Effect of process parameters on the properties of Stellite-6 coatings deposited by Cold Gas Dynamic Spray

Magarò, Pietro; Marino, A.; Schino, Andrea Di; Furgiuele, Franco; Maletta, Carmine; Pileggi, R.; Sgambitterra, Emanuele; Testani, Claudio; Tuluí, M.

doi:10.1016/j.surfcoat.2019.124934

Cited by 17 publications

(10 citation statements)

References 32 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Like other manufacturing processes, cold spraying is also a multi-parameter and multi-response process. Therefore, the process or operation parameters involved in a cold spray process, including, but not limited to, gas pressure, temperature, stand off distance, feed rate, powder morphology, substrate roughness, and substrate temperature can all have an effect on various characteristics of the coating [25][26][27][28][29][30][31][32][33]. Since cold spray coatings are often used for geometric and functional repairs, achieving desired characteristics, including coating thickness, hardness, density, and porosity is important.…”

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

Towards optimization of thickness, hardness, and porosity of low-pressure cold sprayed WC-Ni coatings

Jibran

Hogan

McDonald

2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In this study, a 3 3 full factorial design methodology was used to analyze the effects of spray parameters on the thickness, hardness, and surface porosity of low-pressure cold-sprayed WC-17Ni coatings. Three levels were selected for the spray parameters included in the design which were the powder feed rate (17.1 g/min, 21.1 g/min, and 23.7 g/min), gas temperature (475℃, 500℃, and 525℃), and the nozzle to substrate stand-off distance (3 mm, 5 mm, and 10 mm). It was found that the feed rate was the most signi cant parameter that affected the coating thickness. The surface porosity was most signi cantly affected by stand-off distance. The coating hardness was most in uenced by the interaction between the feed rate and stand-off distance. An optimization study was then performed to maximize the coating thickness and hardness while minimizing the surface porosity. The optimal spray parameters (OSP) were found to be at a feed rate of 23.7 g/min, 500℃ for the carrier gas temperature, and 10 mm for the standoff distance. The OSP yielded a coating that was 1.22 ± 0.06 mm thick, with a hardness of 364.5 ± 8.5 HV and porosity of 6.8 ± 0.6%. With a multi-parameter process, the system response is affected by both the variation in the individual parameters and the interaction of the parameters with each other. It was also concluded that the interaction between the parameters signi cantly affected the coating hardness. These results suggest that variation of the selected parameters produce statistically signi cant effects on the coating quality of WC-17Ni coatings using a low-pressure cold spray system.

show abstract

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

Towards optimization of thickness, hardness, and porosity of low-pressure cold sprayed WC-Ni coatings

Jibran

Hogan

McDonald

2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

“…Some researchers have explored optimization methods for various thermal spraying processes [34][35][36][37] such as plasma spraying and HVOF spraying. Since optimization is a crucial part of any production process, optimization methods are widely studied and they typically employ experimental methods [32], numerical analyses [25-27, 33, 35-38], or use arti cial intelligence approaches [39]. In one study, Sarikaya [37] conducted an experimental optimization study for HVOF sprayed alumina coatings to analyze the effect of stand-off distance, substrate temperature, and surface roughness on the coating hardness, thickness, and porosity.…”

Section: Optimization Methods For MMC Coatingsmentioning

confidence: 99%

Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Jibran

Hogan

McDonald

2021

Preprint

View full text Add to dashboard Cite

In this study, a 33 full factorial design methodology was used to analyze the effects of spray parameters on the thickness, hardness, and surface porosity of low-pressure cold-sprayed WC-17Ni coatings. Three levels were selected for the spray parameters included in the design which were the powder feed rate (17.1 g/min, 21.1 g/min, and 23.7 g/min), gas temperature (475℃, 500℃, and 525℃), and the nozzle to substrate stand-off distance (3 mm, 5 mm, and 10 mm). It was found that the feed rate was the most significant parameter that affected the coating thickness. The surface porosity was most significantly affected by stand-off distance. The coating hardness was most influenced by the interaction between the feed rate and stand-off distance. An optimization study was then performed to maximize the coating thickness and hardness while minimizing the surface porosity. The optimal spray parameters (OSP) were found to be at a feed rate of 23.7 g/min, 500℃ for the carrier gas temperature, and 10 mm for the stand-off distance. The OSP yielded a coating that was 1.22 ± 0.06 mm thick, with a hardness of 364.5 ± 8.5 HV and porosity of 6.8 ± 0.6%. With a multi-parameter process, the system response is affected by both the variation in the individual parameters and the interaction of the parameters with each other. It was also concluded that the interaction between the parameters significantly affected the coating hardness. These results suggest that variation of the selected parameters produce statistically significant effects on the coating quality of WC-17Ni coatings using a low-pressure cold spray system.

show abstract

“…For true residual stress σ reztrue (MPa) and for engineering residual stress σ rezeng (MPa) the following Equations (19) and (20) apply:…”

Section: Derivation Of the Equations For Cutting Parameters Predictionmentioning

confidence: 99%

“…This is a discrete expression of important technological functions. These functions are in the basic concept of the requirement set on: R mp , R mptr , Ra substrate, D gr coating, normal machining true stress σ rz , normal machining engineering stress σ rzx , residual machining true stress σ rez (19), residual machining engineering stress σ rezx (20), equivalent depth h ekv = f (a p ). In Table 6, based on relationship (52), the adhesion values are determined for each experiment performed.…”

Section: Adhesion a Dhmp Of The Coating Materials On The Substratementioning

confidence: 99%

Prediction of Cutting Parameters of HVOF-Sprayed Stellite 6

et al. 2020

View full text Add to dashboard Cite

In this research, the authors set out to propose a new method of predicting and adjusting the main cutting parameters of chip machining, namely spraying on the substrate. In the experiments, a total of 28 turning cuts on a Stellite 6 coating layer were realized. The base materials of the Stellite 6 layers were EN S235JRG1 and carbide WC-Co. This work aimed to find out and optimize the influence of different combinations of cutting parameters. Due to the coating solution, the work is focused on the evaluation of the roughness Ra (μm) of the turned substrate, the grain size Dgr (μm) of the spraying, the normal stress σrz (MPa), the residual stress σrez (MPa), the specific cutting force Fc (N), the quality of adhesion to the substrate Adhmp (MPa) and other parameters. For the sake of a comprehensive solution to the problem, several new predictive equations and subsequent suggestions for solutions have been derived from this research topic based on the newly obtained experimental results. The proposed models and procedures make it possible to get new results and insights into coating technologies.

show abstract

Effect of process parameters on the properties of Stellite-6 coatings deposited by Cold Gas Dynamic Spray

Cited by 17 publications

References 32 publications

Towards optimization of thickness, hardness, and porosity of low-pressure cold sprayed WC-Ni coatings

Towards optimization of thickness, hardness, and porosity of low-pressure cold sprayed WC-Ni coatings

Influence of Spray Parameters on the Thickness, Hardness and Porosity of low-pressure Cold Sprayed WC-Ni Coatings

Prediction of Cutting Parameters of HVOF-Sprayed Stellite 6

Contact Info

Product

Resources

About