Cold Spray Research Articles

Coordination Variations within Binuclear Copper Dioxygen-Derived (Hydro)Peroxo and Superoxo Species; Influences upon Thermodynamic and Electronic Properties.

Copper ion is a versatile and ubiquitous facilitator of redox chemical and biochemical processes. These include the binding of molecular oxygen to copper(I) complexes where it undergoes stepwise reduction-protonation. A detailed understanding of thermodynamic relationships between such reduced/protonated states is key to elucidate the fundamentals of the chemical/biochemical processes involved. The dicopper(I) complex [CuI2(BPMPO-)]1+ {BPMPOH = 2,6-bis{[(bis(2-pyridylmethyl)amino]methyl}-4-methylphenol)} undergoes cryogenic dioxygen addition; further manipulations in 2-methyltetrahydrofuran generate dicopper(II) peroxo [CuII2(BPMPO-)(O22-)]1+, hydroperoxo [CuII2(BPMPO-)(-OOH)]2+, and superoxo [CuII2(BPMPO-)(O2•-)]2+ species, characterized by UV-vis, resonance Raman and electron paramagnetic resonance (EPR) spectroscopies, and cold spray ionization mass spectrometry. An unexpected EPR spectrum for [CuII2(BPMPO-)(O2•-)]2+ is explained by the analysis of its exchange-coupled three-spin frustrated system and DFT calculations. A redox equilibrium, [CuII2(BPMPO-)(O22-)]1+ ⇄ [CuII2(BPMPO-)(O2•-)]2+, is established utilizing Me8Fc+/Cr(η6-C6H6)2, allowing for [CuII2(BPMPO-)(O2•-)]2+/[CuII2(BPMPO-)(O22-)]1+ reduction potential calculation, E°' = -0.44 ± 0.01 V vs Fc+/0, also confirmed by cryoelectrochemical measurements (E°' = -0.40 ± 0.01 V). 2,6-Lutidinium triflate addition to [CuII2(BPMPO-)(O22-)]1+ produces [CuII2(BPMPO-)(-OOH)]2+; using a phosphazene base, an acid-base equilibrium was achieved, pKa = 22.3 ± 0.7 for [CuII2(BPMPO-)(-OOH)]2+. The BDFEOO-H = 80.3 ± 1.2 kcal/mol, as calculated for [CuII2(BPMPO-)(-OOH)]2+; this is further substantiated by H atom abstraction from O-H substrates by [CuII2(BPMPO-)(O2•-)]2+ forming [CuII2(BPMPO-)(-OOH)]2+. In comparison to known analogues, the thermodynamic and spectroscopic properties of [CuII2(BPMPO-)] O2-derived adducts can be accounted for based on chelate ring size variations built into the BPMPO- framework and the resulting enhanced CuII-ion Lewis acidity.

Controlling splat boundary network evolution towards the development of strong and ductile cold sprayed refractory metals: The role of powder characteristics

Feedstock powder characteristics such as composition (specific alloying elements and concentrations and impurity levels), microstructure, thickness/composition of surface oxide layers, and particle size distribution play a crucial role in determining the overall mechanical properties of cold sprayed deposits. Herein, we report on two deposits consolidated via cold spray processing from differently-sourced batches of nominally identical elemental refractory powders under identical spraying conditions, which exhibit bending strength and ductility values that differ by more than a factor of two – and with the weakest sample displaying negligible effective ductility. Through chemical, microstructural and micromechanical characterization of both the feedstock powders and cold sprayed deposits, we consider the possible influences of feedstock characteristics on the mechanical performance of cold spray consolidated deposits. It is shown that while differences in interstitial oxygen and hydrogen content may result in differences in the intrinsic yield characteristics of the feedstock material, both feedstocks maintain the ductile behavior required to induce good metallurgical bonding upon impact of optimally sized powder particles. We conclude that the deposits formed from the two feedstock powders are indistinguishable and exhibit high ductility when characterized locally within the relatively undeformed bulk of a single particle or splat. However, the two sprayed deposits show low ductility or brittle behavior when loaded in tension across intersplat boundary domains comprising material that has undergone extensive deformation. In addition, one feedstock incorporates a broader particle size distribution, with a long tail of larger-than-optimal particles. These larger particles are accelerated below the critical impact velocity, resulting in observed imperfect metallurgical bonding at splat interfaces and higher porosity at such intersplat boundaries. This result, combined with the overall differences in the morphology of the intersplat boundary network between the two deposits, explains the difference in macroscopic mechanical behavior. We conclude that accurate control of the powder feedstock particle size distribution is essential for optimizing the mechanical integrity of cold sprayed refractory elements and alloys.

