Thermal Claddings for Engineering Applications

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
About the Editors
List of Contributors
Aim and Scope
Chapter 1 Fundamentals and Applications of Thermal Claddings
	1.1 Introduction
	1.2 Historical Development of Thermal Claddings
		1.2.1 Thermal-Spraying Processes
		1.2.2 Thermal Barrier Coatings
		1.2.3 Laser Claddings
		1.2.4 Electron Beam Claddings
		1.2.5 Microwave Cladding
		1.2.6 Metal and Tungsten Gas Arc Cladding
	1.3 Classification of Claddings
		1.3.1 Thermal Spray Processes
			1.3.1.1 Features of Thermal Spraying Processes [10]
			1.3.1.2 Advantages [28]
			1.3.1.3 Disadvantages [28]
			1.3.1.4 Applications
			1.3.1.5 Key Challenges [10]
			1.3.1.6 Future Scope [32]
		1.3.2 Laser Cladding Process
			1.3.2.1 Advantages [15]
			1.3.2.2 Disadvantages [15]
			1.3.2.3 Applications
			1.3.2.4 Key Challenges
			1.3.2.5 Future Scope [37]
		1.3.3 Electron Beam Cladding Process
			1.3.3.1 Advantages [18]
			1.3.3.2 Limitations [18]
			1.3.3.3 Applications [40]
			1.3.3.4 Key Challenges
			1.3.3.5 Future Scope
		1.3.4 Thermal Barrier Cladding (TBC) Process
			1.3.4.1 Advantages [13]
			1.3.4.2 Limitations [13]
			1.3.4.3 Applications [45]
			1.3.4.4 Key Challenges [14]
			1.3.4.5 Future Scope [44]
		1.3.5 Microwave Cladding Process
			1.3.5.1 Advantages [21]
			1.3.5.2 Limitations [46]
			1.3.5.3 Applications [21]
			1.3.5.4 Key Challenges
			1.3.5.5 Future Scope
		1.3.6 Metal Inert Gas (MIG) Cladding Process
			1.3.6.1 Advantages [53]
			1.3.6.2 Limitations [4]
			1.3.6.3 Applications [54]
			1.3.6.4 Key Challenges
			1.3.6.5 Future Scope
		1.3.7 Tungsten Inert Gas (TIG) Cladding Process
			1.3.7.1 Advantages
			1.3.7.2 Disadvantages
			1.3.7.3 Applications
			1.3.7.4 Key Challenges
			1.3.7.5 Future Scope
	1.4 Conclusion
	Conflicts of Interest
	Acknowledgement
	References
Chapter 2 Improved Room and High-Temperature Wear Performance With Inconel 625 TIG Weld Cladding
	2.1 Introduction
	2.2 Materials and Methods
		2.2.1 Substrate and Clad Alloy Materials
		2.2.2 Cladding Procedure
	2.3 Characterisation
	2.4 Tests and Results
		2.4.1 Dilution
		2.4.2 Microhardness Test
		2.4.3 At Room Temperature and 650°C Sliding Wear Test
	2.5 Conclusion
	References
Chapter 3 Corrosion and Microstructural Behaviour of Inconel 625 Microwave Clad Deposited On Mild Steel
	3.1 Introduction
		3.1.1 Material Detail
	3.2 Experimental Procedure
	3.3 Microstructural and Mechanical Characterisation
	3.4 Results and Discussion
		3.4.1 XRD Study
		3.4.2 Microstructural Analysis
		3.4.3 Porosity
		3.4.4 Vickers Microhardness
	3.5 Corrosion Performance
	3.6 Conclusions
	References
Chapter 4 Artificial Intelligence Revolutionizing the Laser Cladding Industry
	4.1 Introduction
	4.2 Artificial Intelligence
		4.2.1 Parametric Optimization in Laser Cladding Using AI
		4.2.2 Artificial Neural Network Model in Laser Cladding
		4.2.3 Support Vector Machines (SVMs)
	4.3 Novel Non-Dominated Sorting Genetic Algorithm II (NSGA-II)
		4.3.1 Particle Swarm Optimization Model in Laser Cladding (PSO)
		4.3.2 Random Forest Model
		4.3.3 Adaptive Neuro-Fuzzy Inference Model
	4.4 Conclusion and Future Scope
	References
Chapter 5 Multi-Objective Optimisation of Wire Arc Additive Manufacturing Deposition Using Genetic Algorithm
	5.1 Introduction
	5.2 Experimental Procedure
	5.3 Mathematical Models
	5.4 Parametric Effects
	5.5 Multi-Objective Genetic Algorithm
	5.6 Optimisation Results
	5.7 Conclusions
	References
Chapter 6 Techniques for Improving Engineering Material’s Tribological Performance Using Laser Cladding Process in Laser Surface Texturing
