Novel Ni- and Fe-based alloys are developed to impart improved mechanical properties and corrosion resistance. The designed alloys are manufactured as a powder and deposited on a steel substrate using a high-velocity oxygen-fuel process. The coating layer demonstrates good corrosion resistance, and the thus-formed passive film is beneficial because of the Cr contained in the alloy system. Furthermore, during low-temperature heat treatment, factors that deteriorate the properties and which may arise during high-temperature heat treatment, are avoided. For the heattreated coating layers, the hardness increases by up to 32% and the corrosion resistance improves. The influence of the heat treatment is investigated through various methods and is considered to enhance the mechanical properties and corrosion resistance of the coating layer.

The purpose of this study is to improve the mechanical properties and develop manufacturing technology through self-soluble alloy powder flame spray coating on the surface of a run-out table roller for hot rolling. The roller surface of the run-out table should maintain high hardness at high temperatures and possess high wear, corrosion, and heat resistances. In addition, sufficient bonding strength between the thermal spray coating layer and base material, which would prevent the peel-off of the coating layer, is also an important factor. In this study, the most suitable powder and process for roll manufacturing technology are determined through the initial selection of commercial alloy powder for roll manufacturing, hardness, component analysis, and bond strength analysis of the powder and thermal spray coating layer according to the powder.

Ni-rich계 양극 소재는 낮은 가격과 높은 용량으로 인해 고용량 달성을 위한 상용화 소재로 주목받고 있지만, 이 소재의 경 우 전기화학적 불안정성으로 인한 한계를 가진다. 그래서 다양한 표면 코팅 방법을 통해 성능향상을 이루고 있지만, 성능향상이 소 재와 코팅 방법때문인지 또는 코팅 범위가 넓어진 것 때문인지는 모호하게 남아 있다. 본 연구에서는 전이금속으로 양극 활물질을 코팅할 때 전구체 코팅 범위에 따른 리튬이온배터리 전기화학 성능평가를 분석하였다. 상업용 LiNi0.8Co0.1Mn0.1O2 양극 소재 표면을 에탄올 용액에 용해된 리튬-코발트와 리튬-주석 아세테이트 전구체를 코팅하였고, 교반속도를 다르게 하여 (200 rpm 및 600 rpm) 전구체 코팅 범위를 다르게 하였다. 리튬-코발트 아세테이트 전구체의 경우 교반속도가 증가할수록 코팅 범위가 증가하였지만, 리튬 -주석 아세테이트 전구체의 경우 교반속도가 증가할수록 코팅 범위가 감소하였다. 하지만 원소의 종류에 관계없이 코팅 범위가 넓 은 경우에 상대적으로 우수한 전기화학적 성능을 나타내었다. 코팅된 양극 활물질의 물리적 특성은 SEM 및 XRD를 이용하여 분석하 였으며, 전기화학적 성능은 초기 충·방전 용량, 사이클 안정성 및 율속특성 테스트를 통해 조사하였다.

A novel approach was presented for deposition of nickel–graphene nanocomposite coating on copper. Unlike conventional methods, graphene and graphene oxide nanosheets were not used. The basis of the method is to synthesize graphene oxide by oxidation of graphite anode during the electrochemical deposition process. The obtained graphene oxide sheets were reduced during the deposition in the cathode and co-formed with the nickel deposition in the coating. The pulsed ultrasonic force was applied during the deposition process. When the ultrasonic force stops, the deposition process begins. Scanning electron microscopy, Raman spectroscopy, atomic force microscopy, X-ray diffraction and X-ray photoelectron spectroscopy confirmed the presence of graphene nanosheets in the coating. The amount of graphene nanosheets increases up to a maximum of 14.8 wt% by increasing the time of applying ultrasonic force to 6 s. In addition, with the presence of graphene in the nickel coating, the wear rate dramatically decreased.

In this study, the formation, microstructure, and wear properties of Colmonoy 88 (Ni-17W-15Cr-3B-4Si wt.%) + Stellite 1 (Co-32Cr-17W wt.%) coating layers fabricated by high-velocity oxygen fuel (HVOF) spraying are investigated. Colmonoy 88 and Stellite 1 powders were mixed at a ratio of 1:0 and 5:5 vol.%. HVOF sprayed selffluxing composite coating layers were fabricated using the mixed powder feedstocks. The microstructures and wear properties of the composite coating layers are controlled via a high-frequency heat treatment. The two coating layers are composed of γ-Ni, Ni3B, W2B, and Cr23C6 phases. Co peaks are detected after the addition of Stellite 1 powder. Moreover, the WCrB2 hard phase is detected in all coating layers after the high-frequency heat treatment. Porosities were changed from 0.44% (Colmonoy 88) to 3.89% (Colmonoy 88 + ST#1) as the content of Stellite 1 powder increased. And porosity is denoted as 0.3% or less by inducing high-frequency heat treatment. The wear results confirm that the wear property significantly improves after the high-frequency heat treatment, because of the presence of wellcontrolled defects in the coating layers. The wear surfaces of the coated layers are observed and a wear mechanism for the Ni-based self-fluxing composite coating layers is proposed.

