Thermomechanical Characterization Research Articles

Temperature-dependent hardening of zirconium alloys under heavy ion-irradiation: Experimental observation and theoretical analysis

In this work, microstructure observation and thermo-mechanical property characterization of ion-irradiated Zr-0.5Sn-0.5Nb-0.3Fe-0.015Si alloys were addressed by both experimental measurements and theoretical analyses. In experiments, 6 MeV Au3+ irradiation was carried out for Zr alloys with the irradiation dose up to 30 displacements per atoms (dpa). Transmission electron microscopy (TEM) indicated the addition of solute elements could facilitate the formation of second phase particles (SPPs) like (Zr, Nb)2Fe, Zr(Nb, Fe)2 and Zr-Nb-Fe-Si precipitates in the unirradiated matrix, which were then transformed from the crystalline to amorphous state during the irradiation process. Moreover, it was indicated that there existed microband structures with different orientations inside the grains, and the actual irradiation depth had exceeded the value predicted by the SRIM simulation. The influence of irradiation-induced defects on the macroscopic mechanical behaviors of Zr alloys was characterized by both nano-indentation test (NIT) at 298 K and high-temperature nano-indentation test (HTNIT) at 573 K and 673 K. To theoretically address the hardness-indentation depth relations of ion-irradiated Zr alloys at elevated temperatures, a mechanistic model considering the underlying hardening mechanisms was developed. It was revealed that the irradiation hardening behavior was attributed to the contribution of irradiation-induced defects, while the decrease of hardness at elevated temperatures was ascribed to the weakening of all hardening mechanisms. In addition, with increasing indentation depth, the dominant hardening mechanisms changed from the contribution of irradiation-induced defects and geometrically necessary dislocations (GNDs) to those of statistically stored dislocations (SSDs).

A Combined Rheological and Thermomechanical Analysis Approach for the Assessment of Pharmaceutical Polymer Blends

The viscoelastic nature of polymeric formulations utilised in drug products imparts unique thermomechanical attributes during manufacturing and over the shelf life of the product. Nevertheless, it adds to the challenge of understanding the precise mechanistic behaviour of the product at the microscopic and macroscopic level during each step of the process. Current thermomechanical and rheological characterisation techniques are limited to assessing polymer performance to a single phase and are especially hindered when the polymers are undergoing thermomechanical transitions. Since pharmaceutical processing can occur at these transition conditions, this study successfully proposes a thermomechanical characterisation approach combining both mechanical and rheological data to construct a comprehensive profiling of polymeric materials spanning both glassy and rubbery phases. This approach has been used in this study to assess the mechanical and rheological behaviour of heterogenous polymer blends of hydroxypropyl cellulose (HPC) and hydroxypropyl methylcellulose (HPMC) over a shearing rate range of 0.1–100 s−1 and a temperature range of 30–200 °C. The results indicate that HPC and HPMC do not appear to interact when mixing and that their mixture exhibits the mechanistic properties of the two individual polymers in accordance with their ratio in the mixture. The ability to characterise the behaviour of the polymers and their mixtures before, throughout, and after the glassy to rubbery phase transition by application of the combined techniques provides a unique insight towards a quality-by-design approach to this and other polymer-based solid dosage forms, designed with the potential to accelerate their formulation process through obviating the need for multiple formulation trials.

Hybrid deposition additive manufacturing: novel volume distribution, thermo-mechanical characterization, and image analysis

The structural integrity of additive manufacturing structures is a pronounced challenge considering the voids and weak layer-to-layer adhesion. One of the potential ways is hybrid deposition manufacturing (HDM) that includes fused filament fabrication (FFF) with the conventional filling process, also known as “HDM composites". HDM is a potential technique for improving structural stability by replacing the thermoplastic void structure with a voidless epoxy. However, the literature lacks investigation of FFF/epoxy HDM-based composites regarding optimal volume distribution, effects of brittle and ductile FFF materials, and fractographic analysis. This research presents the effects of range of volume distributions (10–90%) between FFF and epoxy system for tensile, flexure, and compressive characterization. Volume distribution in tensile and flexure samples is achieved using printable wall thickness, slot width, and maximum width. For compression, the printable wall thickness, slot diameter, and external diameter are considered. Polylactic acid and acrylonitrile butadiene styrene are used to analyze the brittle and ductile FFF structures. The research reports novel application of image analysis during mechanical characterization using high-quality camera and fractographic analysis using scanning electron microscopy (SEM). The results present surprising high tensile strain (0.038 mm/mm) and compressive strength (64.5 MPa) for lower FDM-percentages (10%, 20%) that are explained using in situ image analysis, SEM, stress–strain simulations, and dynamic mechanical analysis (DMA). In this regard, the proposed work holds novelty to apply DMA for HDM. The optimal volume distributions of 70% and 80% alongside fractographic mechanisms for lower percentages (10%, 20%) can potentially contribute to structural applications and future material-based innovations for HDM.