How increasing cold spray coatings thickness affects their residual stress and properties

Cold spray (CS) is a solid state deposition presented in the literature to produce coatings for various applications, e.g., corrosion-resistant 316L stainless steel, Ti light alloy parts repairing, and hydrophobic Cu coatings. CS sprays particles under high velocity, impacting onto a prepared surface or substrate, and the powders bond by a severe and fast plastic deformation, consolidating the coating layer by layer. The number of layers depends on the designed coating thickness since each powder and CS parameters results in a different layer thickness. This work evaluates three feedstock powders (Cu, Ti, and 316L) for CS processing, and the characteristics and properties of the CS-ed coatings, studying the effects of the thickness coatings on their microstructure, porosity, hardness, adhesion to the substrate, and residual stress generated. The images of microstructures were obtained by optical microscopy and SEM, and the near-to-surface residual stress was measured by X-ray diffraction (XRD). Increasing the coating thickness produced a substrate deformation due to the compressive residual stress dominating the coating, which is numerically obtained and proven by XRD. Besides that, increasing the coating thickness slight increased the deposition efficiency for Cu ant Ti, but went in the opposite way for 316L; reduced the coating adhesion to the substrate; and did not altered significantly the hardness.

Erosion behaviour of cold sprayed stainless-steel coatings for civil infrastructures: An energetic approach

Along with corrosion, erosion is one of the main causes of damage to civil infrastructures. The continuous impact of fine particles carried by the air produces a deterioration in the elements of these structures. When this damage is significant, these elements are replaced by new ones. In this work, the possibility of extending the useful life of these components by spraying coatings on the damaged areas is proposed. In this sense, repair techniques such as cold spray deposition are possibilities for this purpose. Therefore, this study focuses on evaluating the erosion behaviour of stainless-steel coatings deposited on structural steel. In addition, the erosion results have been correlated with the model proposed by Hutchings, and an energetic interpretation of the erosion process through this model has been proposed. To carry out this study, stainless steel coatings have been deposited on carbon steel substrates to improve their resistance to corrosion. Different spraying temperatures, from 800 °C to 1100 °C, combined with different pressures of the carrier gas, from 40 to 70 bar, have been analysed. The elastic moduli of the coatings, and their stress-strain curve, have been determined by depth sensing indentation tests with Berkovich and spherical tips, respectively. Erosion tests with normal incidence have been programmed to obtain the corresponding erosion rates. From the results of this work, the optimal projection conditions of stainless steel on carbon steel substrates for the repair of civil infrastructures subjected to erosion processes could be identified.

Corrosion of Zinc Cold Spray Coatings in a Wet Sweet and Sour Gas Environment

Internal corrosion is a problem for steel pipelines transporting natural gas or CO2 containing water and partial pressures of H2S higher than 0.3 kPa (0.05 psi). This work aims to mitigate internal corrosion in steel pipelines transporting natural gas containing H2S using cold spray coatings. Two types of the cold spray binary metallic coatings (zinc chromium [ZnCr]. zinc niobium [ZnNb]) were studied using electrochemical techniques: potentiodynamic polarization, linear polarization resistance, and electrochemical impedance spectroscopy. The corrosion resistance of cold spray coatings (ZnCr, ZnNb) was evaluated in an environment containing 4 bar CO2 pressure, simulating the partial pressures found in gas transmission lines over a solution of 3.5 wt% NaCl heated to 40°C. A concentration of 0.003 M Na2S2O3·5H2O, corresponding to H2S partial pressures around 0.079 bar (1.146 psi), was used to simulate sour conditions. Postcorrosion surface characterization was performed using a scanning electron microscope (SEM) equipped with an energy-dispersive x-ray spectroscope (EDS) and x-ray diffraction analysis. The data showed that the presence of 0.003 M Na2S2O3·5H2O shifted the corrosion potential to more anodic values and decreased the corrosion current density. Both coatings showed similar behavior after 1 h of exposure in the CO2/H2S environment, indicating that similar electrochemical reactions were occurring on ZnNb and ZnCr. SEM images and EDS surface analyses for specimens showed a significant change in the surface chemical composition of carbon steel coated with ZnNb and ZnCr after 24 h of immersion. In the presence of thiosulfate (under sour conditions), the formation of corrosion product layers (ZnCO3 and ZnS) on top of ZnNb and ZnCr coatings increased their corrosion resistance, which helped to reduce their corrosion by a factor of 2. Under a sweet environment, the corrosion rates for steel coated with cold spray coatings after 14 d of exposure are lower than that for galvanized steel by a factor of 5 due to the ZnCO3 layer formed on top of the coatings. The ZnCO3 layer formed on the steel surface acts as a physical barrier against corrosion by blocking the diffusion of corrosive species to the surface. No localized attack was observed. ZnCr Cold spray coating with defect showed promising corrosion protection against CO2 corrosion (sweet corrosion) after 14 d of exposure to a CO2 environment. The scratch on the coating simulated damage created in service, and it was deep enough to expose the substrate material (steel). The formation of zinc oxide (ZnO) and zinc carbonate (ZnCO3) on the scratch confirmed the cathodic protection of the steel by ZnCr and ZnNb coatings.

