Recent Developments in Cladding and Coating Using Cold Metal Transfer Technology

Das, Bappa; Panda, Biranchi N.; Sharma, Faladrum; Dixit, Uday S.

doi:10.1007/s11665-023-08940-z

J. of Materi Eng and Perform

2023

DOI: 10.1007/s11665-023-08940-z

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Recent Developments in Cladding and Coating Using Cold Metal Transfer Technology

Bappa Das,

Biranchi N. Panda,

Faladrum Sharma

et al.

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2024

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Cited by 3 publications

References 95 publications

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Influence of CMT welding parameters on microstructural and properties investigation of dissimilar weld joint for aluminum bronze and carbon steel

Tamilkolundhu,

Josephraj

et al. 2024

Materials Science and Technology

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Cold Metal Transfer (CMT) welding technology has improved the appearance of weld beads and revolutionized the welding of thicker materials and dissimilar metals with precise metal deposition and reduced heat input. Cold Metal Transfer welding is predominantly used in a variety of industry applications, including aerospace, shipbuilding, automotive and marine industries. In this study, aluminum bronzes and carbon steel were joined by using CMT welding, a variant of the Gas Metal Arc Welding process, with ERCuAl-A2 as the filler metal. Optical microscopy was used to examine the microstructure of the CMT weld joint between aluminum bronze and carbon steel. Results have indicated that dissimilar metals such as aluminum bronze, and carbon steel could be successfully joined by CMT under various processing parameters. The tensile and bending strengths of the dissimilar joint were 490 MPa and 822 MPa, respectively. A variety of intermetallic compounds and solid solutions were generated in the weld zone and fusion zone. The micro-hardness in the carbon steel side of the fusion zones increased sharply, which was 164 HV in the welded condition. The dissimilar joint was stronger than the carbon steel, as the ductile fracture occurred on the carbon steel during the transverse tensile test of the welded specimen. The microstructure interpretation of welded dissimilar joints was analyzed by scanning electron microscopy and transmission electron microscopy.

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Influence of CMT welding parameters on microstructural and properties investigation of dissimilar weld joint for aluminum bronze and carbon steel

Tamilkolundhu,

Josephraj

et al. 2024

Materials Science and Technology

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Tailoring mechanical, microstructural and toughening characteristics of plasma-sprayed graphene-reinforced samarium niobate coatings for extreme environments

Kumar,

Pandey

2024

Proceedings of the Institution of Mechanical Engineers, Part E:

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Thermal barrier coatings (TBCs) are advanced ceramic layers applied to metal components to provide insulation and protection against high temperatures in extreme operating environments. This study investigated the effects of graphene nanoplatelet (GNP) reinforcement on samarium niobate (SN: SmNbO4) TBCs for extreme environments. Four ceramic top coat compositions were plasma-sprayed onto Inconel 718 substrates: Yttria-stabilized zirconia (YSZ), SmNbO4 (SN), and SN reinforced with 1 and 1.5 wt% GNPs (SN-1GNP, SN-1.5GNP). The research examined microstructural characteristics, phase evolution, mechanical properties and toughening mechanisms. GNP reinforcement significantly improved coating density, with SN-1.5GNP reaching 97.4 ± 1.64% compared to 91.3 ± 1.69% for SN and 86.6 ± 1.47% for YSZ. Hardness and elastic modulus were enhanced by 86.38% and 57.91% for SN-1GNP, and 101.09% and 65.23% for SN-1.5GNP respectively. Moreover, fracture toughness experienced a significant increase from 1.86 ± 0.4 to 5.48 ± 0.7 MPa·m1/2, facilitated by toughening mechanisms, like splat bridging, GNP pull-out, crack arrest and ferroelastic domain switching. Additionally, the SN-1.5GNP coating exhibited a higher adhesion strength of 36.84 MPa, thereby leading to improved layer distribution and lesser chance of delamination. Compared to YSZ, these findings suggest that GNP-reinforced SN coatings offer enhanced performance for extreme environment applications.

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Interfacial Behavior of Copper/Steel Bimetallic Composites Fabricated by CMT-WAMM

Liu,

Li,

Zhang

et al. 2024

Coatings

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Copper/steel bimetallic composites were made by using cold metal transfer wire and arc additive manufacturing (CMT-WAAM) with 1.2 mm diameter ER120S-G high-strength steel and 1.2 mm diameter ERCuSi-A silicon bronze welding wires. Based on the optimal tensile strength, the optimal CMT additive parameters of the copper layer were determined by the single-factor method under the conditions of the fixed steel layer process parameters of a 100 A welding current and 550 mm/min welding speed. The interfacial behavior of copper/steel bimetallic composites with the optimum parameters was investigated in particular. The results show that the optimum CMT additive process parameters for depositing a copper layer on a steel layer are a welding current of 100 A and a welding speed of 500 mm/min. The steel side consists mainly of martensite and ferrite, and the copper side consists of α-Cu matrix, Cu3Si, and Cu15Si4 reinforcing phases. The composite interfacial region is mainly composed of the FeSi2 reinforcing phase. At the optimum parameters, the ultimate tensile strength of the composites can reach 404 MPa with a ductile fracture on the copper side. Under the optimum parameters, the microhardness of the composites declines gradually from the steel side to the copper side, and the microhardness at the interface is higher than that at copper side, reaching 190 HV. In addition, the corrosion current density of the copper-side metal is 2.035 × 10−6 A·cm−2, and the corrosion current density of the steel-side metal is 7.304 × 10−6 A·cm−2. The corrosion resistance of the copper-side metal is higher than that of the steel-side metal. The CMT-WAAM process can produce copper/steel bimetallic composites with excellent comprehensive performance. The advantage of material integration makes it a broad application prospect.

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Recent Developments in Cladding and Coating Using Cold Metal Transfer Technology

Cited by 3 publications

References 95 publications

Influence of CMT welding parameters on microstructural and properties investigation of dissimilar weld joint for aluminum bronze and carbon steel

Influence of CMT welding parameters on microstructural and properties investigation of dissimilar weld joint for aluminum bronze and carbon steel

Tailoring mechanical, microstructural and toughening characteristics of plasma-sprayed graphene-reinforced samarium niobate coatings for extreme environments

Interfacial Behavior of Copper/Steel Bimetallic Composites Fabricated by CMT-WAMM

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