Comparison of Three Additive Manufacturing (AM) Techniques for Manufacturing Complex Hollow Composite Parts

AbstractAdditive manufacturing (AM) is well known for supporting the manufacturing of composites through the 3D printing of lay‐up tools, sacrificial mandrels, trim molds, etc. The fused deposition modeling (FDM) is a pioneer in composite tooling. This technique is advantageous in many scenarios in which it is convenient to obtain hollow composite parts by dissolving sacrificial mandrels, removing the use of expensive and heavy metal molds. However, the effects that the removal process has on the thermomechanical properties of the composite must be considered. The convenience of another AM technique, liquid crystal display (LCD) printing, has also recently been demonstrated. The present work aims to compare three different techniques, FDM, fused filament fabrication (FFF), and LCD, each using different materials and, therefore, different mandrel removal processes. DMA analyses have highlighted the impact of some dissolution processes on thermomechanical properties. Further mechanical analysis is conducted to support what is found in the thermomechanical characterization tests. Finally, an economic analyses highlight the time and cost savings of some AM technologies compared to the conventional method for manufacturing composite parts.

Synthesis, morphological and thermomechanical characterization of light weight silica foam via reaction generated thermo-foaming process

Low-cost thermo-foaming technique involving sucrose dehydration reaction with H2SO4 has been used for ceramic foam processing. The heat and gas generated during the reaction induces a thermo-foaming effect in the sucrose-ceramic mixture. This converts the sucrose-ceramic slurry into a carbonaceous porous ceramic-scaffold. The converted carbon is seen to agglutinate with the ceramic particles. During sintering, they are removed subsequently, thereby enlarging the pores. Influence of solids-loading, sintering temperature and H2SO4 concentration on the foaming behaviour, pore morphology and thermo-mechanical properties are studied. The fabricated silica foams are found to have porosity within the range of 70 %− 90 % and compressive strength of 0.8–2.8 MPa. The extreme porosity of the silica foams and their intercrystallite pores within the struts results in the low thermal conductivity (0.0943 Wm−1K−1) of the specimens. The fabricated foam is seen as a promising material for insulation applications like catalyst supports, filters and bio-scaffolds.

Morpho-structural and thermo-mechanical characterization of recycled polypropylene and polystyrene from mixed post-consumer plastic waste

In this work, a complete sorting and characterization of dirty non-recyclable mixed plastic (plasmix fraction) from municipal solid waste was performed. The procedure comprised a visual inspection and identification of the materials presented in the mixed plastic bales, and subsequent moisture and dirt content determination. Afterwards, both polypropylene and polystyrene fractions obtained from the sorting process were recycled and physico-mechanically and thermally characterized for the assessment of recycled material quality. The dirty non-recyclable mixed plastic from municipal solid waste was composed of polypropylene (28.89 %), polyethylene terephthalate (22.02 %), polystyrene (9.65 %) and rigid polyethylene (4.68 %). Regarding the moisture and dirt content of the mixed plastic fraction, the results were highly variable, mainly due to the heterogeneity of the material, its origin, atmospheric conditions, etc. The average sum of both parameters (moisture and dirt) was around 15 %. The mechanical properties were within the expected range for each type of polymer, noting that polystyrene recycled materials are more brittle than recycled polypropylene. The recycling of non-food polypropylene wastes yielded a material with higher impact resistance (70 kJ m−2) and Young´s modulus (1934 MPa) as compared to that obtained from the recycling of food packages. Concerning the polystyrene recyclates, it is worth mentioning that recycled materials obtained from foamed residues (expanded polystyrene and extruded polystyrene showed approximately twice the tensile strength with respect to the recycled materials from high impact polystyrene and general-purpose polystyrene residues. In some cases, infrared and thermal analyses revealed cross-contamination with traces of other polymers.