Research on the trajectory planning and global optimization strategy of cold spraying technique for complex products coating preparation

PurposeThis paper aims to present a set of processes for obtaining the global spraying trajectory of a cold spraying robot on a complex surface.Design/methodology/approachThe complex workpiece surfaces in the project are first divided by triangular meshing. Then, the geodesic curve method is applied for local path planning. Finally, the subsurface trajectory combination optimization problem is modeled as a GTSP problem and solved by the ant colony algorithm, where the evaluation scores and the uniform design method are used to determine the optimal parameter combination of the algorithm. A global optimized spraying trajectory is thus obtained.FindingsThe simulation results show that the proposed processes can achieve the shortest global spraying trajectory. Moreover, the cold spraying experiment on the IRB4600 six-joint robot verifies that the spraying trajectory obtained by the processes can ensure a uniform coating thickness.Originality/valueThe proposed processes address the issue of different parameter combinations, leading to different results when using the ant colony algorithm. The two methods for obtaining the optimal parameter combinations can solve this problem quickly and effectively, and guarantee that the processes obtain the optimal global spraying trajectory.

The Effect of the Deposition Strategy and Heat Treatment on Cold Spray Additive Manufactured 316L Stainless Steel

Herein, the effect of heat treatment on the characteristics and properties of cold spray additive manufactured 316L stainless steel employing traditional and a new metal knitting strategy is investigated. 316L feedstock powder characteristics, the geometry of the bulk, microstructure, porosity, microhardness, mechanical isotropy, and residual stress are analyzed in both strategies in as‐sprayed and heat‐treated conditions. Results show that the traditional deposition strategy produced higher mechanical resistance, whereas metal knitting presents a better part geometry accuracy. The heat treatment significantly improves the material strength and the quality of the parts by recovery and recrystallization phenomena. The same microhardness and planar isotropy are achieved after heat treatment of samples produced by both strategies. A discussion about the mechanisms, microstructural, and residual stress evolution is presented.

CFD Investigation of a Co-Flow Nozzle for Cold Spray Additive Manufacturing Applications

This current work evaluates the efficacy of a co-flow nozzle for cold spray applications with the aim of mitigating nozzle clogging issues, which can occur during long-duration operations, by replacing the solid wall of a divergent nozzle section with an annular co-flow fluid boundary. Simulations were conducted on high-pressure nitrogen flowing through convergent–divergent (C–D) axisymmetric nozzles, with a stagnation pressure of 6 MPa and a stagnation temperature of 1273 K. In these simulations, Inconel 718 particles of varying sizes (15 µm to 35 µm) were modeled using a 2-way Lagrangian technique, and the model’s accuracy was confirmed through validation against experimental results. An annular co-flow nozzle with a circular cross section and straight passage covering the primary C–D nozzle has been designed and modeled for cold spray application. Co-flow was introduced to the reduced nozzle length to compensate for particle velocity loss at higher operating conditions. It was found that co-flow facilitates momentum preservation for primary flow by providing an annular gas boundary, resulting in increased particle speed for a longer axial distance beyond the nozzle exit of the reduced divergent length nozzle. The particle acceleration performance of the reduced divergent section nozzle, when combined with co-flow, is comparable to the original length nozzle.

