Military operations occurring in particle-laden environments have resulted in aircraft incidents and loss of life due to sand ingestion into the engine. Sand melts in the hot combustion environment and deposits as glassy calcia–magnesia–alumino–silicates (CMAS) which leads to rapid performance degradation due to clogged air pathways in the engine. A novel, composite thermal barrier coating (TBC) consisting of yttria-stabilized zirconia (YSZ) blended with gadolinia is proposed that combines the excellent thermo-mechanical properties of YSZ together with the CMAS resistance of rare-earth oxides. YSZ was blended with 2, 8, 17, and 32 vol% gadolinia and tested under simulated engine-relevant conditions. The presence of gadolinia in the composite coating reduced the adhesion of the CMAS, and at 32 vol% gadolinia addition, the CMAS was completely delaminated. A possible CMAS adhesion mitigating mechanism is discussed. This work demonstrated the capability of a new composite TBC to significantly reduce CMAS adhesion.

Mixing metal powders in cold spray is of significant interest not only because it is a straightforward method to produce novel composites, but also it has been observed to generate beneficial effects, e.g. improved deposition efficiency (DE). However, the mechanisms behind DE improvements are still not clear fundamentally. In this paper, two examples of mixing metal powders effects in cold spray are introduced: 1) the first example focuses on the effects of different particle/substrate interactions which occurred during cold spray of SS/Fe mixed powders; 2) the second example presents the DE-improving effect of depositing mixed metal powders onto polymers. Various mechanisms associated with the cold spray deposition characteristics of mixed metal powders are discussed in this paper.

The present work has been carried out in order to investigate the sliding wear performance of a Ni-Cr based alloy, containing boron, carbon, silicon and iron, deposited onto a SAE 1045 steel substrate. The coatings were thermally sprayed by means of a High Velocity Oxy-Fuel system and post heat-treated for one hour at 760°C in an argon atmosphere. The relative sliding performance was evaluated under unlubricated dry conditions at different applied normal loads and sliding velocities, in order to analyze the influence of these parameters on the wear response. Test results are discussed and interpreted on the basis of both microstructural evaluations and mechanical properties measurements. The surface morphology and topography of the wear scars have been studied through of a Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS) techniques. The results have shown an improved wear resistance of the coated steel samples as compared to the uncoated ones.

Ti–Al alloys are established as promising candidates for aerospace applications due to their lightweight, good elevated temperature strength, and decent corrosion resistance. In this study, a Ti–51Al (at.%) alloy is fabricated by spray deposition. The effects of temperature and strain rate on the deformation behavior of the spray-deposited Ti–Al alloy are investigated. The microstructural evolution of the Ti–Al alloy with different deformation temperatures is discussed in detail. A strain-dependent constitutive equation was proposed to predict the flow stresses at the elevated temperatures for the spray-deposited Ti–Al alloy. The microstructure of the as-deposited Ti–51Al alloy exhibits a α2/γ lamellar-structure with average size 25 ± 2 μm, due to the high cooling rate observed during solidification. The lamellar structure is embedded on a γ matrix. The amount of the α2/γ lamellar-structure reduces gradually with increasing the hot deformation temperature. After hot isostatic pressing at 1523 K, the microstructure is mainly comprised of the γ matrix.

Ternary lead chalcogenides, such as PbSxSe1-x, offer the possibility of room-temperature infrared detection with engineered cut-off wavelengths within the important 3-5 micron mid-wave infrared (MWIR) wavelength range. We present growth and characterization of aqueous spray-deposited thin films of PbSSe. Complexing agents in the aqueous medium suppress unwanted homogeneous reactions so that growth occurs only by the heterogeneous reaction on the hydrophilic substrate. The strongly-adherent films are smooth with a mirror-like finish. The films comprise densely packed grains with tens of nm dimensions and a total film thickness of ∼400-500 nm. Measured optical constants reveal absorption out to at least 4.5 μm wavelength and a ∼0.3 eV bandgap intermediate between those of PbS and PbSe. The semiconducting films are p-type with resistivity ∼1 and 85 Ohm-cm at 300 and 80 K, respectively. Sharp x-ray diffraction peaks identify the films as Clausthalite-Galena solid-state solution with a lattice constant that indicates an even mixture of PbS and PbSe. The photoconductive response is observed at both nitrogen and room temperature up to at least 2 kHz chopping frequency.

