Cold Spray Aluminum–Alumina Cermet Coatings: Effect of Alumina Content

Fernández, Ramón Fernández-Guerra; Jodoin, B.

doi:10.1007/s11666-018-0702-6

Cited by 73 publications

(28 citation statements)

References 60 publications

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“…However, unfavourable properties, such as low strength of matrix or poor bonding between metal and reinforced ceramic particles, might result in excessive pullout from the matrix during wear and subsequently lead to high wear rates due to three-body abrasion [21]. The tribological properties of MMCs are mainly influenced by cohesion between particles (metal-metal and metalceramic), ceramic content, ceramic particle size, morphology, and their distribution in the matrix [2,[21][22][23][24][25][26]. During sliding wear of MMCs, plastic deformation of the metallic matrix and dislodging of the reinforced particles, their fragmentation result in the formation of wear debris.…”

Section: Introductionmentioning

confidence: 99%

The role of metal powder properties on the tribology of cold sprayed Ti6Al4V-TiC metal matrix composites

Munagala

Chromik

2021

Surface and Coatings Technology

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Ti6Al4V-TiC metal matrix composite (MMC) coatings were cold sprayed using spherical and irregular Ti6Al4V powders manufactured with plasma gas atomization and the Armstrong process, respectively. Composite coatings deposited using irregular powders showed higher ceramic retentions and lower porosity compared to spherical powders coatings. Sliding wear tests were performed at two different normal loads using a spherical WC-Co ball as counterface. Wear test results showed that at similar ceramic contents, spherical powder (SP) composites exhibited abrasive wear mechanisms with high coefficients of friction (CoF) and wear rates. In irregular powder (IP) composites, islands of tribolayers, comprised of fragmented TiC and TiO2 particles, resisted the localized shear deformation leading to low wear, and with free carbon from the TiC particles also lowered the CoF. Increase in ceramic content in the IP MMCs to 23% led to higher coverage of wear track area with tribolayers and further lowered the wear rate. At higher load, 23% TiC composite coatings showed a more continuous tribolayer, whereas lower ceramic content MMCs showed no significant formation of tribolayers. The formation of a highly continuous tribolayer at higher load (in 23% TiC MMC), led to extremely low CoF (~ 0.25) compared to other coatings along with low wear rate. Electron channel contrast imaging and transmission electron microscopy analysis of the worn subsurface under the tribolayers showed coarse-grain microstructures compared to the bare regions of the wear track (i.e. without tribolayer coverage).The formation of coarser grain microstructures indicated less stress transfer to the subsurface both due to the high hardness and lubricating nature of the tribolayers.

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Section: Introductionmentioning

confidence: 99%

The role of metal powder properties on the tribology of cold sprayed Ti6Al4V-TiC metal matrix composites

Munagala

Chromik

2021

Surface and Coatings Technology

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“…This effect has been used to establish an in-situ shot peening cold spray deposition process, that improves deposition and coating properties through the addition of large stainless-steel particles (200-300 µm) [29][30][31]. Recently, Fernandez and Jodoin [32,33] advanced potential mechanisms explaining the coating deposition improvement (surface roughening by the secondary component (SC) through generation of asperities and oxide removal), as well as the coating property improvement (generation of oxide clean surfaces and peening of the SC). Che et al [34] made similar observations related to coating deposition improvement when mixing metallic powders (zinc or copper) with tin powders, and this improvement was associated with the shot-peening effect of the SC on the relatively softer tin.…”

Section: Introductionmentioning

confidence: 99%

“…Nevertheless, in a more recent study, evidence appeared that the shot-peening effect may not be at cause: when comparing the deposition efficiency of pure tin to tin powders mixed with aluminum or aluminum alloy powders on a steel substrate (ideal deposition scenario of a soft metal on a relatively harder metal), no notable improvements are brought by the use of the aluminum/aluminum alloy SCs [35]. Height profiles of the coatings were acquired, and the addition of the SC does not noticeably modify the roughness of the surface, which would imply that the surface roughening mechanism suggested by Fernandez and Jodoin [32,33] would not apply during the buildup phase, and so the observed improvement of the DE of tin on the CFRP would not occur in the build-up phase, but necessarily during the first-layer deposition phase [35]. The study suggested that an ideal SC hardness was one of the main causes for deposition improvement, and that this improvement would be most noticeable when the SC hardness was close to the hardness of the substrate: the nature of the improvement would then originate from the potential of the SC to generate cracks that the impinging tin could fill [35], and so the quicker the substrate surface would be activated, the quicker the build-up phase could begin.…”

