Influence of Defects on the Mechanical Properties of Metallic Coatings Obtained by Thermal Spraying: A Review

Uirá Rodrigues da Silveira Montani; Marilia Garcia Diniz; Paolo Bettini; Hector Reynaldo Meneses Costa

doi:10.5935/jetia.v12i57.2851

Authors

Uirá Rodrigues da Silveira Montani Programa de Pós-Graduação em Engenharia Mecânica e dos Materiais do Centro Federal de Educação Tecnológica Celso Suckow da Fonseca (PPEMM - CEFET-RJ), Rio de Janeiro, Brazil https://orcid.org/0009-0005-8174-9164 (unauthenticated)
Marilia Garcia Diniz Programa de Pós-Graduação em Engenharia Mecânica da Universidade do Estado do Rio de Janeiro (PPGEM – UERJ), Rio de Janeiro, Brazil https://orcid.org/0000-0002-1836-8618 (unauthenticated)
Paolo Bettini Aerospace Science and Technology Department of Politecnico Di Milano, Milan, Italy. https://orcid.org/0000-0003-1083-5792 (unauthenticated)
Hector Reynaldo Meneses Costa CEFET - RJ - Centro Federal de Educação Tecnológica Celso Suckow da Fonseca https://orcid.org/0000-0002-0887-6838 (unauthenticated)

DOI:

https://doi.org/10.5935/jetia.v12i57.2851

Abstract

Thermally sprayed coatings are used as superior engineering materials, to prolong the service life of components and reduce manufacturing costs, but also significantly saving limited resources and energy, a technique capable to protect surfaces from erosive wear, corrosion, and enhance the tribological properties of a broad range of engineering materials. The study outlines the technological principle and process of thermal spray technique, and explores microstructural defects of thermal sprayed coatings, including pores, microcracks, unmelted particles, and oxides, exploring their formation mechanisms and effects. This paper also explores machine learning as a valuable tool that enables more accurate prediction of defect formation and supports the development of optimized spraying parameters.