Strain rate-dependent behavior of cold-sprayed additively manufactured Al–Al[formula omitted]O[formula omitted] composites: Micromechanical modeling and experimentation

Metal matrix composites (MMCs) fabricated by cold spray additive manufacturing (CSAM) are increasingly gaining attention as structural materials due to their rapid production and scalability. Herein, the failure behavior of CSAM Al–Al2O3 composites under quasi-static and dynamic compression was studied by an experimentally informed/validated 3D microstructure-based finite element (FE) model. The debonding mechanism was found to grow at a higher rate consequently dampening the particle cracking mechanism when the strain rate rises to dynamic regimes. The stress-bearing capacity of the particles plays a key role in enhancing the flow stress and elongation at failure of the CSAM composite under high strain rates due to the lower propensity of particle cracking. Eventually, the model was exercised to study the microscale failure progression in the material under elevated temperatures. For the first time in the literature, this study informs on the correlation between the microscale failure mechanisms and the mechanical performance of CSAM MMCs at the macro scale across strain rates and temperatures whose outcomes are applicable to the design of next-generation materials with a tailored performance.

Cold spray deposition of high density polyethylene composite powders

In this paper, we investigate the use of the cold spray additive manufacturing technique to deposit micron-sized composite particles of high-density polyethylene (HDPE) compounded with either micron or nanometer sized particles of silicon dioxide (SiO2) or copper (Cu). In this study, the mass fraction of the SiO2 and copper particles added into the final composite powders was varied between 0.5 % and 9.1 % and the deposition efficiency of each composite powder was measured. Deposition of the composite powders onto an HDPE substrate was successful even at the highest particle loadings tested. In each case, an optimal mass fraction of silicon dioxide or copper particles was observed with a maximum value of deposition efficiency larger than that of the pure HDPE. For the silicon dioxide composite powders, the deposition efficiency nearly doubled compared to the pure HDPE powders. The improvement of deposition efficiency at moderate particle loadings is likely due to the increase in the impact kinetic energy of the particles resulting from the increase in the density of the composite powders. While the decrease in deposition efficiency at high particle loadings is likely the result of the increased coverage of the silicon dioxide and copper particles on the surface of the HDPE powders limiting the interaction between the HDPE of the composite powder with the HDPE substrate. SEM images show that it is possible to create a smooth, dense, and uniform thin-film polymer composite coating using cold spray.

Considerations on the Failure Mechanisms at Fatigue Loading of 1018 Steel Samples Coated with Wip-C1 by Cold Spray.

There are some important advantages presented by metal specimens coated with WIP-C1 (Ni/CrC)-type materials. However, given the coating methods and the stress under dynamic loads, there are issues that need to be taken into account, particularly in terms of the behavior at the interface between the two materials. Using standardized cylindrical 1018 steel specimens uniformly coated with WIP-C1 (Ni/CrC) by cold spraying, this study investigated the fatigue behavior of the specimen as a whole, focusing on the interface areas of the two materials. The fatigue life diagram is given, to a large extent, by the behavior of the base material. As a result, in this work, we have focused not so much on the fatigue behavior of the assembly as on the integrity of the coating material and the defects, failures, etc., that may occur at the interface after a certain number of cycles. The applied load was cyclic fatigue through alternating-symmetric cycles. Scanning optical microscopy was used to observe plastic deformations and crack propagation during the breakage process. It was found that both the base material zone and the cover material zone presented good performance when the maximum stresses were at low values. A fatigue durability curve was also plotted, showing a conventional appearance for a metallic material, slightly influenced by the destruction of the base material interface. At higher maximum stress and, consequently, to large strains, a series of destructions at the interface of the two materials, of different types, were observed and will be highlighted in the paper.

