In aerosol deposition, fine ceramic powders in sizes of less than typically 5 μm are deposited as a coating at room temperature. Aerosol deposition must be performed under a vacuum to apply such fine powders and avoid bow shock effects. According to experimental results, coating formation by aerosol deposition only occurs if particle velocities exceed a material-specific threshold velocity. Thus, knowledge of attained particle velocities over acceleration in the nozzle and under the expansion into a vacuum is essential for deriving conditions for successful deposition. In the present study, 3D CFD simulations were used to investigate the key geometric variables in particle acceleration. Three different nozzle geometries were investigated: a converging nozzle, a converging–diverging nozzle, and a converging nozzle followed by a constant cross section toward the exit. In addition, these three nozzle geometries were optimized to maximize the particle impact velocity. The results show that the converging–diverging nozzle supplies the highest particle velocities within this comparison. By the design of optimization, the particle velocities can be improved for all the geometry types. The most promising geometry from the CFD optimization was manufactured and compared to the original one, providing a gain in experimentally measured particle velocity of 24

This paper investigates three different types of nozzle geometries and the first steps for individual shape optimization to maximize the powder impact velocities. The basic types concern (i) a convergent, (ii) a convergent-divergent, and (iii) a convergent-constant geometry. For each nozzle type, four geometrical variables were investigated to reveal their individual and possibly combined potential to improve particle impact velocities.

This study primarily demonstrates the feasibility of using aerosol deposition to produce thin GaN coatings through systematic investigation. To date, the roles of particle size and powder morphology in the consolidation of ceramic particles during aerosol deposition remain unclear. To enhance understanding of this process, two GaN powders, one coarse agglomerated and the other a fine monolithic powder, were deposited under various process conditions. The findings revealed that fine GaN powder is more effective in forming denser coating layers as compared to agglomerated GaN powder. Furthermore, the use of helium gas at higher pressures was observed to enhance coating formation in comparison with nitrogen gas. This study not only validates the potential of aerosol deposition for forming thin GaN coatings but also contributes to our understanding of the critical role that particle sizes play in the aerosol deposition process.

Photoelectrochemical (PEC) water splitting is a viable route for green hydrogen generation. In PEC cells, the electrodes are coated with suitable semiconductor materials, which absorb the sunlight, generating charge carriers that are used to split water molecules into H2 and O2. CuFeO2 is one promising photocathode material for water splitting. However, its performance is limited by electron/hole pairs recombination within the film and at the film/substrate interface. Aerosol deposition (AD) can be employed to minimize charge recombination by spraying dense, thin films and by establishing a good back-contact interface. In this study, CuFeO2 powders were synthesized through a conventional solid-state technique and sprayed by AD under varied parameter sets. The effect of particle size distributions, carrier gas, gas pressure and substrate temperature was investigated. The best spraying parameter set was then tuned to obtain thin coatings (< 1 µm). Single-particle deformation and coatings microstructure were investigated by scanning electron microscopy. Optical properties of CuFeO2 films were analyzed by UV–Vis spectroscopy, while photoelectrochemical performances were estimated through amperometry tests under simulated sunlight. The results of this research show that CuFeO2 photocathodes can be successfully manufactured by AD. Their performance can be optimized by adjusting coating thickness and by annealing in air.

Bismuth vanadate (BiVO 4 ) offers high photon efficiencies in solar photo-anodes, due to its suitable semiconductor band gap energies and associated visible light absorption. In well-tuned conditions, such anodes enable green hydrogen generation in photoelectrochemical water splitting cells. Bismuth vanadate films have to ensure high efficiencies in electron/hole pair generation and sufficiently high rates of charge transfer to the conducting substrate and the electrolyte, respectively. Thus, the tuning of coating properties has to aim for high phase purity, good layer integrity as well as optimum diffusion path lengths. In order to explore the potential of aerosol deposition to produce BiVO 4 films with high photoelectrochemical activity and to elucidate influences on microstructure and application properties, powder sizes and spraying parameters had to be tailored. By ball milling over durations of up to 20 min, particles sizes in the range from 8.3 down to 0.6 µm were obtained. With respect to spray conditions, the process gas pressure was varied from 1.0 to 2.1 bar corresponding to gas flow rates of 10-40 l/min. The wide range of powder sizes and parameters in aerosol deposition allowed for developing a window of deposition in order to derive the most promising combinations for layer build-up. Optimum parameter sets in application on stainless steel substrates were transferred to FTO-coated glass substrates for backlit cell layouts. The thickness and conductivity of the layers were adjusted to a layer thickness range of 200-500 nm in order to achieve maximum photocurrents. The production of homogeneous, large-scale prototypes demonstrates that aerosol deposition is suitable for processing layers for solar energy harvesting with high photo current densities of up to 3.55 mA/cm 2 .

