Microstructure and mechanical properties of cold sprayed 6061 Al in As-sprayed and heat treated condition

Rokni, Masoud; Widener, Christian; Özdemir, Ozan Ç.; Crawford, Grant A.

doi:10.1016/j.surfcoat.2016.12.035

Cited by 141 publications

(44 citation statements)

References 48 publications

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“…Rokni et al [24] observed similar microstructure in their as-deposited cold-sprayed Al 6061 materials and found the imperfections to influence the mechanical properties. They also performed electron back-scatter diffraction (EBSD) mapping in order to characterize the grain structure, and in doing so, Roki et al [24] identified the presence of two distinct regions, particle interiors and prior particle boundary (PPB) regions. The first was characterized by small grain size, approximately 1-10 μm in size and was attributed to significant plastic deformation that occurs in the feedstock powders.…”

Section: Microstructural Characterizationmentioning

confidence: 89%

“…Upon inspection, interparticle voids and porosity can be observed; lower particle-impact velocity and subsequent lack of local deformation in some particles results in these types of imperfections forming in cold spray deposits [32][33][34]. Rokni et al [24] observed similar microstructure in their as-deposited cold-sprayed Al 6061 materials and found the imperfections to influence the mechanical properties. They also performed electron back-scatter diffraction (EBSD) mapping in order to characterize the grain structure, and in doing so, Roki et al [24] identified the presence of two distinct regions, particle interiors and prior particle boundary (PPB) regions.…”

Section: Microstructural Characterizationmentioning

confidence: 99%

“…Also, because the process requires high levels of plasticity, it is important to have a feedstock material that can undergo high levels of strain with low energy input, but also work-harden sufficiently to obtain Since preliminary tensile data for the cold-sprayed 6061 was close to the wrought values (other than % elongation), it was decided that the SCC performance of the materials would be compared in these respective processing conditions. Furthermore, Rokni et al [24] observed that ultimate tensile strength did not substantially increase with subsequent heat treatment after deposition. They noted that the increase in ultimate tensile strength (UTS) for the solution-treated and peak-aged coldsprayed Al 6061 was relatively small.…”

Section: Introductionmentioning

confidence: 99%

“…Aluminum alloy 6061-T6 (peak-aged) is typically not susceptible to this type of corrosion, but more understanding of this behavior is required, as published research in this area is often contradictory.As high-pressure cold spray (HPCS) continues to gain interest in various applications such as repair, wear and corrosion resistance, there is a necessity to understand the effects of the processing parameters and resulting microstructure and mechanical/corrosion performance of defense-related alloys produced by cold spray. Postdeposition heat treatments are often used in cold-sprayed materials to improve ductility [24][25][26][27]. In precipitation-hardened alloys, such as Al 6061 that is used in various defense applications, it is important to consider the effect the heat treatment may have on corrosion resistance and precipitation strengthening.…”

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Stress Corrosion Cracking Resistance of Cold-Sprayed Al 6061 Deposits Using a Newly Developed Test Fixture

et al. 2019

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The stress corrosion cracking (SCC) response of Al 6061 bulk deposits produced by high-pressure cold spray (HPCS) was investigated and compared to commercial wrought Al 6061-T6 material. Representative tensile coupons were stressed to 25%, 65% and 85% of their respective yield strength and exposed to ASTM B117 salt fog for 90 days. After exposure, the samples were mechanically tested to failure, and subsequently investigated for stress corrosion cracking via optical and scanning electron microscopy with energy-dispersive X-ray spectroscopy (EDS). The results were compared to the wrought Al 6061-T6 properties and correlated with the observed microstructures. Wrought samples showed the initiation of stress corrosion cracking, while the cold-sprayed deposits appeared to be unaffected or affected by general corrosion only. Optical microscopy revealed evidence of stress corrosion cracking in the form of intergranular corrosion in the wrought samples, while no significant corrosion was observed in the cold-sprayed deposits. Fractography revealed wrought samples failed due to multiple mechanisms, with predominant cleavage and intergranular failure, but cold-sprayed samples only failed by ductile dimple rupture. The difference in SCC response between the differently processed materials is attributed to the documented benefits of the cold spray process, which includes maintaining fine grain structure of the feedstock powder and high density after consolidation, low oxidation, and work hardening effect.the strength required. The cold spray process can also produce near-net shapes before machining to final components, making it a possible method for three-dimensional (3D) manufacturing. Unlike thermal spray methods or conventional manufacturing processes, the main advantages of using cold spray is that it can produce coatings and bulk materials with no recrystallization, thus maintaining the structure and size of starting powders. As a low-temperature process, it operates below the melting point of metals and results in very low porosity deposits without the need for combustible gasses. Additional motivation to use this process is the low oxide content, which can improve corrosion resistance, mechanical properties, and wear resistance by eliminating sites for localized corrosion and premature failure.There has been a great deal of research into corrosion mechanisms in metallic materials over the past century [5][6][7][8][9][10][11][12][13][14][15][16][17]. Atmospheric or environmentally assisted corrosion is one of the least understood areas of corrosion. Stress corrosion cracking is a type of atmospheric corrosion that is very difficult to detect and mitigate, since it only occurs in alloys that have been under stress in corrosive environments. Metallic materials used extensively in engineering and defense applications are susceptible to corrosion. Corrosion costs the US billions of dollars per year in preventative maintenance and product loss. There are many different types of corrosion that can attack metallic materials,...

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Section: Microstructural Characterizationmentioning

confidence: 89%

Section: Microstructural Characterizationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

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Stress Corrosion Cracking Resistance of Cold-Sprayed Al 6061 Deposits Using a Newly Developed Test Fixture

et al. 2019

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“…An alternative to improve the performance of these coatings is the use of heat treatment as previously reported 63,66,75,78,81,84,93,96,97 . , stainless steel coatings 60,100 and Inconel 718 101 .…”

Section: Some Relevant Corrosion Studies Of Cold Spray Coatings and Cmentioning

confidence: 99%

Cold gas spray coatings: basic principles corrosion protection and applications

et al. 2017

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ABSTRACT:In this review, the beginnings and evolution of the cold gas spray (CGS) technique are described, followed by the main fundamental aspects of the technique together with a description of the several spraying systems up to date. Sequentially, the main spray parameters and their influence on the properties of the coatings are reported. Afterwards, the most important methodologies for preparing the feedstock powders to be sprayed, the effect of the powder composition, microstructure, particle size and shape on the properties of the coatings are discussed. The nature of the spray gun and nozzle, and the substrate pre-treatments were also discussed. With regard to microstructure and properties, the chemical and physical characterization of the coatings and the performance in protecting the substrates against corrosion together with some mechanical properties are presented and compared. The lacking systematic studies about the great part of investigated systems is the main drawback to compare the published results. Closing this review, the main applications, and the potentialities of the CGS coatings are evidenced.

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Microstructures and Microstructural Evolution in Cold‐Sprayed Materials

Brewer,

Perez‐Andrade

2024

Solid‐State Metal Additive Manufacturing

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Microstructure and mechanical properties of cold sprayed 6061 Al in As-sprayed and heat treated condition

Cited by 141 publications

References 48 publications

Stress Corrosion Cracking Resistance of Cold-Sprayed Al 6061 Deposits Using a Newly Developed Test Fixture

Stress Corrosion Cracking Resistance of Cold-Sprayed Al 6061 Deposits Using a Newly Developed Test Fixture

Cold gas spray coatings: basic principles corrosion protection and applications

Microstructures and Microstructural Evolution in Cold‐Sprayed Materials

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