	6.1 Introduction
		6.1.1 Laser Cladding
			6.1.1.1 Biomedical Applications
		6.1.2 Periodic Surface Structures Induced By Lasers, Fundamentals, and Theory
		6.1.3 Theory of Laser-Induced Periodic Surface Structures
	6.2 Most Recent Developments in Laser-Induced Periodic Surface Patterns On Different Materials
		6.2.1 LC By Direct Laser Ablation
		6.2.2 LC By Laser Shock Processing
	6.3 Effects of Laser Parameters On Surface Texturing
		6.3.1 Pulse Duration Types
			6.3.1.1 Millisecond (Ms) Lasers
			6.3.1.2 Nanosecond (Ns) Lasers
			6.3.1.3 Picosecond (Ps) Lasers
			6.3.1.4 Femtosecond (Fs) Lasers
		6.3.2 Laser Power Intensity
	6.4 Applications
	6.5 Challenges and Future Directions
		6.5.1 Current Challenges
	6.6 Future Directions
	6.7 Conclusion
	References
Chapter 7 Prediction and Performance of Thermal Cladding Using Artificial Intelligence and Machine Learning: Design Analysis and Simulation
	7.1 Introduction
		7.1.1 Challenges in the Thermal Cladding
		7.1.2 Importance of the Artificial Intelligence (AI) and Machine Learning (ML) Techniques
	7.2 Thermal Cladding Techniques
		7.2.1 Overview of the Laser Cladding Process
		7.2.2 Advantages Laser Cladding Process Characteristics
	7.3 Role of Machine Learning Techniques in Thermal Cladding
	7.4 Intelligent Optimisation Methods
		7.4.1 Artificial Neural Network Model
		7.4.2 Genetic Algorithm Optimises BP Neural Network (GABP)
	7.5 Conclusion
	References
Chapter 8 Evolution of Nickel-Based Superalloy Claddings for Against High-Temperature Oxidation and Wear
	8.1 Introduction to Critical Raw Materials (CRMs)
	8.2 Turbojet Engine and Its Components
	8.3 Evolution of Ni-Based Superalloys
	8.4 Laser Cladding of Ni-Based Superalloys
	8.5 Conclusions
	References
Chapter 9 Enhancing the Durability and Performance of High-Value Components Through Thermal Cladding: A Study On Materials and Process Parameters for Repair, Refabrication, and Remanufacturing
	9.1 Introduction
	9.2 Objectives and Scope of the Chapter
	9.3 Thermal Claddings: Overview and Types
	9.4 Properties of Thermal Claddings
	9.5 Manufacturing Processes for Thermal Claddings
	9.6 Applications of Thermal Claddings for Component Repair, Refabrication, and Remanufacturing
	9.7 Overview of the Types of High-Value Components That Can Benefit From Thermal Claddings
	9.8 Advantages of Using Thermal Claddings for Component Repair, Refabrication, and Remanufacturing
	9.9 Examples of Successful Applications of Thermal Claddings for Component Repair, Refabrication, and Remanufacturing
	9.10 Experimental Studies On Thermal Claddings
	9.11 Results of Thermal Conductivity Measurements On Thermal Claddings
	9.12 Wear and Corrosion Resistance Tests On Thermal Claddings
	9.13 Challenges in Thermal Cladding Research
	9.14 Emerging Trends and Opportunities in Thermal Cladding Research
	9.15 Future Directions for Research On Thermal Claddings for Component Repair, Refabrication, and Remanufacturing
	9.16 Conclusion
	References
Chapter 10 Application of Thermal Claddings for Materials Used as Biomedical Implants
	10.1 Introduction
		10.1.1 Bioactive Glass Coating
		10.1.2 Thermal Cladding Methods
			10.1.2.1 High-Velocity Oxygen Fuel
			10.1.2.2 Plasma Transferred Arc
			10.1.2.3 Laser Cladding
	10.2 Properties of the Biomaterials in Biomedical Implants
		10.2.1 Various Medical Applications
	10.3 Metallic Alloys in Biomedical Implants
		10.3.1 Stainless Steel
		10.3.2 Cobalt Alloys
		10.3.3 Titanium and Titanium-Based Alloys
	10.4 Conclusion
	References