Crystallization behaviour analysis of norbornene based semicrystalline cyclic olefin copolymer (c-COC) for Point-of-care (PoC) device manufacturing

Cyclic Olefin Copolymer (COC) based on norbornene and ethylene is known to be one of the most promising materials for the fabrication of low-cost miniaturized Point-of-care (PoC) devices. Although semicrystalline materials are chemically more resistant and less brittle than amorphous ones, little literature has been reported on the unique semicrystalline COC (c-COC) grade. In this work, a thorough analysis of the crystallization behaviour of a semicrystalline COC (c-COC) is reported for the first time to better understand the relationship between the crystallization and injection moulding processing parameters of the material for the mass manufacturing of PoC devices. The complete thermomechanical characterization carried out by dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC) for the analysis of the crystallization behaviour suggested that even though a bimodal melting was detected by calorimetry, a unique crystalline structure was detected by X-ray scattering patterns confirming that the crystalline structure generated during the injection moulding of PoC parts is always the same regardless of processing conditions. In non-isothermal crystallization kinetics, the Ozawa model failed describing the crystallization behaviour of the c- COC whereas the combined Avrami-Ozawa and Avrami models successfully described the crystallization behaviour showing an excellent fitting to experimental values and suggesting a three-dimensional growth of nucleus for non-isothermal crystallization.

Synthesis of Shape-Memory Polyurethanes: Combined Experimental and Simulation Studies.

The presented research focuses on the synthesis and structure–properties relationship of poly(carbonate-urea-urethane) (PCUU) systems including investigations on shape-memory effect capability. Furthermore, we approached the topic from a broader perspective by conducting extensive analysis of the relationship between the synthesized compounds and the results of computer simulations by means of the Monte Carlo method. For the first time, by using a unique simulation tool, the dynamic lattice liquid model (DLL), all steps of multi-step synthesis of these materials were covered by the simulations. Furthermore, broad thermal, mechanical, and thermomechanical characterization of synthesized PCUUs was performed, as well as determining the shape-memory properties. PCUUs exhibited good mechanical properties with a tensile strength above 20 MPa, elongation at break around 800%, and an exhibited shape-memory effect with shape fixity and shape recovery ratios above 94% and 99%, respectively. The dynamic lattice liquid model was employed to show the products and their molar mass distribution, as well as monomer conversion or the dispersity index for individual reaction steps. The results obtained in the following manuscript allow the planning of syntheses for the PCUUs of various structures, including crosslinked and soluble systems, which can provide a broad variety of applications of these materials, as well as a better understanding of the composition–properties relationship.

Experimental and simulative study of warpage behavior for fan-out wafer-level packaging

Controlling warpage effects in fan-outwafer-level packaging (FO-WLP) is of key importance for realizing reliable and cost-efficient system in packages (SiPs). However, warpage effects can occur during the manufacturing process, caused by a combination of different processing temperatures, different materials, and the changing properties of the materials (e.g. polymerization and related cure shrinkage). One approach to controlling warpage could be realized by assessing a numerical simulation workflow of the FO-WLP process chain, in which the relevant material properties and geometry are used as input. Since there are many different steps included in the FO-WLP process, accompanied by complex material behavior, this workflow is not straight-forward. In the present paper, the first FO-WLP processing steps are investigated in detail by performing extensive thermo-mechanical material characterization, temperature-dependent warpage measurements, and numerical simulations. The investigation focuses on two epoxy mold compound (EMC) materials with completely different physical properties.The warpage measurements of bi-material (EMC and silicon) samples reveal an irreversible effect after passing certain processing temperatures, which are significant for final warpage at room temperature. A new approach to measuring the coefficient of thermal expansion (CTE) is discussed, using a temperature profile based on the temperature in the process, instead of the three identical temperature ramps suggested by the typical standards. This new approach makes it possible to determine possible shrinkage effects. Within the simulation model, the hysteresis effect observed in the experiment is taken into account by adding a shrinkage strain as well as changing the CTE values during the process. A very good agreement between the experiment and simulation is achieved, which is shown for several demonstrators with different epoxy mold compound materials and thicknesses.