Tailoring strength and ductility in additive manufacturing or repair is key to successful applications. Therefore, cold spraying must be tuned for maximum amounts of well-bonded internal interfaces as well as sufficient softening of the highly workhardened deposit. Zinc (Zn) with its low melting temperature is an ideal model system to study phenomena associated with high strain rate deformation and local temperature distributions, both, in single impacts and thicker deposits. Bonding and recrystallization can be facilitated by covering selected wide parameter regimes in cold spraying. Despite the low temperatures, Zn single splats already show recrystallization at internal interfaces, the respective amounts then scaling with increasing process gas temperatures. At higher process temperatures, deposits are almost fully recrystallized. The recrystallization seems to improve bonding at internal and at deposit-substrate interfaces. Under optimum conditions, an ultimate deposit cohesive strength of up to 135 MPa and an elongation to failure of 18.4% are reached, comparable to that of laser-manufactured or bulk Zn parts. This demonstrates a welltuned interplay between high amounts of bonded interfaces and softening by recrystallization that allows for deriving bulk-like performance of cold sprayed material without additional posttreatments. Correlations between microstructures, mechanical properties, and fracture mechanisms supply information about prerequisites needed for reaching high ductility as obtained in damage and failure modes of deposits and bulk materials in global and local approaches.

Due to its suitable semiconductor band gap energies and associated visible light absorption, bismuth vanadate offers high photon efficiencies in solar photo-anodes, enabling green hydrogen generation in photoelectrochemical water splitting cells. Respective bismuth vanadate films have to ensure high efficiencies in electron / hole pair generation, and sufficiently high rates of charge transfer, for both, electrons to the conducting substrate, as well as holes to the electrolyte. Thus, tuning of coating properties has to aim for high phase purity and good layer integrity. So far, respective films are mainly produced by thin film techniques, but at rather high costs and low deposition rates. Less costly processing routes are opened by thermal spraying or sol-gel techniques, however, these cannot guarantee the required phase purity or absence of remnants from the binder. As solid state and binderless alternative, Aerosol Deposition (AD) offers several advantages: comparative low costs, high deposition rates, no undesired phase transformations, and no impurities or residues that could reduce the photoelectrochemical activity. Under the scope of this research on photo-electrochemically active bismuth vanadate films, powder sizes were tailored by milling, and spray parameter sets like the process gas pressure were varied, in order to elucidate their influence on microstructure and application properties. Covering a wide parameter range in aerosol deposition allowed for the development of a window of deposition. Most promising combinations for layer build-up were derived. The results on stainless steel substrates were transferred to FTO-coated glass substrates, as needed in backlit cell layouts. For fine tuning of maximum photocurrents, layer thickness and conductivity were then systematically adjusted. Homogeneous large-scale prototypes demonstrate that aerosol deposition is suitable for processing layers for solar energy harvesting.