Self-assembled TiO2 films deposited by aqueous-spray deposition were investigated to evaluate morphology, crystalline phase, and infrared optical constants. The Anatase nano-crystalline film had ∼10 nm characteristic surface roughness sparsely punctuated by defects of not more than 200 nm amplitude. The film is highly transparent throughout the visible to wavelengths of 12 μm. The indirect band gap was determined to be 3.2 eV. Important for long-wave infrared applications is that dispersion in this region is weak compared with the more commonly used dielectric SiO2 for planar structures. An example application to a metal-insulator-metal resonant absorber is presented. The low-cost, large-area, atmospheric-pressure, chemical spray deposition method allows conformal fabrication on flexible substrates for long-wave infrared photonics.

The effects of retrogression and re-aging (RRA) treatment on intergranular corrosion (IGC), exfoliation corrosion (EXCO), stress corrosion cracking (SCC) behavior and microstructure of spray formed Al-7075 were investigated by a scanning electron microscope, a transmission electron microscope, slow strain rate test, and EXCO and IGC test. The results show that the precipitates are redissolved in the matrix of the alloy after retrogression at 200 °C for a suitable time (8 min), and the grain boundary precipitates are discrete and the obvious precipitate free zones are left at the grain boundaries. After RRA with suitable retrogressed time, thin homogeneous dispersive precipitates are separated out again in the matrix. After retrogression at 200 °C for 8 min and re-aging, the ultimate tensile strength, elongation, IGC depth, EXCO rating, and SCC index of spray formed Al-7075 are 791 MPa, 8.5%, 29.8 μm, EA, and 0.155, respectively.

Greenhouse studies were conducted to investigate the effects of adjuvant and rainfall on bentazon spray retention, efficacy, and foliar washoff in hemp sesbania, sicklepod, smooth pigweed, and velvetleaf. Bentazon was applied at 0.28 to 2.24 kg ai/ha with Agri-Dex, a crop oil concentrate (COC) or Kinetic, an organiosilicone-nonionic surfactant blend (OSB) when weeds were at the three- to five-leaf stage. Plants were subjected to 2.5 cm simulated rainfall for 20 min at 1 and 24 h after application of bentazon. Shoot fresh weight reduction assessed 2 wk after treatment was similar with either adjuvant on velvetleaf and smooth pigweed. OSB enhanced bentazon efficacy in hemp sesbania and sicklepod as compared to COC. Rainfall at 1 h after application generally reduced bentazon activity in all weeds. OSB maintained bentazon activity in hemp sesbania when subjected to rainfall at 1 h after application as compared to COC. Overall, bentazon spray retention on plants was 9 to 550% higher with OSB as compared to COC among the species at 1 h after application. Amount of bentazon residue washed off from the foliage by rainfall within a weed species was relatively similar for both adjuvants except in smooth pigweed and ranged from 39 to 98% among the four weed species at 1 h after application. OSB exhibited specificity for certain weed species and the potential to minimize bentazon spray reaching the soil by increasing deposition.

A plant-weighing procedure was used to measure the total mass of spray mixture intercepted by small whole corn and cotton plants. Mixtures of water and water plus crop oil concentrate or spreader–sticker were applied at spray volumes of 280 to 28,000 L/ha. The plants were weighed before and after passing under the spray and leaf areas, and shoot fresh and dry weights for each plant were measured. Spray deposition increased with spray volumes but not proportionally. Corn plants were larger than cotton plants and retained more spray per plant; however, cotton retained more spray per unit leaf area. The two adjuvants had similar effects on deposition, tending to increase it in corn and decrease it in cotton.

Greenhouse and laboratory experiments were conducted to evaluate the influence of two organosilicone surfactants and spray nozzle types on the spray deposition, absorption, translocation, and efficacy of the monoethanolamine salt of clopyralid on honey mesquite. Sylgard 309 or Silwet L-77 added to the spray solution at 0.1, 025 and 0.5% by vol did not increase spray deposition, absorption, translocation, or phytotoxicity of clopyralid applied at 140 g ae ha-1 on honey mesquite compared to no surfactant An air-assist spray nozzle at 9.4 L ha-1 by vol resulted in greater initial clopyralid deposit on honey mesquite than hydraulic nozzles at 9.4 or 187 L ha-1 by vol, but air-assist application did not increase phytotoxicity compared to hydraulic nozzles.

