Bonding mechanism from the impact of thermally sprayed solid particles

Power particles are mainly in solid state prior to impact on substrates from high velocity oxy-fuel (HVOF) thermal spraying. The bonding between particles and substrates is critical to ensure the quality of coating. Finite element analysis (FEA) models are developed to simulate the impingement process of solid particle impact on substrates. This numerical study examines the bonding mechanism between particles and substrates and establishes the critical particle impact parameters for bonding. Considering the morphology of particles, the shear-instability–based method is applied to all the particles, and the energy-based method is employed only for spherical particles. The particles are given the properties of widely used WC-Co powder for HVOF thermally sprayed coatings. The numerical results confirm that in the HVOF process, the kinetic energy of the particle prior to impact plays the most dominant role in particle stress localization and melting of the interfacial contact region. The critical impact parameters, such as particle velocity and temperature, are shown to be affected by the shape of particles, while higher impact velocity is required for highly nonspherical powder

Microstructural Studies of Cold Sprayed Copper, Nickel, and Nickel-30% Copper Coatings

Cold spraying enables to produce metallic coatings with low porosity level and low oxygen content. Several material properties such as electrical conductivity and corrosion resistance rely on these properties. Aim of this study was to characterize microstructural properties of cold sprayed copper, nickel, and nickel-30%copper coatings. Microstructures, denseness, and deformation of particles were investigated. SEM analysis and corrosion tests were done to get information of through-porosity. Open porosity has an important role on protectiveness of anodically protective coatings, such coating materials like copper and nickel. In this study, cold-sprayed Cu coating was fully dense. However, cold-sprayed Ni and Ni-30%Cu coatings seemed to be microstructurally dense but some porosity in some areas of the coatings especially in some parts of particle boundaries was noticed after corrosion tests. Furthermore, effect of annealing to microstructure and corrosion test behavior was studied. Cold sprayed Ni coating became denser during heat treatment.</p

Laser shock flier impact simulation of particle-substrate interactions in cold spray

International audienceCoating-substrate adhesion in cold spray is a paramount property, the mechanisms of which are not yet well elucidated. To go into these mechanisms, due to the intrinsic characteristics of the cold spray process (particle low-temperature and high velocity) direct observation and control of inflight particles and related phenomena cannot be done easily. For this reason, an experimental simulation of the particle-substrate reactions at the particle impingement was developed. This simulation is based on original flier impact experiments from laser shock acceleration. Relevant interaction phenomena were featured and studied as a function of shearing, plastic deformation, phase transformation primarily. These phenomena were shown to be similar to those involved in cold spray. This was ascertained by the study of the Cu-Al metallurgically reactive system using SEM, TEM, EPMA, and energy balance and diffusion calculations. This simulation could also be used to feed finite element modeling of cold spray and laser shock flier impact

Effect of ball milling of feedstock powder on microstructure and properties of TiN particle-reinforced Al alloy-based composites fabricated by cold spraying

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