Wear and corrosion properties of Cu–AlN composite coatings deposited by cold spray

Copper and copper alloy are commonly used to fabricate ship propellers and sealing valves that encounter harsh corrosion and wear. To improve their service life, Cu coating and Cu–AlN composite coatings with different volume content of AlN (10%, 20%, 30%) were prepared by cold spraying. The investigation focused on analyzing the coatings’ microstructure, microhardness, resistance to wear, and corrosion. Results show that the composite coatings with AlN have fewer pores and denser microstructure than the Cu coating. The coating demonstrates a relatively low deposition efficiency, resulting in the attainment of only 3.8 vol% of AlN when the feedstock AlN powder content was 30 vol%. The microhardness of Cu-3.8AlN coating is 159.7 HV, about 53.1% higher than that of Cu coating. The specific wear rate of Cu-3.8AlN coating is reduced by about 73.5% compared to that of Cu coating, measuring at 1.69 × 10−3 mm3/(N·m). Compared with other coatings, Cu-3.8AlN has the highest corrosion resistance (Ecorr = −0.199 V, Icorr = 1.2 μA/cm2, Rct = 3200 Ω·cm2). The Cu-3.8AlN coating exhibits superior wear and corrosion resistance among the four coatings, attributed to its highest level of densification and the presence of AlN particles.

Evaluation of Three Methods for the Treatment of Dentin Hypersensitivity: A Randomised Clinical Trial

ObjectivesIn this study, we aimed to compare the effectiveness of Gluma and high-power 980-nm diode laser, alone or in combination, in the treatment of cervical dentin hypersensitivity. MethodsA total of 20 patients (5 men and 15 women), aged 25 to 60 years, who met the inclusion criteria, were enrolled in this study. A total of 60 teeth were randomly divided into 4 groups: G1, 980 nm diode laser (in 2 sessions within a 1-week interval); G2, Gluma (in 2 sessions within a 1-week interval); G3, 980 nm diode laser plus Gluma; and G4: control. Thermal (cold spray) and air blast (air syringe of dental unit) stimuli were used to evaluate cervical dentin hypersensitivity in the patients. Their pain response was assessed using a visual analogue scale (VAS) before treatment (baseline), in the first treatment session (15 minutes after treatment), in the second treatment session (after 1 week), and in 2-week, 1-month, and 3-month follow-up sessions. The obtained data were analysed using non-parametric tests, including Kruskal–Wallis test, Friedman test, Mann–Whitney test, and Wilcoxon test, in SPSS Version 22 at a significance level of P < .05. ResultsBased on the results, there was a significant difference in the average VAS scores for cold and air blast stimuli between the 4 groups 1 month after the intervention (P < .05). Meanwhile, the laser group had the lowest VAS score for cold and air stimuli. On the contrary, no significant difference was found between the 4 groups 3 months after the intervention (P ˃ .05). ConclusionThe present results showed that 980-nm diode laser alone was more effective than the other 2 intervention methods for 1 month. Trial registrationThe study was registered in the Iranian Registry of Clinical Trials (IRCT20120901010703N5).

Analysis of Data Generation and Preparation for Porosity Prediction in Cold Spray using Machine Learning

Cold spray is an additive manufacturing and coating process in which powder particles are accelerated to supersonic speeds without melting them and then deposit on a surface to form a layer of a coating. Process parameters and materials affect the characteristics of manufactured parts and therefore must be chosen with care. Machine learning (ML) techniques have been specifically applied in additive manufacturing for tasks such as predicting and characterizing porosity. Machine learning algorithms can learn how a variation in the input spray parameters affects annotated output data, such as experimentally measured part properties. In this work, a dataset was developed from experiments reported in published academic papers, to train ML algorithms for the porosity prediction of cold spray manufactured parts. Data cleaning steps, such as null value replacement and categorical feature handling, were applied to prepare the dataset for the training of different ML models. The dataset was split into training and testing portions, and floating feature selection and hyperparameter optimization were performed using parts of the training set. A final evaluation of all trained models, using the test portion of the dataset, showed that a prediction accuracy with an average deviation of 0-2% porosity of the predicted values compared to the true values can be achieved.Graphical

The influences of traces of oxygen and sulfide on the corrosion of copper in concentrated chloride solutions

The corrosion of wrought, electrodeposited, and cold spray deposited copper was electrochemically monitored for ∼160 days in 3 M NaCl solution containing traces of sulfide under anoxic and Ar-purged conditions. Corroded specimens were analyzed using scanning electron microscopy and Raman and X-ray photoelectron/Auger spectroscopies. Under anoxic conditions, corrosion was supported by sulfide only and the rate decreased with time causing only minor damage. Under low oxygen conditions maintained by Ar-purging, the rate increased with time and significant damage was observed, attributed to oxy-sulfur species formation. These results suggest that oxy-sulfur species, not just sulfide, are required to cause intergranular corrosion.