U-channel forming of an 7075-T6 in warm conditions

The use of high mechanical strength aluminum coupled with the warm forming process makes it possible to replace certain steel parts in vehicles, thus reducing its mass and consequently greenhouse gas emissions. Warm forming of aluminum alloys requires heating the part between 150°C and 250°C to increase formability and reduce springback. In this study, a 7075-T6 alloy U-channel part was warm formed at 200°C in a short enough time to maintain the T6 state of the material. The process consisted of successively performing the heating by contact and stamping steps on the same mechanical press. From a thermomechanical characterization of the alloy in the temperature range between RT and 200°C and several strain rates, numerical simulations of the forming of the U-channel part were carried out using Abaqus. The experimental springbacks reduced with temperature were in agreement with the numerical simulations. An analysis of the conductivity and hardness of the material showed also that the 7075 keeps its T6 state until 10 s of warm forming.

Thermo-mechanical characterization and dynamic failure of a CoCrFeNi high-entropy alloy

This paper investigates the thermo-mechanical constitutive relationships of a CoCrFeNi high-entropy alloy (HEA) from quasi-static 10−2/s, medium strain rate of 101/s to high strain rates of 5 × 102/s-1.1 × 104/s. A series of tests, with the use of cylindrical specimen and shear compression specimen (SCS), were performed on a hydraulic Instron machine and a split Hopkinson pressure bar (SHPB) synchronized with a high-speed camera. The temperature rise (self-heating) during medium strain rate deformation is evaluated experimentally. Effects of the environmental temperatures on the dynamic flow response are studied using the SHPB and an environmental chamber. The constitutive relationships of CoCrFeNi HEA present noticeable strain rate and strain sensitivity. This HEA shows exceptional resistance to dynamic shear failure, with an equivalent shear failure strain of about 173%. Microstructural examinations illustrate that the CoCrFeNi HEA fails by adiabatic shear banding. A comparison of dynamic shear flow responses of the CoCrFeNi HEA and eight different metals and alloys is made. This reveals the potential use of HEA in impact resistant applications in aerospace engineering and armour design.

Thermo Physical and Mechanical Characterization of Lightweight Porous Ceramics Produced from Porcelain Polishing Residues

Traditional porcelain tile companies worldwide produce large amounts of residues during the polishing process. The recycling of these porcelain polishing residue becomes more critical. This study evaluates the incorporation of porcelain polishing residues as a raw material to produce lightweight porous ceramics as a new insulation material. Also, cellulose was used as the pore-making additive. The effect of sintering temperature and cellulose additive on the sintering behavior of porous ceramics, such as bulk density, linear shrinkage, water absorption were investigated. Flexural strength of the fired specimens was measured by three-point bending method. Thermal conductivities of the porous ceramics were predicted using laser flash method. Microstructural and phase observations were performed by scanning electron microscopy and X-ray diffractometry. Relatively low thermal conductivity of the samples sintered at 1100°C was obtained at 0.097 W.m–1.K–1 when 2.5 wt% cellulose additive was added, with low bulk density (<1 g.cm–3), water absorption (0.7%) and flexural strength (3.09 Mpa). These results indicate that the porcelain polishing residues could be used for lightweight porous ceramics production, thus giving rise to a new possibility for an environmental management of this abundant waste.

Development of Experimental Device with Data Acquisition for Thermomechanical Characterization of Polymers

Abstract The aim of this paper is to present a handmade laboratory device with data acquisition for estimating the thermomechanical characteristics (caused by dimensional changes in height) of polymeric materials. This experimental device is able to perform penetration tests, monitoring the expansion of the samples and based on experimental tests, the thermal expansivity or coefficient of thermal expansion (CTE) can be determined. A data acquisition instrument, which register (i) the deformation of the specimen, by using two displacement transducers (an inductive proximity transducer and an transmission type photoelectric linear encoder) as well as registers (ii) the temperature (at the base of the specimen and in the vicinity of the point of contact with the penetrator) is used. In order to test the device and to highlight its qualities, preliminary tests were carried out on a thermosetting polymeric material in various stages of polymerization.

Physico-Chemical and Thermomechanical Analysis and ‎Characterization of ‎a Thermoplastic Composite Material Reinforced by Washingtonia Filifera Novel Vegetable Fibers

