Laser-Assisted Cold-Sprayed Corrosion- and Wear-Resistant Coatings: A Review

Abstract

Laser-assisted cold spray (LACS) process will be increasingly employed for depositing coatings because of its unique advantages: solid-state deposition of dense, homogeneous, and pore-free coatings onto a range of substrates; and high build rate at reduced operating costs without the use of expensive heating and process inert gases. Depositing coatings with excellent performance indicators via LACS demands an accurate knowledge and control of processing and materialsÕ variables. By varying the LACS process parameters and their interactions, the functional properties of coatings can be manipulated. Moreover, thermal effect due to laser irradiation and microstructural evolution complicate the interpretation of LACS mechanical deformation mechanism which is essential for elucidating its physical phenomena. In order to provide a basis for follow-on-research that leads to the development of high-productivity LACS processing of coatings, this review focuses on the latest developments in depositing corrosion-and wearresistant coatings with the emphasis on the composition, structure, and mechanical and functional properties. Historical developments and fundamentals of LACS are addressed in an attempt to describe the physics behind the process. Typical technological applications of LACS coatings are also identified. The investigations of all process sequences, from laser irradiation of the powder-laden gas stream and the substrate, to the impingement of thermally softened particles on the deposition site, and subsequent further processes, are described. Existing gaps in the literature relating to LACS-dependent microstructural evolution, mechanical deformation mechanisms, correlation between functional properties and process parameters, processing challenges, and industrial applications have been identified in order to provide insights for further investigations and innovation in LACS deposition of wear-and corrosionresistant coatings.

Microstructure and tribological performance of tungsten carbide reinforced stainless steel composite coatings by supersonic laser deposition

“…A variety of materials, such as copper, titanium, Al-Cu alloy, Al-Si alloy, Stellite 6 and so on [11][12][13], have been processed with SLD.…”

Research progress of supersonic laser deposition technology

“…This reduction in capital and operating costs means that SLD may be viable in many applications, for which CS has proved too costly allowing the fully solid process route found in CS to find a use in a wider range of applications. A variety of material coatings such as Cu, Ti, Stellite 6, Ni60, Al-Cu and Al-Si alloys, have been successfully prepared with SLD technique [4][5][6][7][8][9][10][11][12][13][14][15][16].…”

Anticorrosion Properties of Zn–Al Composite Coating Prepared by Cold Spraying

“…Therefore, it is of great significance to effectively protect metal materials in the marine environment. The research on marine metal materials has also received extensive attention from scholars [1][2][3][4][5].…”

“…as an accelerated gas stream to drive powder particles (size of 1-50 µm) to collide with the substrate at a low temperature (room temperature to 600 • C) and a supersonic speed (300-1200 m/s) to complete solid state, so that the particles will undergo a strong plastic deformation and deposit to form a coating [10][11][12][13][14][15][16]. Compared with the traditional painting, thermal spraying and other processes of offshore equipment, the low-temperature characteristics of cold spraying has the following advantages: (1) The cold working environment has a low temperature, and it results in a fast deposition coating speed, so there is a wide range of substrate can be applied. It is portable to the entire surface of offshore equipment and is also suitable for the surface of equipment of various bases.…”