Prediction of heterogeneous microstructural evolution in cold sprayed copper coatings using local Zener-Hollomon parameter and strain

Liu, Zhiying; Wang, Hongze; Haché, Michel J.R.; Chu, Xin; Irissou, Éric; Zou, Yu

doi:10.1016/j.actamat.2020.04.041

Cited by 49 publications

(18 citation statements)

References 46 publications

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“…(b) The strong plastic deformation of the particles of the cold spray coating can increase the dislocation density [32][33][34], resulting in the dislocation of strengthening effect. (c) The deposition of particles during cold spraying causes a high residual compressive stress inside the coating [35,36].…”

Section: Wear Performancementioning

confidence: 99%

Microstructure and Properties of Cold Sprayed NiCrAl Coating on AZ91D Magnesium Alloy

Zhao

Dong

et al. 2021

Coatings

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Herein, a NiCrAl coating was prepared on the AZ91D magnesium alloy by cold spraying technology. The microstructure, wear resistance, and corrosion resistance of the cold sprayed NiCrAl coating were studied and compared with two NiCrAl coatings prepared by plasma spraying. The results showed that the porosity of the two-plasma sprayed NiCrAl coatings was 3.21% and 2.66%, respectively, while that of the cold sprayed NiCrAl coating was only 0.68%. The hardness of the cold sprayed NiCrAl coating (650 HV0.1) was higher than those of the two-plasma sprayed NiCrAl coatings (300 HV0.1, 400 HV0.1). In the abrasion resistance test, the cold sprayed NiCrAl coating showed a lower friction coefficient (0.346), less wear volume (3.026 mm3), and superior wear resistance accordingly compared with the two-plasma sprayed NiCrAl coatings. Moreover, the scanning electron microscopy (SEM) morphology at the bottom of the wear trace of the cold sprayed NiCrAl coating showed a compact mechanically mixed layers (MML) structure, and its wear mechanism was mainly abrasive wear, with some fatigue wear. In the electrochemical test, the corrosion current density of the cold sprayed NiCrAl coating (4.404 × 10−2 A·cm−2) was much lower than those of two plasma sprayed coatings (25.96 A·cm−2, 26.98 A·cm−2), indicating that the cold sprayed NiCrAl coating had superior corrosion resistance. Therefore, preparing a cold sprayed NiCrAl coating is a feasible method to comprehensively improve the wear resistance and corrosion resistance of the AZ91D magnesium alloy.

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Section: Wear Performancementioning

confidence: 99%

Microstructure and Properties of Cold Sprayed NiCrAl Coating on AZ91D Magnesium Alloy

Zhao

Dong

et al. 2021

Coatings

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“…Recently, the author and his co-workers deposited copper coatings over a large range of processing conditions and systematically investigated the microstructural evolution of as-sprayed copper using SEM, EBSD, and TEM. 24 Distinct microstructural features, such as recrystallized grains, shear bands, deformation twinning, and nanosized grains, are observed in the samples prepared at various processing temperatures (Figures 5 and 6). Figure 5 shows the EBSD maps of a copper sample prepared at 473 K. Figure 5a and b reveal a non-uniform grain size distribution: (i) Deformed regions (the dark areas) have a low image quality (IQ) value, indicating a high level of strain and defect density.…”

Section: Cold-sprayed Coppermentioning

confidence: 99%

“…Based on the experimental and FEA results, they created the first deformation mechanism map for cold-sprayed coatings to interpret and predict heterogeneous microstructural evolutions in copper using the local Zener− Hollomon (Z) parameter and plastic strain (strain-Z-microstructure map). 24 Due to the large gradient in deformation conditions from the edge to the center of powder particles, the Cu powder particles experience a large range of strain and Z values (∼1 < ε < ∼15 and ∼20 < LnZ < ∼40). Such strain and Z gradients in local deformation lead to the formation of heterogeneous microstructures in the cold-sprayed copper.…”

Section: Cold-sprayed Coppermentioning

confidence: 99%

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

Zou

2021

Acc. Mater. Res.

