Laser surface texturing to enhance adhesion bond strength of spray coatings – Cold spraying, wire-arc spraying, and atmospheric plasma spraying

Kromer, Robin; Costil, S.; Verdy, C.; Gojon, Sébastien; Liao, H.

doi:10.1016/j.surfcoat.2017.05.007

Cited by 109 publications

(49 citation statements)

References 27 publications

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“…This new textured TBC system enables a large durability by increasing the mechanical anchoring mechanisms. The patterns seem to change the distributions of crack propagation [41]. Ranjbar-Far et al [42] have developed a numerical modeling with the finite element code ABAQUS considering a non-homogenous temperature model to study the thermo-mechanical behavior of the thermal barrier coatings system.…”

Section: Discussionmentioning

confidence: 99%

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Kromer

Cormier

Costil

et al. 2018

Surface and Coatings Technology

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Thermal barrier coating systems are usually build-up with bond coats to ensure a good adhesion of the ceramic top coat and to protect the substrate against oxidation and corrosion. Such system is often subjected to complex thermo-mechanical loading. Because of the very different damage processes encountered during service operations, a simplified system was investigated by removing the bond-coat. Recently adhesion bond strength was enhanced using laser surface texturing of the substrate in thermal spraying processes. Atmospheric plasma spray yttria-stabilized-zirconia thermal barrier coating system was deposited on the Ni-based AM1 single crystalline superalloy without bond coat. Adhesion bond strength was already increased compared to conventional processing method. Top coat durability was evaluated at high temperature and damage mechanisms were studied. Isothermal and cyclic oxidation tests showed durability of 1000 h and 400 cycles at 1100°C. The oxidation mechanisms at the substrate/top coat interface changed due to fast solidification during the laser texturing process. Then, TBC system was studied under high temperature mechanical solicitation in tension creep. The textured interfaces were not damaged after 1% creep strain while top-coat/substrate interfacial cracking was observed for grit-blasted specimens. Moreover, no preferential crack development in the substrate was observed. Patterns provided an enhanced adhesion by changing the stress distribution near the interface.

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Section: Discussionmentioning

confidence: 99%

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Kromer

Cormier

Costil

et al. 2018

Surface and Coatings Technology

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“…Adhesion of the cold-sprayed coatings can be improved by spray parameter optimization, or with advanced substrate surface pre-treatments, e.g., laser texturing [39] or by using assisting spray processes, e.g., laser-assisted cold spraying [2,3] or by heat treatments as post-treatment [40]. While spraying Al alloy material by using cold spray processing with the pressure of 30 bar and heating of 500 • C, Kromer et al [37] achieved adhesion bond strengths for Al alloy coatings on grit-blasted, and two laser textured Al alloy substrates as 20, 40, and 50 MPa, respectively.…”

Section: Cold-sprayed Al6061 Coatings-mechanical Propertiesmentioning

confidence: 99%

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Koivuluoto

Larjo²,

Marini

et al. 2020

Coatings

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Process optimization and quality control are important issues in cold spraying and coating development. Because the cold spray processing is based on high kinetic energy by high particle velocities, online spray monitoring of particle inflight properties can be used as an assisting process tool. Particle velocities, their positions in the spray jet, and particle size measurements give valuable information about spraying conditions. This, in turn, improves reproducibility and reliability of coating production. This study focuses on cold spraying of Al6061 material and the connections between particle inflight properties and coating characteristics such as structures and mechanical properties. Furthermore, novel 2D velocity scan maps done with the HW CS2 online spray monitoring system are presented as an advantageous powder and spray condition controlling tool. Cold spray processing conditions were similar using different process parameters, confirmed with the online spray monitoring prior to coating production. Higher particle velocities led to higher particle deformation and thus, higher coating quality, denser structures, and improved adhesions. Also, deposition efficiency increased significantly by using higher particle velocities.

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“…Surface roughness of the substrate has a great influence on the adhesion of thermally sprayed coatings and therefore on their lifetime [21][22][23], corrosion resistance of many materials [16,24], in diffusion bonding [25] and tribological behavior of the surfaces [22,26]. Accuracy in evaluation of surface roughness and its topography is of great importance in those applications.…”

Section: Surface Roughness Evaluationmentioning

confidence: 99%

“Mechanically prepared copper surface in oxidizing and non-oxidizing conditions”

Serafin

Nowak

Wierzba

2019

Applied Surface Science

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In the present work surface roughness of copper samples after mechanical surface preparation processes (polishing, grinding, sand-blasting) and after exposure in non-oxidizing (high purity argon) and oxidizing (air) conditions at 700 and 750°C have been evaluated by contact profilometer and by fractal analysis. Quantitative description of surfaces that are hidden from the sight of conventional methods is possible by fractal analysis, e.g. in the present work, the roughness of Cu 2 O/Cu boundary has been evaluated under oxide layer. It has been pointed out, that in both oxidizing and non-oxidizing conditions initial surface roughness of copper is affected by annealing at high temperature: at 700°C surface roughness of polished and ground samples increased but at 750°C decreased in comparison to surface roughness prior to heat treatment. For sand-blasted samples in both oxidizing and non-oxidizing conditions the lowest values of surface roughness parameters were obtained at 750°C. It is then concluded that two phenomena are responsible for such effect: chemical reaction between copper and oxygen and surface diffusion of copper due to high temperature of annealing.

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Laser surface texturing to enhance adhesion bond strength of spray coatings – Cold spraying, wire-arc spraying, and atmospheric plasma spraying

Cited by 109 publications

References 27 publications

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

High temperature durability of a bond-coatless plasma-sprayed thermal barrier coating system with laser textured Ni-based single crystal substrate

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

“Mechanically prepared copper surface in oxidizing and non-oxidizing conditions”

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