Low ductility of metallic deposits manufactured by cold spraying (CS) impedes potential mechanical performances in industrial applications. Through appropriate annealing treatment, the amount of both, non bonded interfaces and work hardening promoted dislocations during CS can be significantly reduced. Consequently, the annealed samples exhibit higher strength and fracture strain than the as-deposited ones. Cu was selected as a reliable material for CS. To correlate Cu deposit strength with primary process parameters and material properties, the Cu powder strength was assessed. Crack characterization of Cu deposits was performed by in-situ microscopic observations during tensile testing. The direct observation of crack initiation, growth and final fracture allows revealing failure mechanisms. The in-situ tests allow distinguishing the effects of reduced initial defect sizes due to annealing and improved ductility in the vicinity of initial defects on possible crack growth and part failure. Considering the necessary compromise between strength, uniform elongation, ductility and microhardness, a post-spraying annealing process is desirable for CSed Cu deposits. The identification of macroscopic and micro-mechanical properties attained under respective process parameters and influences of annealing processes therefore allow identifying solutions for improvements of CSed deposits for load-carrying applications, which is a prerequisite for using CS as additive manufacturing technique. (c) 2021 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http:// creativecommons.org/licenses/by/4.0/).

For the present study on Aerosol Deposition of MAX-phase materials, Ti3SiC2 was chosen as model system due to the availability of property data and commercial powder. The as-received powder was milled to different nominal sizes. For revealing details on coating formation and possible bonding mechanisms, Aerosol Deposition experiments were performed for different particle size batches and process gas pressures. Microstructural analyses reveal that coating formation preferably occurs for particle sizes smaller two microns. Using such small particle sizes, crack-free, dense layers can be obtained. The individual deposition efficiencies for the different particle sizes, particularly the critical size below which deposition gets prominent, vary with process gas flows and associated pressures. Detailed microstructural analyses of coatings by high-resolution scanning electron microscopy reveal plastic deformation and fracture, both attributing to shape adaption to previous spray layers and probably bonding. In correlation to coating thickness or deposition efficiencies, respective results give indications for possible bonding mechanisms and a tentative window of Aerosol Deposition for Ti3SiC2 MAX-phases as spray material.

Hydrogen generation from renewable energy sources will play a key role in the concerted endeavor to constrain climate change. One environmentally friendly route, powered by sunlight, is the photoelectrochemical water splitting cell (PEC). This technology employs electrodes coated with thin films of semiconductor materials to capture light and generate charge carriers that directly drive the water splitting reaction. Bismuth vanadate is a promising metal oxide semiconductor, as it absorbs visible light, and is abundant, non-toxic and cost-effective. The present study investigates the formation of bismuth vanadate thin films by the aerosol deposition (AD) method. Operating with layer formation at room temperature, AD offers advantages over other routes for the fabrication of photoactive thin film coatings, as no binders or sintering processes need to be applied. Furthermore, compared to traditional cold spraying, micrometer-sized particles can be used, resulting in coatings with thicknesses below 1 µm. Additionally, the lower kinetic energy of the feedstock powder particles enables the use of delicate substrates, such as FTO-coated glass, expanding the range of possible PEC device configurations. The process parameters explored in this study had considerable influence on the resulting coating microstructure, which in turn showed a significant impact on the photoelectrochemical performance.

As solid-state deposition technique avoiding oxidation, cold gas spraying is capable of retaining feedstock material properties in the coatings, but typically fails to build up coatings of brittle materials. Ceramic MAX phases show partial deformability in particular lattice directions and may thus successfully deposit in cold spraying. However, deformation mechanisms under high strain rate, as necessary for cohesion and adhesion, are not fully clear yet. A MAX-phase deposit only builds up, if the specific mechanical properties of the MAX phase allow for, and if suitable spray parameter sets get realized. To investigate the influence of material properties and deposition conditions on coating microstructure and quality, three MAX phases, Ti 3 SiC 2 , Ti 2 AlC and Cr 2 AlC, were selected. Up to ten passes under different spray parameters yielded Ti 2 AlC and Cr 2 AlC coatings with thicknesses of about 200-500 µm. In contrast, Ti 3 SiC 2 only forms a monolayer, exhibiting brittle laminar failure of the impacting particles. In all cases, the crystallographic structure of the MAX-phase powders was retained in the coatings. Thicker coatings show rather low porosities (< 2%), but some laminar cracks. The deposition behavior is correlated with individual mechanical properties of the different MAX-phase compositions and is discussed regarding the particular, highly anisotropic deformation mechanisms.