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Conspectus Most metal additive manufacturing (AM) methods involve the melting or sintering of feedstock powder or wire using an energy source (laser, electron beam, or electric arc). Solid-state AM, sometimes also known as non-beam-based AM, is a process in which the deposited material does not melt and is built up layer-by-layer, typically through severe plastic deformation. Initially considered to be a coating technique, by virtue of its high deposition rate, cold spray additive manufacturing (CSAM) is attractive as a solid-state AM technology. In the CSAM process, metal powder particles are impacted onto a substrate at a supersonic velocity and relatively low temperature. The CSAM process reduces or eliminates many problems associated with melting or beam-based AM methods, making the CSAM technically attractive for a wide range of applications, such as in the aerospace, automobile, marine, biomedical, machinery, and energy sectors. In this Account, the author briefly reviews the setup of a cold spray system and discusses the strengths and drawbacks of CSAM compared with thermal sprays and beam-based AM processes, as well as applications in relevant industries. The author summarizes the bonding mechanisms proposed for the cold spray process. The focus of this Account is to review the microstructure evolution of several typical model metals (copper, nickel, aluminum, and titanium) during the cold spray process. The author shows a large variety of microstructure characteristics (recrystallized grains, annealing twins, shear bands, submicron-sized grains, deformation twins, and nanometer-sized grains) in cold-sprayed copper, dynamic recrystallization of cold-sprayed nickel, and the formation of refined grains even below 10 nm in size in cold-sprayed aluminum. The magnitude of the stacking fault energy of as-sprayed materials considerably influences the microstructure after cold spray and postprocessing. Due to the relatively low thermal conductivity and ductility of titanium, cold spraying of titanium shows both a high deposition efficiency and relatively high porosity of as-sprayed parts, as well as a heterogeneous microstructure. Moreover, the Account introduces the postprocessing heat treatment and nanoindentation characterization of cold-sprayed materials. A fundamental understanding of microstructure evolution during and after the cold spray process is essential for optimal mechanical properties. Lastly, the author provides a perspective on applying old lessons and taking advantage of new techniques and materials, including powder characterization, hybrid additive manufacturing, machine learning for searching process windows, nanomechanical testing, and emerging alloys (high-entropy alloys, nanocrystalline alloys, and quasicrystals), to advance the research and applications of CSAM.

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“…Comparison of the Cu microstructures by solid-state additive manufacturing. Cold spray: microstructure of (a) powder before spray and (b) spray deposition . AFSD: microstructure of (c) stock rod and (d) as-deposited material .…”

Section: Feasible Solid-state Metal Additive Manufacturing Processes ...mentioning

confidence: 99%

Section: Feasible Solid-state Metal Additive Manufacturing Processes ...mentioning

confidence: 99%

Solid-State Metal Additive Manufacturing for Structural Repair

et al. 2021

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Metrics & MoreArticle Recommendations CONSPECTUS: Structural metal components play a vital role in a broad range of industries, from aerospace and automotive to infrastructure and defense. In service, these components can experience substantial wear, thermal fatigue, erosion, corrosion, or chemical reactions, resulting in significant surface or even volumetric damages. Replacement of these components is often energy-intensive and economically impractical. Structural repair, which aims to restore the original geometry while enabling good mechanical performance postrepair, can offset the costs dramatically. Depending on the additive capabilities and bonding mechanisms, structural repair technologies can be divided into four categories: nonadditive, nonmelting-based; nonadditive, melting-based; additive, nonmelting-based; additive, melting-based. Although melting-based approaches can be applied to various repair geometries with good precision, the underlying melting and solidification processes inevitably lead to crucial problems impacting the mechanical performance, such as solidification porosity, high residual stresses, dendritic microstructure formation, elemental segregation, hot cracking, and stress corrosion cracking. To fundamentally solve or minimize these problems, one may employ solid-state technologies that leverage ultrasonic vibration, friction stirring, or particle impact to facilitate metallurgical bond formation. For robust geometry restoration, an additive capability needs to be incorporated for continuous material feeding and precise deposition path control. Currently, two solid-state technologies satisfy the requirement, cold spray and additive friction stir deposition.In this Account, we discuss the structural repair enabled by solid-state metal additive manufacturing, focusing on (i) cold spray, which is a relatively established process, and (ii) additive friction stir deposition, which is an emerging process recently triggering significant research effortsthe authors are particularly invested in this process and are pioneering the research on process fundamentals and structural repair applications. In cold spray, a substrate is bombarded with small metal particles at high speed; upon impact, the particles and substrate co-deform, resulting in interfacial bonding and mechanical interlocking. In additive friction stir deposition, frictional heat is created after the rapidly rotating feed-rod contacts the substrate, followed by co-plastic deformation and mixing between the deposited material and substrate surface. This renders a strong interface with complex 3D features. Both cold spray and additive friction stir deposition can be applied to a wide range of repair geometries while preventing hot cracking and high thermal exposure. Although cold spray has better portability and spatial resolution than additive friction stir deposition, we believe that additive friction stir deposition is the top choice for repairing load-bearing components given its unparalleled capabilities of rendering equiaxed...

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Prediction of heterogeneous microstructural evolution in cold sprayed copper coatings using local Zener-Hollomon parameter and strain

Cited by 49 publications

References 46 publications

Microstructure and Properties of Cold Sprayed NiCrAl Coating on AZ91D Magnesium Alloy

Microstructure and Properties of Cold Sprayed NiCrAl Coating on AZ91D Magnesium Alloy

Cold Spray Additive Manufacturing: Microstructure Evolution and Bonding Features

Solid-State Metal Additive Manufacturing for Structural Repair

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