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Residual Stress in Cold Spray SS304L Measured Via Neutron Diffraction and Comparison of Analytical Models to Predict the Residual Stress

Chloride-induced stress corrosion cracking in Austenitic steels for SNF storage canisters - Recent understanding and advances in mitigation and repair

Chloride-induced stress corrosion cracking (CISCC) is a critical threat to stainless steel (SS) spent nuclear fuel (SNF) and radioactive materials storage canisters currently in service worldwide. In the past decade, extensive research has been conducted to understand fundamental mechanisms of CISCC, as well as to develop effective repair and mitigation methods to prevent catastrophic failure of the SNF canisters from CISCC. This review article aims to: (1) summarize recent progress from fundamental studies of CISCC in SS, and (2) present state-of-the-art developments in CISCC mitigation and repair techniques that may be especially well-suited for SNF storage applications, including cold spray (CS), friction stir welding (FSW), friction surfacing (FS), laser shock peening (LSP), and ultrasonic nanocrystal surface modification (UNSM). Knowledge gaps in current understanding of CISCC and roadmaps for deployment of the repair techniques are also discussed.

Additive manufacturing of Al thick wall using high-pressure cold spraying: issues of porosity and mechanical properties

Additive manufacturing of Al thick wall using high-pressure cold spraying: issues of porosity and mechanical properties

Manufacturing Oxide Dispersion Strengthened (ODS) steel plate via cold spray and friction stir processing

Oxide dispersion strengthened (ODS) steels, traditionally fabricated by ball milling and conventional powder metallurgy techniques to achieve bulk form, followed by intricate rolling and thermal treatment steps to achieve plate or sheet form. Here, we present a novel processing route that combines cold spray (CS) with friction stir processing (FSP) to manufacture ODS steel plate directly from gas atomization reaction synthesis (GARS)-prepared powder, thus no rolling steps involved. Microstructural and mechanical characterizations were performed to assess the quality and properties of the resulting ODS steel plate. Our findings demonstrate that the slightly porous CS deposited layer was fully consolidated after FSP, yielding a fully dense ODS steel plate that exhibited a favorable tradeoff between strength and ductility upon extraction from the substrate. Furthermore, through microstructural analysis, we revealed the presence of an appreciable density (∼1022/m3) of nano-sized oxide particles, with the majority being smaller than 5 nm via the combined CS + FSP fabrication route. This work serves as a first proof-of-concept demonstration of the manufacturing approach described herein, offering a possible alternative route for producing ODS steel plates.

A Comparative Study of the Life Cycle Inventory of Thermally Sprayed WC-12Co Coatings

In this research, a life cycle inventory (LCI) is developed for tungsten carbide–cobalt (WC-Co) coatings deposited via atmospheric plasma spray (APS), high-velocity oxy-fuel (HVOF), and cold gas spray (CGS) techniques. For the APS process, a mixture of Ar/H2 was used, while the HVOF process was fueled by H2. The carrier gas for CGS was N2. This study aims to determine and quantify the inputs (consumption of inputs and materials) and outputs (emissions to air, soil, water, and waste generation) that could be used in the life cycle analysis (LCA) of these processes. The dataset produced will allow users to estimate the environmental impacts of these processes using WC-Co feedstock powder. To obtain a complete and detailed LCI, measurements of electrical energy, gas, WC-CO powder, and alumina powder consumption were performed (the use of alumina was for sandblasting). Furthermore, emissions like carbon dioxide (CO2), carbon monoxide (CO), and noise were also measured. This practice allowed us to determine the input/output process quantities. For the first time, it was possible to obtain LCI data for the APS, HVOF, and CGS deposition processes using WC-12Co as a feedstock powder, allowing access to the LCI data to a broader audience. Comparisons were made between APS, HVOF, and CGS processes in terms of consumption and emissions. It was determined that the APS process consumes more electrical energy and that its deposition efficiency is higher than the other processes, while the HVOF process consumes a large amount of H2, which makes the process costlier. CGS has comparatively low electricity consumption, high N2 consumption, and low deposition efficiency. The APS, HVOF, and CGS processes analyzed in this study do not emit CO, and CO2 emissions are negligible.