Al–Zn–Mg–Cu–Zr alloys are very important aeronautical materials because of their low density, high strength, and high ductility. Corrosion failure is a significant factor causing aviation accidents, which should be investigated to develop an aeronautical material but has not been done yet. In this work, the effects of aging mechanisms on the exfoliation corrosion behavior of a spray deposited Al–Zn–Mg–Cu–Zr alloy were investigated. Natural aging (NA), single-stage aging (SA), and retrogression and re-aging (RRA) were treated on specimens before exfoliation corrosion testing. Corrosion attacks were evaluated using the optical microscope (OM) and scanning electron microscope (SEM). Corrosion mechanisms were deduced on the basis of polarization curve results and an equivalent circuit. The RRA sample exhibited the smallest corrosion attack among the three samples, while the NA sample showed the largest corrosion attack. Intergranular corrosion on grain boundaries was discussed to understand the exfoliation corrosion process in the RRA sample. The amount and size of precipitates in grain interior and grain boundary of RRA samples are larger than those in SA and NA samples, leading to the low corrosion susceptibility of the RRA sample.

Preharvest applications of glyphosate can be useful in controlling perennial weeds. Experiments were conducted from 1996 to 1999 to determine whether preharvest glyphosate applications are affected by differences in the amount of soybean canopy present at the time of application by measuring spray deposition and subsequently horsenettle or Canada thistle control. Soybean leaf interference levels were achieved by use of three soybean cultivars with different maturity groups to achieve no leaf interference, moderate leaf interference, and maximum leaf interference, and soybean was planted in three row spacings ranging from 19 to 76 cm. As soybean leaf interference increased, spray coverage of spray deposition cards decreased. There was a similar trend for relative spray volume, determined by intensity of the color change with water-sensitive cards. Row spacing did not influence spray coverage or relative spray volume. Percent change in horsenettle or Canada thistle stems from fall to spring counts was inconsistent. Differences detected in spray coverage did not influence weed control or weed stem density the following spring.

In this work, we present low temperature flash light based curing of spray coated high-k zirconium oxide (ZrOx) thin film to realize low voltage operated flexible and fully patterned organic thin film transistors (OTFTs). A simple sol-gel technique was followed to prepare ZrOx from a zirconium complex. By spraying the precursor solution onto substrate through shadow mask, a patterned film was obtained. On the other hand subsequent flash light curing of the coated film not only reduced processing time but also allowed us to fabricate device on polymeric flexible substrate. Spectroscopic analysis confirmed formation of ZrOx film from the solution of zirconium complex. Finally as prepared ZrOx was used as gate dielectric layer in OTFT structure to keep operating voltage as low as -3V. Flexible polyethylenetrephthalate (PET) sheet was used as flexible substrate and pentacene was used as organic active layer. Each and every layer was deposited through metal made shadow mask to develop fully patterned OTFT. Field effect mobility and ON/OFF ratio of as fabricated transistor was found to be as high as 1.2 cm2V-1S-1 and 105 respectively.

A new lab-based aerosol jet fog (ajFOG) deposition system with an atomizer consisting of two opposing jets located within the deposition chamber is introduced and its capabilities are examined. The unique opposing configuration of the atomizer enables the formation of a highly uniform fog even from low volatility precursors. Aluminum oxide phosphate (AlPO) thin films were deposited onto Si wafers at room temperature and sub-atmospheric pressure by using an aqueous precursor. Films were characterized by spectroscopic ellipsometry, x-ray diffraction and reflectivity, scanning electron microscopy, and metal/oxide/semiconductor (MOS) capacitor electrical measurements. Film thickness uniformity, density, surface roughness, and charge transport mechanisms were found to be comparable to spin-coated thin films deposited using the same precursor, demonstrating the effectiveness of this aerosol technique. A process model was developed to predict film thickness as a function of precursor concentration, exposure time, fog settling time, and number of exposures.

The microstructure formation and wear resistance of a superduplex stainless steel modified with the addition of 3 wt% boron produced by spray forming were investigated. Thermodynamic simulations were used as comparison basis and to explain the experimentally observed microstructure, which was composed by primary M2B-type borides, an austenitic-ferritic matrix, and eutectic M3B2-type borides. The predicted solidification sequence started with the precipitation of primary M2B boride, followed by ferrite/austenite formation and a final eutectic reaction resulting in M3B2 borides. A good correlation with the simulations and final microstructure was found. The abrasive wear resistance was investigated with the dry sand/rubber wheel test and the results indicated an outstanding performance, similar to the cobalt-based Stellite 1016 alloy. The excellent wear resistance resulted from the presence of a significant amount (about 35 vol%) of hard borides homogeneously dispersed in the microstructure, which was effective at increasing hardness and protecting the duplex matrix against abrasion.