Section: Introductionmentioning

confidence: 99%

Effect of Secondary Component Properties when Cold Spraying Mixed Metal Powders on Carbon Fiber Reinforced Polymers

Liberati

Che

Yue

et al. 2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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In previous studies at McGill University; tin was successfully cold sprayed onto carbon fiber reinforced polymers (CFRPs). A “crack-filling” mechanism was described as the deposition mechanism that allowed deposition of tin onto the CFRP. Improving the coating conductivity for lightning strike protection (LSP) purposes was achieved by adding other metal powders (aluminum; copper; zinc) to tin and cold spraying on the CFRP. At the same time; it was noticed that the addition of this secondary component (SC) provided an increase in deposition efficiency (DE); tamping was initially hypothesized to explain this improvement; thus prompting a study solely on the effect of SC hardness; which is reported elsewhere in this conference. However; it is recognised that other powder characteristics may also be influencing the DE. Thus; in this study; SCs with a wider variety of particle sizes; morphologies; densities and hardness values were mixed with tin and sprayed on CFRPs. The effect of SC properties on tin deposition is discussed and an optimal combination of SC properties for cold spraying of tin is suggested.

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“…Among these reinforcing particles, Al2O3 has been frequently used due to a better corrosion resistance and chemical stability [14]. Recently, the application of Al-Al2O3 composites fabricated by the cold-spray additive manufacturing process used as protective coatings against wear, erosion, corrosion, and high temperature degradation in aerospace and other industrial sectors have been studied in the literature [15,16]. Among many deposition routes for producing coatings made of pure Al, cold spray stands out due to minimal heat loading of the substrate during the deposition process [17].…”

Section: Introductionmentioning

confidence: 99%

3D Microstructure-Based FE Simulation of Cold-Sprayed Al-Al2O3 Composite Coatings under Indentation and Quasi-Static Compression

Sayahlatifi

Shao

McDonald

et al. 2021

Thermal Spray 2021: Proceedings From the International Thermal Spray Conference

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This study developed microstructure-based finite element (FE) models to investigate the behavior of cold-sprayed aluminum-alumina (Al-Al2O3) metal matrix composite (MMCs) coatings subject to indentation and quasi-static compression. Based on microstructural features (i.e., particle weight fraction, particle size, and porosity) of the MMC coatings, representative volume elements (RVEs) were generated by using Digimat software and then imported into ABAQUS/Explicit. State-of-the-art physics-based modelling approaches were incorporated into the model to account for particle cracking, interface debonding, and ductile failure of the matrix. This allowed for analysis and informing on the deformation and failure responses. The model was validated with experimental results for cold-sprayed Al-18 wt.% Al2O3, Al-34 wt.% Al2O3, and Al-46 wt.% Al2O3 metal matrix composite coatings under quasi-static compression by comparing the stress versus strain histories and observed failure mechanisms (e.g., matrix ductile failure). The results showed that the computational framework is able to capture the response of this cold-sprayed material system under compression and indentation, both qualitatively and quantitatively. The outcomes of this work have implications for extending the model to materials design and under different types of loading (e.g., erosion and fatigue).

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Cold Spray Aluminum–Alumina Cermet Coatings: Effect of Alumina Content

Cited by 73 publications

References 60 publications

The role of metal powder properties on the tribology of cold sprayed Ti6Al4V-TiC metal matrix composites

The role of metal powder properties on the tribology of cold sprayed Ti6Al4V-TiC metal matrix composites

Effect of Secondary Component Properties when Cold Spraying Mixed Metal Powders on Carbon Fiber Reinforced Polymers

3D Microstructure-Based FE Simulation of Cold-Sprayed Al-Al2O3 Composite Coatings under Indentation and Quasi-Static Compression

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