Chapter 11 Study On the Thermal Claddings Used in Biomedical Implants
	11.1 Introduction to Thermal Claddings
		11.1.1 Importance of Thermal Claddings for Biomedical Implants
		11.1.2 Materials for Thermal Claddings
	11.2 Coating Techniques Used in Thermal Claddings for Biomedical Implants
		11.2.1 Properties of Thermal Claddings
		11.2.2 Applications of Thermal Claddings
	11.3 Future Scope of Thermal Claddings
	11.4 Challenges and Opportunities for Thermal Claddings
	11.5 Conclusion
	References
Chapter 12 Nanostructured Thermal Claddings for Improved Life and Performance of Engineering Components
	12.1 Introduction
	12.2 Overview of Nanostructured Materials
	12.3 Nanostructured Thermal Cladding Materials
		12.3.1 Types of Nanostructured Materials
		12.3.2 Synthesis and Processing Techniques
	12.4 Characterization Techniques
	12.5 Properties of Nanostructured Materials
	12.6 Thermal Performance of Nanostructured Thermal Claddings
		12.6.1 Thermal Conductivity and Diffusivity
		12.6.2 Heat Transfer Coefficient
	12.7 Thermal Stability and Durability
	12.8 Mechanical Performance of Nanostructured Thermal Claddings
		12.8.1 Mechanical Properties of Nanostructured Materials
		12.8.2 Mechanical Performance of Nanostructured Thermal Claddings
	12.9 Adhesion Strength of Nanostructured Materials
	12.10 Wear Resistance of Nanostructured Materials
	12.11 Applications of Nanostructured Thermal Claddings
		12.11.1 Applications in Aerospace Industry
		12.11.2 Applications in Automotive Industry
		12.11.3 Applications in Electronics Industry
		12.11.4 Applications in Energy Industry
		12.11.5 Applications in Medical Industry
	12.12 Future Trends and Challenges
	12.13 Opportunities for Further Research and Development
	12.14 Barriers to Commercialization
	12.15 Environmental and Safety Concerns
	12.16 Conclusion
	References
Chapter 13 Wire Arc Additive Manufacturing: Study of Microstructure and Defects
	Abbreviations
	13.1 Introduction
	13.2 Wire Arc Additive Manufacturing Systems
	13.3 Processes for WAAM
		13.3.1 Tungsten Inert Gas Welding (TIG)
		13.3.2 Gas Metal Arc Welding (GMAW)
		13.3.3 Plasma Arc Welding (PAW)
	13.4 Metal Deposition By Using WAAM Process
		13.4.1 Titanium (Ti6Al4V) Alloy
		13.4.2 Aluminium Alloy
		13.4.3 Bimetallic (Monel–Inconel) Alloy
		13.4.4 Other Metals
	13.5 Common Defects in WAAM-Fabricated Component
		13.5.1 Deformation and Residual Stresses
		13.5.2 Porosity
		13.5.3 Cracks and Delamination
	13.6 Mechanical Properties
	13.7 Applications of WAAM
	13.8 Conclusion
	Funding Declaration
	References
Chapter 14 Development of MoCoCrSi/fly Ash Composite Cladding On Stainless Steel Substrate Through Microwave Irradiation
	14.1 Introduction
	14.2 Microwave Cladding
	14.3 Basics of Microwave Material Processing
	14.4 Experiment and Characterization
	14.5 Results and Discussion
		14.5.1 Morphology Studies
	14.6 Conclusions
	Conflicts of Interest
	Acknowledgment
	References
Chapter 15 Advantages and Applications of Various Surface Engineering Techniques
	15.1 Introduction to Cladding Technology
	15.2 Surface Cladding Techniques
		15.2.1 Thermal Spraying Process
		15.2.2 Advantages
		15.2.3 Disadvantages
	15.3 Physical Vapor Deposition (PVD)
		15.3.1 Advantages
		15.3.2 Disadvantages
	15.4 Chemical Vapor Deposition (CVD)
		15.4.1 Advantages
		15.4.2 Disadvantages
	15.5 Laser Cladding Process
		15.5.1 Advantages
		15.5.2 Disadvantages
	15.6 Materials for Surface Cladding
	15.5 Surface Preparation
	15.7 Design Considerations
	15.8 Applications of Surface Cladding
	15.9 Challenges and Future Trends
	References
Index