In this paper, ‎morphological, physico-chemical and thermal properties investigations‎ are carried out for a ‎novel ‎composite material reinforced by Washingtonia Filifera (WF) palm fibers using a 20 weight (wt) % loading rate. The experimental analysis by Scanning Electron Microscopy (SEM) shows the longitudinal roughness of the surface, which plays a very important role in the adhesion between the WF fibers and the High Density ‎PolyethylenE (HDPE) resin. FTIR tests of the composite (WF 20%/ HDPE) represent out of plane vibrations involving ring and CH2 symmetric bending in cellulose chain.‎ Thermogravimetric analysis (TGA) and Derivative thermogravimetric ‎(DTG) thermal analysis show a thermal stability at 210°C, 2.5% residual mass ‎and 745 °C maximum ‎temperature. X-Ray Diffraction (XRD) analysis shows that the ‎crystallinity index is 59.2%, with a size of ‎‎23 nm. Using tensile tests, a Young modulus of 858.6 MPa, ‎17% elongation and a maximum stress of 15 MPa ‎are found. The obtained characteristics of WF reinforced composite are better than those of Bamboo reinforced composites which has been proven to have characteristics superior to those of standard particleboard and medium density fiberboard used mainly in the construction industry.

Effect of plastic aggregates addition on accelerated carbonation of sand concrete

PurposeThis study aims to the framework of the development of a new sand concrete, essentially manufactured with river/dune sand and recycled plastic aggregates (PAs; 0/3.15 mm). This new concrete may have a great interest, as it can enable us to achieve the best economical, technical and ecological solutions for local construction problems. Given the high abundance of dune sand (DS) and the large quantities of plastic waste, plastic–mineral sand concrete can be a good alternative to the ordinary building materials available on the local market.Design/methodology/approachA replacement of sand by PAs is made by volume substitution. The plastic percentages laid down are 0%, 25%, 50% and 100%. Indeed, after a general experimental characterization of the studied composites, the investigation mainly concentrated on the study of the effect of the addition of plastic particles on the accelerated carbonation of river sand (RS) concrete and DS concrete, separately.FindingsThe density of the composites and consequently their compressive strength are slightly reduced; but their thermal insulation is significantly improved. Their structure seems to be homogeneous, the plastic grains are well distributed in the matrix and the adhesion “plastic–matrix” is good. At small plastic contents, the RS concrete is slightly better. As regards the carbonation results, the PAs significantly contribute to the improvement of the resistance of the composite against carbonation effect. It can be observed that increasing the proportion of plastic particles in sand concrete considerably decreases the thickness of the carbonated concrete.Originality/valueThe studies led on the behavior of plastic concrete, particularly in arid zones, are very limited. Moreover, for sand concrete, there are no similar studies. Therefore, the characterization of such materials is necessary. In addition of thermo-mechanical characterization, this work aims at studying the durability of the material, especially its resistance to carbonation. On the other hand, this work has a significant positive impact on both environment and economy, since it focuses on the recycling of industrial waste, and the valorization of DS, which is available in great quantities in south of Algeria.

Site characterization for the design of thermoactive geostructures

This paper addresses the topic of site characterization for the design of Shallow Geothermal Energy (SGE) systems, namely of thermoactive geostructures, which are geotechnical structures, such as piles, retaining walls and tunnel linings, also used as heat exchangers as part of closed-loop SGE systems. Such solutions, being increasingly adopted for buildings’ and infrastructures’ heating and/or cooling, are considered sustainable and cost effective. For the design of the primary circuit of the SGE system, which is embedded within the superficial soil layers, a comprehensive knowledge of the ground condition at the site is mandatory. This includes the evaluation of the energy features and whether the system can provide the required energy needs during the operational period, as well as the verification of the structural and geotechnical safety and functionality requirements. The site characterization for SGE systems involves different stages, from desk studies to detailed characterization, including in-situ trials, laboratory testing of undisturbed soil samples and the study of possible interferences. The specific aspects that will be addressed are: (i) the assessment of the site undisturbed ground temperature and its hydrogeological features; (ii) the thermal and thermomechanical characterization of the different soil layers; (iii) the investigation of the ground-heat exchanger thermal resistance; (iv) the collection of information related to the environmental constraints and to potential interferences among multiple users, which are related to the service life of the structure. The overall aim is to ensure a proper design of the SGE system for guaranteeing its sustainability in the long term.

