In this work High Velocity Oxy-fuel (HVOF) thermal spray techniques, spraying process optimization, and characterization of coatings are reviewed. Different variants of the technology are described and the main differences in spray conditions in terms of particle kinetics and thermal energy are rationalized. Methods and tools for controlling the spray process are presented as well as their use in optimizing the coating process. It will be shown how the differences from the starting powder to the final coating formation affect the coating microstructure and performance. Typical properties of HVOF sprayed coatings and coating performance is described. Also development of testing methods used for the evaluation of coating properties and current status of standardization is presented. Short discussion of typical applications is done.

Infected superficial wounds were traditionally controlled by topical antibiotics until the emergence of antibiotic-resistant bacteria. Silver (Ag) is a kernel for alternative antibacterial agents to fight this resistance quandary. The present study demonstrates a method for immobilizing small-sized (~5 nm) silver nanoparticles on silica matrix to form a nanosilver–silica (Ag–SiO₂) composite and shows the prolonged antibacterial effects of the composite in vitro. The composite exhibited a rapid initial Ag release after 24 h and a slower leaching after 48 and 72 h and was effective against both methicillin-resistant Staphylococcus aureus (MRSA) and Escherichia coli (E. coli). Ultraviolet (UV)-irradiation was superior to filter-sterilization in retaining the antibacterial effects of the composite, through the higher remaining Ag concentration. A gauze, impregnated with the Ag–SiO₂ composite, showed higher antibacterial effects against MRSA and E. coli than a commercial Ag-containing dressing, indicating a potential for the management and infection control of superficial wounds. Transmission and scanning transmission electron microscope analyses of the composite-treated MRSA revealed an interaction of the released silver ions with the bacterial cytoplasmic constituents, causing ultimately the loss of bacterial membranes. The present results indicate that the Ag–SiO₂ composite, with prolonged antibacterial effects, is a promising candidate for wound dressing applications.

The growth of silver nanoparticles, the activation energy for silver particle growth, and the release of silver species in heat treated ${\mathrm{SiO}}_2$ -Ag composite powders are investigated. The silver particle growth is controlled by heat treatment for 75 min of the as-synthesized ${\mathrm{SiO}}_2$ -Ag composite powder at 300–800 °C. During heat treatment the mean size of the Ag particles increases from 10 nm up to 61 nm with increasing temperature, however, the particle size distribution widens and the mean size increases with increasing heat treatment temperature. Based on X-ray photoelectron spectroscopy (XPS) and transmission electron microscopy (TEM) studies, silver particles are crystalline and in a metallic state after annealing in all ${\mathrm{SiO}}_2$ -Ag composite powders. The growth of Ag particles is suggested to take place via diffusion and Ostwald ripening. The activation energy for particle growth was determined as 0.14 eV. The dissolution of silver in aqueous solutions from the ${\mathrm{SiO}}_2$ -Ag composites heat treated, at 300 °C, 600 °C, and 700 °C, was investigated by varying pH and temperature. The dissolution was reduced in all conditions with increasing silver particle size, i.e., when the total surface area of Ag particles is reduced. It is suggested that the dissolution of silver from the composite powders can conveniently be adjusted by controlling the Ag particle size by the heat treatment of the composite powder.

Cold gas spraying was used to make a coating from an equiatomic CrFeNiMn high-entropy alloy. This four-component alloy was chosen because it is Co-free, thus allowing application in nuclear industries as a possible replacement of currently used stainless steel coatings. The feedstock material was gas atomized powder with a particle size distribution from 20 to 45 µm. A number of parameters were tested, such as the powder feed rate and gas feed pressure, in order to obtain as dense a coating as possible with nitrogen as the process gas. Spraying was performed using a gas preheating temperature of 1000 °C, gas feed pressure ranging from 50 to 60 bar, and two powder feeding rates. The coating thicknesses ranging from 230 to 490 µm and porosities ranging from 3% to 10% were obtained depending on the powder feed rate and gas feed pressure. The hardness of the cross-section of the coating was usually lower than that of the surface. The highest coating hardness obtained was above 300 HV_0.3 for both the surface and the cross-section. The as-atomized powder consisted of a face-centered cubic (FCC) phase with a minute amount of body-centered cubic (BCC) phase, which was no longer detectable in the coatings. The microstructure of the coating was highly stressed due to the high degree of deformation occurring in cold gas spraying. The deformation leads to strain hardening and induces a pronounced texture in the coating. The {111} planes tend to align along the coating surface, with deformation and texturing concentrating mainly on particle boundaries. A high-entropy alloy (HEA) coating was successfully sprayed for the first time using nitrogen as a process gas. The coating has the potential to replace stainless steel coatings in nuclear industry applications.

Tunable core-shell Ag@Mesoporous SiO₂ spheres were synthesized via an in situ modified Stöber approach by varying the amount of ethanol (EtOH) expanding their potentials in many applications. Mesoporous silica was generated by adding tetraethyl orthosilicate (TEOS) to the mixture of colloidal Ag particles prepared by reducing silver nitrate (AgNO₃) with L-ascorbic acid and using hexadecyltrimethylammonium bromide (CTAB) as a template at the presence of ethanol and sodium hydroxide (NaOH) at pH 10 as a catalyst. The average sizes of the Ag cores at the three increasing volumes of ethanol were ~47 ± 6, 36 ± 4, and 11 ± 5 nm, while the silica particle size and the thickness of the silica shells increased, resulting in a blueshift of localized surface plasmon resonances (LSPR) of the Ag NPs. The corresponding specific surface areas of silica particles were 356 ± 10, 419 ± 20 and 490 ± 25 m² g⁻¹, and average pore diameters varied from 5.7, 5.0 to 3.3 nm according to BET and BJH analyses. TEM studies confirmed the core-shell structure, pore sizes and shapes of mesoporous shells. The dissolution tests demonstrated that the release of Ag from the powder samples is pH-sensitive and time-dependent.

Orthopedic applications commonly require the administration of systemic antibiotics. Gentamicin is one of the most commonly used aminoglycosides in the treatment and prophylaxis of infections associated with orthopedic applications, but gentamicin has a short half-life. However, silica nanoparticles (SiO₂ NPs) can be used as elegant carriers for antibiotics to prolong their release. Our goal is the preparation and characterization of SiO₂-gentamicin nanohybrids for their potential antimicrobial administration in orthopedic applications. In vitro gentamicin release profile from the nanohybrids (gentamicin-conjugated SiO₂ NPs) prepared by the base-catalyzed precipitation exhibited fast release (21.4%) during the first 24 h and further extension with 43.9% release during the five-day experiment. Antimicrobial studies of the SiO₂-gentamicin nanohybrids versus native SiO₂ NPs and free gentamicin were performed against Bacillus subtilis (B. subtilis), Pseudomonas fluorescens (P. fluorescens) and Escherichia coli (E. coli). SiO₂-gentamicin nanohybrids were most effective against B. subtilis. SiO₂ NPs play no antimicrobial role. Parallel antimicrobial studies for the filter-sterilized gentamicin were performed to assess the effect of ultraviolet (UV)-irradiation on gentamicin. In summary, the initial fast gentamicin release fits the need for high concentration of antibiotics after orthopedic surgical interventions. Moreover, the extended release justifies the promising antimicrobial administration of the nanohybrids in bone applications.