In this study we manufacture a Ni-Cr-B-Si +WC/12Co composite coating layer on a Cu base material using a laser cladding (LC) process, and investigate the microstructural and mechanical properties of the LC coating and Ni electroplating layers (reference material). The initial powder used for the LC coating layer is a powder feedstock with an average particle size of 125 μm. To identify the microstructural and mechanical properties, OM, SEM, XRD, room and high temperature hardness, and wear tests are implemented. Microstructural observation of the initial powder and LC coating layer confirm the layer is composed mainly of γ-Ni phases and WC and Cr23C6 carbides. The measured hardness of the LC coating and Ni electroplating layers are 653 and 154 Hv, respectively. The hardness measurement from room up to high temperatures of 700°C result in a hardness decrease as the temperature increases, but the hardness of the LC coating layer is higher for all temperature conditions. Room temperature wear results show that the wear loss of the LC coating layer is 1/12 of the wear level of the Ni electroplating layer. The measured bond strength is also greater in the LC coating than the Ni electroplating.

For enhanced cavitation erosion resistance of vessel propellers, an electroless Ni-P plating method was introduced to form a coating layer with high hardness on the surface of Cu alloy (CAC703C) used as vessel propeller material. An electroless Ni-P plating reaction generated by Fe atoms in the Cu alloy occurred, forming a uniform amorphous layer with P content of ~10 wt%. The amorphous layer transformed to (Ni3P+Ni) two phase structure after heat treatment. Cavitation erosion tests following the ASTM G-32 standard were carried out to relate the microstructural changes by heat treatment and the cavitation erosion resistance in distilled water and 3.5 wt% NaCl solutions. It was possible to obtain excellent cavitation erosion resistance through careful microstructural control of the coating layer, demonstrating that this electroless Ni-P plating process is a viable coating process for the enhancement of the cavitation erosion resistance of vessel propellers.

WC-CrC-Ni coatings were prepared by nine processes of the Taguchi program with three levels for the four spray parameters: spray distance, flow rates of hydrogen and oxygen, and powder feed rate. The optimal coating process (OCP) was oxygen flow rate of 38 FMR, hydrogen flow rate of 53 FMR, powder feed rate of 25 g/min, and spray distance of 7 inches. Hardness of 1150 Hv and porosity of 1.2 %, were obtained by OCP; these are better results compared with the highest 1033 Hv and the lowest 1.5% porosity obtained by nine processes of the Taguchi program. Friction coefficient of the WC-CrC-Ni coating decreased from 0.36 ± 0.07 at 25 oC to 0.23 ± 0.07 at 450 oC. These values were smaller than those of the EHC (electrolytic hard chrome) plating at both temperatures due to lubrication from the oxide debris. The wear trace and wear depth of the coating are smaller than those of the EHC at both temperatures. Pitting was not found in the WC-CrC-Ni coating sample, while it did appear in the EHC sample.

The influence of NiCrAlY bond coating on the adhesion properties of an Fe thermal coating sprayed on an Al substrate was investigated. By applying a bond coat, an adhesion strength of 21MPa was obtained, which was higher than the 15.5MPa strength of the coating without the bond coat. Formation of cracks at the interface of the bond coat and the Al substrate was suppressed by applying the bond coat. Microstructural analysis of the coating interface using EBSD and TEM indicated that the dominant bonding mechanism was mechanical interlocking. Mechanical interlocking without crack defects in the coating interface may improve the adhesion strength of the coating. In conclusion, the use of an NiCrAlY bond coat is an effective method of improving the adhesion properties of thermal sprayed Fe coatings on Al substrates.

This study attempts to manufacture a Ni-Cr-Al-Y coating layer using a kinetic spray process and investigates the microstructure and physical properties of the manufactured layer. The Ni-22Cr-10Al-1Y (wt.%) composition powder is used, and it has a spherical shape with an average diameter of 23.7 μm. Cu plate is used as the substrate. Optical microscope, X-ray diffraction, scanning electron microscope and Vickers hardness test are carried out to characterize the macroscopic properties of the coating layer. Furthermore, the coating layer underwent vacuum heat treatment at temperatures of 400˚C and 600˚C for 1 hour to check the effect of heat treatment temperature on the properties. The manufactured coating layer is 1.5 mm thick, and featured identical phases to those found in the powder. The porosity of the coating layer is measured at 2.99%, and the hardness is obtained at 490.57 Hv. The layer shows reduced porosity as heat treatment temperature increased, and hardness is reduced at 400˚C but shows a slight increase at 600˚C. Based on the findings described above, this study also discusses possible manufacturing methods for a Ni-Cr-Al-Y coating layer using the kinetic spray process.

Correlations between in-flight particle, splat and coating microstructure of thermally sprayed Ni20Cr were investigated. Flame spray and arc spray systems were employed for spraying Ni20Cr powder and Ni20Cr wire, respectively. The results showed that the arc spray process produced a broader size distribution for both in-flight particles and splats compared to flame process. Flower-like splat morphology was obtained from the arc spray whereas a pancake-like splat was obtained by flame spray. Ni20Cr coating sprayed by arc process had a denser microstructure, lower porosity and better adhesion at the interface.