agent used in the testing. In this work, a new approach has been proposed to evaluate the adhesion of TS coatings. A systematic investigation of the effects of substrate roughness on both the uniaxial tensile yield strength and traditional bond pull adhesive strength of HVOF Ni and Ni-5wt.%Al, as well as cold-sprayed Ni-coated laminates revealed a strong correlation between these two test methodologies for the respective materials and processes. This approach allows measurement of the adhesion response even where the adhesive method is not applicable, overcoming many of the issues in the traditional ASTM C633. Analysis of cracking patterns of the coatings after 10.5% strain was used to assess the adhesion and cohesion properties. The mechanisms which determine the load transfer between the substrate and the coating are also briefly discussed.     

Fracture Toughness of Plasma‐Sprayed Thermal Barrier Ceramics: Influence of Processing,Microstructure, and Thermal Aging

Fracture toughness of thermal barrier coatings (TBCs) has gained significant interest in recent years as one of the dominant design parameters dictating selection of materials and assessing durability. Much progress has been made in characterizing and understanding fracture toughness of relevant TBC compositions in their bulk form, but it is also apparent that the toughness is significantly affected by process‐induced microstructural defects. In this investigation, a systematic study of the influence of coating microstructure on the fracture toughness of atmospheric plasma‐sprayed TBCs has been carried out. Yttria partially stabilized zirconia (YSZ) coatings were fabricated under different process conditions inducing different levels of porosity and defect densities. Fracture toughness was measured on free‐standing coatings in as‐processed and thermally aged conditions using the double torsion technique. Results indicate significant variance in fracture toughness among coatings with different microstructures including changes induced by thermal aging. Comparative studies were also conducted on an alternative composition, Gd₂Zr₂O₇ which, as anticipated, shows significantly lower fracture toughness compared to YSZ. The results not only point toward a need for process and microstructure optimization for enhancing TBC performance, but also a framework for establishing performance metrics for promising new TBC compositions.     

Compact hybrid Sierpinski Koch fractal UWB MIMO antenna with pattern diversity

In this article, a compact 2 element UWB MIMO antenna is proposed. It has a compact size of 40 mm × 20 mm (800 mm²). The antenna utilizes hybrid Sierpinski Koch fractal shape as the radiating element. The antenna elements are placed parallel and close to each other. The isolation between the antenna elements is increased by employing a modified stepped ground plane and a reflecting ground stub. The use of stub results in pattern diversity. A U‐ Shaped slot is etched in the radiating element to notch the WLAN band that interferes with UWB. The antenna performance is measured in terms of S‐parameter, radiation pattern and diversity performance. Considering S₁₁ < ?10 dB, the antenna offers an acceptable impedance bandwidth from 2.5 to 11 GHz, with an isolation better than 20 dB over the UWB range. It has a stable omnidirectional pattern. In terms of diversity performance, the antenna has an envelope correlation coefficient (ECC) of <0.1 and capacity loss of <0.1 bps/Hz. The channel capacity of the antenna in the outdoor environment is obtained using Wireless Insite. The channel capacity is found to be 2 Gb/s. The proposed antenna thus can be a good candidate for portable UWB application.     

Osteogenic protein-1 up-regulation of the collagen X promoter activity is mediated by a MEF-2-like sequence and requires an adjacent AP-1 sequence

Bone morphogenetic proteins induce chondrogenesis and osteogenesis in vivo. To investigate molecular mechanisms involved in chondrocyte induction, we examined the effect of osteogenic protein (OP)-1/bone morphogenetic protein-7 on the collagen X promoter. In rat calvaria-derived chondrogenic C5.18 cells, OP-1 up-regulates collagen X mRNA levels and its promoter activity in a cell type- specific manner. Deletion analysis localizes the OP-1 response region to 33 bp (-310/-278), which confers OP-1 responsiveness to both the minimal homologous and heterologous Rous sarcoma virus promoter. Transforming growth factor-beta2 or activin, which up-regulates the expression of a transforming growth factor-beta-inducible p3TP-Lux construct, has little effect on collagen X mRNA and on this 33-bp region. Mutational analysis shows that both an AP-1 like sequence (-294/-285, TGAATCATCA) and an A/T-rich myocyte enhancer factor (MEF)-2 like sequence (-310/-298, TTAAAAATAAAAA) in the 33-bp region are necessary for the OP-1 effect. Gel shift assays show interaction of distinct nuclear proteins from C5.18 cells with the AP-1-like and the MEF-2-like sequences. OP-1 rapidly induces nuclear protein interaction with the MEF-2-like sequence but not with the AP-1 like sequence. MEF-2-like binding activity induced by OP-1 is distinct from the MEF-2 family proteins present in C2C12 myoblasts, in which OP-1 does not induce collagen X mRNA or up-regulate its promoter activity. In conclusion, we identified a specific response region for OP-1 in the mouse collagen X promoter. Mutational and gel shift analyses suggest that OP-1 induces nuclear protein interaction with an A/T-rich MEF-2 like sequence, distinct from the MEF-2 present in myoblasts, and up-regulates collagen X promoter activity, which also requires an AP-1 like sequence.