An Al–10.83Zn–3.39Mg–1.22Cu–0.16Zr–0.16Sc alloy was produced using the spray deposition technology. The microstructure evolution within temperature ranging between 613 K and 733 K during hot pressing process at different initial strain rate was investigated in a transmission electron microscope (TEM). Partial resolution of the primary precipitates in the deposited microstructure, such as η-MgZn2 and Al3(ScZr), took place. Moreover, new secondary η-MgZn2 and Al3(ScZr) precipitated from the super saturated solid solution and their effects on the recrystallization were also analyzed. The Al3(ScZr) and η-MgZn2 precipitation can act as barriers for the movement of both dislocations and grain boundaries, which are the main factors for hindering the recrystallization. Additionally, the dislocation slide during hot deformation was also investigated in detail. The spray deposition Al–Zn–Mg–Cu alloy own the well deformability, and the typical perfect dislocations can be found in the hot deformation Al–Zn–Mg–Cu alloy.

Conventional retrogression and re-aging (RRA) treatment could not be put to good use for combination property of Al–Zn–Mg–Cu alloys. The new RRA treatment fitted for spray formed Al–Zn–Mg–Cu alloy was investigated by transmission electron microscope, tensile, and conductivity tests. The results show that the pre-aging treatment with under aging of 120 °C for 16 h is beneficial for the redissolution of matrix precipitates during retrogression treatment. With the retrogression of 200 °C for 8 min, grain boundary precipitates are discrete and the corrosion resistance of the alloy is drastically increased. After re-aging (120 °C for 24 h) the strength of the alloy is increased again. According to the above-mentioned new RRA treatment, the ultimate tensile strength, yield strength, elongation, and conductivity of the alloy are 791 MPa, 736 MPa, 8.5%, and 39.5% IACS respectively, which is higher than that after conventional RRA treatment.

In this work, the effect of three principal and independent parameters of Atmospheric Plasma Spray on the properties of coatings deposited using mixtures of commercial powders of titanium dioxide (TiO2) and chromium oxide (Cr2O3) was studied. The results of this work are used for special applications on turbomachinery components such as wear protection in sliding seals and in steam valves for turbines, chemical protection for centrifugal compressor members, and special seal applications.

The design of experiments (DoE) technique has proved to be very useful to study the influence factors and optimization. Pierlot et al. [1] demonstrated that the application of the Hadamard and two factorial design techniques are useful for the optimization of thermal spray processes. An example of the application of the DoE is the one mentioned by Murugan et al. [2]. In their work, a factorial design was used to study the interactions between gas flow, oxygen flow, powder rate and spray distance on the percentage of porosity and hardness of TiO2 - Cr2O3 composite coatings generated by High Velocity Oxy-Fuel.

The ½ fractional two-level factorial DoE technique was used to analyze and optimize the Atmospheric Plasma Spray process parameters. In the current research, experiments were conducted varying the deposition velocity, gas flow and stand-off distance. The effect of these process variables were evaluated by thickness, hardness and microstructure analysis. In this study, an empirical relationship between process variables and response parameters was developed. The entire relationship was made using the results of the DoE.

In the present study, highly sensitive and high-throughput optical waveguide biosensors were fabricated by using the sensing membranes containing dye and polymer-enzyme complex. Optical light waveguide can detect the optical change in the vicinity of the guide surface with high sensitivity due to the evanescent wave scattering. The glucose sensing membranes, composed of dye, enzymes, and biocompatible polymers were prepared by solution processing on the optical waveguide. Herein, we used 3, 3’, 5, 5’-tetramethylbenzidine (TMBZ) as a dye, glucose oxidase (GOD) and peroxidase (POD) as enzymes, phosphatide polymer for protection of biological activity of enzyme, and carboxymethyl cellulose (CMC) as a binder. Then we focused on the optimal composition and structure of sensing membranes for the enhancement in the sensitivity and response speed. The developed glucose sensors demonstrated 20 times higher sensitivity than the conventional light waveguide glucose sensors and the low-detection limit of 0.1g/L glucose within the detection time of 60 sec. For further improvement in the sensitivity, microporous sensing membranes were fabricated by using electrospraying technique. The electroprayed sensing membranes gave 40 % higher sensitivity than nonporous sensing membranes. These results show that both the composition and structure of sensing membrane are crucial factors for highly sensitive and high-throughput optical waveguide biosensors.

We have set a new bench mark for DSSC performances by fabricating a very efficient device with a high photocurrent density and good stability. This bench mark was accomplished by harmonizing the absorption spectrum of the dye with the average size of the aggregates in the TiO2 electrode. The resultant resonant multiple scattering enhanced the light harvesting efficiency and charge collection yield. The high and robust photovoltaic performance (with an initial efficiency of 9.18% and an efficiency of 7.44% after 800 h of irradiation with a light intensity of 100 mW cm-2) of the JH-1 DSSC prepared without an antireflecting layer demonstrated the promise of this novel sensitizer for large scale applications.