Thermomechanical characterization of functionally stabilized nickel-titanium-copper shape memory alloy

Shape memory alloy hybrid composites have promise in realizing the 21st century goal of morphing structures. There is considerable work to be done in the development of characterization and modeling techniques for these materials. The proposed characterization methodology adapts existing standards to include previously omitted factors required for the numerical modelling of shape memory alloys and their integration into end-use applications. A nickel-titanium-copper (NiTiCu) shape memory alloy is characterized using these methods and then numerically modelled. Samples’ mechanical behaviour is shown to stabilize after 43 cycles of mechanical loading. Thermomechanical properties measured before and after stabilization are shown to vary inconsistently by up to 72%, demonstrating the need for stabilization for accurate thermomechanical characterizations and consistency in end-use applications. Physical experiments are numerically replicated in Abaqus\\Standard using the measured properties. Sufficient correlation is shown for the design of shape memory alloy hybrid composites. The result of this work is a comprehensive thermomechanical characterization approach for shape memory alloys which can be used to develop morphing SMA hybrid composite structures.

Novel thermomechanical characterization for shrinkage evolution of unidirectional semi-crystalline thermoplastic prepregs (PPS/CF) in melt, rubbery and glassy states

Shrinkages, distortions and high residual stresses in the thermoplastic composite parts are induced due to high processing temperature, anisotropy, and fiber–matrix shrinkage mismatch. In this paper the shrinkages have been investigated experimentally and modeled by thermo-mechanical constitutive equations for PolyPhenylene Sulfide (PPS) and the unidirectional Carbon Fiber (PPS/CF) composite prepreg. The thermal shrinkage and the crystallization shrinkage were retrieved from Thermal Mechanical Analysis and compared to a Pressure specific volume Temperature diagram. To describe the crystallization shrinkage in the cooling process accurately, the crystallization kinetics of PPS was evaluated using Differential Scanning Calorimetry. The temperature-dependent elastic modulus was measured by a shear rheometer to formulate a new constitutive model. The mathematical model for shrinkage was validated by a press consolidated [0]12 laminate and unbalanced laminates in four lay-ups. The thermo-mechanical model results presented here provide significant rules for the thermomechanical and shrinkage predictions for the industrial applications of thermoplastic composite.

Development and Characterization of Plantain (Musa paradisiaca) Flour-Based Biopolymer Films Reinforced with Plantain Fibers.

Agroindustrial wastes are a cheap and abundant source of natural fibers and macromolecules that can be used in the manufacturing of biocomposites. This study presents the development and thermo-mechanical characterization of a bio-composite film (TPF/PF), made of thermoplastic banana flour (TPF) matrix and plantain fibers (PF). Fabricated materials were characterized by physical analysis, chemical composition, Fourier-transformed spectroscopy (FTIR), thermal analysis (TGA), mechanical analysis, and scanning electronic microscopy (SEM). The physical analysis showed that TPF and PF have a low density and high affinity to water resulting in a lightweight, renewable, and biodegradable TPF/PF composite. The chemical composition and spectra analysis of the fiber showed that PF is a potential candidate for reinforcing composites due to its high α-cellulose and low lignin content. The thermal analysis determined that TPF degrades at a lower temperature than PF, therefore the matrix sets the processing temperature for TPF/PF composite films. The mechanical test showed an improvement in the tensile properties of the composite in comparison to neat TPF. Tensile strength and Young’s modulus were improved by 345% and 1196%, respectively, when PF fibers was used. Good bonding and mechanical interlocking of PF to the TPF were identified by SEM. Therefore, potential biocomposites can be developed using natural fibers and thermoplastic starches obtained from plantain agroindustrial wastes.

Electrophoretic co-deposition of Mn1.5Co1.5O4, Fe2O3 and CuO: Unravelling the effect of simultaneous addition of Cu and Fe on the microstructural, thermo-mechanical and corrosion properties of in-situ modified spinel coatings for solid oxide cell interconnects

A systematic microstructural, thermo-mechanical and electrical characterization of simultaneous Fe–Cu doped Mn–Co spinel coatings processed by electrophoretic co-deposition on Crofer 22 APU is here reported and discussed. An innovative approach for the simultaneous electrophoretic deposition of three spinel precursors is designed, conceived and optimised, with the aim of outlining time- and energy-saving spinel modification routes. The effect of different levels of Cu and Fe co-doping is observed on the stability of the modified Mn–Co spinel phase, the coefficient of thermal expansion (CTE), the corrosion resistance and on the densification behaviour of the obtained coatings. Cu determines an increase of CTE, while Fe has the opposite behavior. The synergic effect of the simultaneous Fe and Cu co-doping results in an improved densification and the stabilization of the MnCo2O4 cubic phase. The most interesting results in terms of corrosion resistance are obtained for the Mn1.28Co1.28Fe0.15Cu0.29O4 spinel.