Wear and Fretting Behavior of Cold Sprayed IN625 Superalloy

Cavaliere, Pasquale; Rizzo, A.; Valerini, D.; Capodieci, L.

doi:10.3390/met11010049

Cited by 8 publications

(8 citation statements)

References 34 publications

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“…Very few experimental evidences are presented on the scratch response of cold spray deposits [39,40]. Here, nanoindentation and scratch are employed to continuously characterize the coatings mechanical properties along the deposition path.…”

Section: Introductionmentioning

confidence: 99%

Fretting Wear and Scratch Resistance of Cold-Sprayed Pure Cu and Ti

Váz

Silvello

Cavaliere

et al. 2021

Metallogr. Microstruct. Anal.

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The paper analyses the fretting and wear behavior of pure copper and pure titanium coatings realized through cold spray. The coatings were designed and produced by employing processing conditions leading to minimum porosity and high hardness; these conditions were 700 °C and 40 bar for Ti powders and 400 °C and 30 bar for Cu ones. The low porosity and high strength materials led to high resistance to wear damaging through the optimal energy dissipation upon fretting. Due to the sprayed particles deformation mode, the sprayed materials show non-uniform hardening along the deposition distance. As a matter of fact, hardness varied in the range 3.7–4.2 GPa for Ti coatings and 1.5–2 GPa for the Cu ones depending on the distance from the substrate and on the coatings thickness. This influenced the materials properties and the response to the wear damaging. This was demonstrated by the scratch tests performed on coatings with different thicknesses. Those coatings sprayed in major thickness revealed the best wear resistance due to the deformation hardening. The harder coatings also revealed brittle fracture at the experienced highest loads.

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Section: Introductionmentioning

confidence: 99%

Fretting Wear and Scratch Resistance of Cold-Sprayed Pure Cu and Ti

Váz

Silvello

Cavaliere

et al. 2021

Metallogr. Microstruct. Anal.

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“…Delving more into the tribological responses of CS Ni-based super alloy deposits, Cavaliere et al [ 116 ] also identified the fretting-based mechanisms of CS IN625 deposit. In contrast to traditional sliding wear, fretting is another area of tribology, which focuses on the effects of low-amplitude tangential cyclic stresses along the surface.…”

Section: Tribological Propertiesmentioning

confidence: 99%

“… The ( a ) fretting wear; ( b ) COF; and OM of the wear tracks of CS IN625 deposit under ( c ) 50 N, ( d ) 100 N, and ( e ) 150 N loadings. Reprinted from Cavaliere et al, Copyright 2021 [ 116 ], under CC BY 4.0. …”

Section: Figurementioning

confidence: 99%

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

et al. 2023

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Ni-based superalloys have been extensively employed in the aerospace field because of their excellent thermal and mechanical stabilities at high temperatures. With these advantages, many sought to study the influence of fusion-reliant additive manufacturing (AM) techniques for part fabrication/reparation. However, their fabrication presents many problems related to the melting and solidification defects from the feedstock material. Such defects consist of oxidation, inclusions, hot tearing, cracking, and elemental segregation. Consequentially, these defects created a need to discover an AM technique that can mitigate these disadvantages. The cold spray (CS) process is one additive technique that can mitigate these issues. This is largely due to its cost-effectiveness, low temperature, and fast and clean deposition process. However, its effectiveness for Ni-based superalloy fabrication and its structural performance has yet to be determined. This review aimed to fill this knowledge gap in two different ways. First, the advantages of CS technology for Ni-based superalloys compared with thermal-reliant AM techniques are briefly discussed. Second, the processing–structure–property relationships of these deposits are elucidated from microstructural, mechanical, and tribological (from low to high temperatures) perspectives. Considering the porous and brittle defects of CS coatings, a comprehensive review of the post-processing techniques for CS-fabricated Ni superalloys is also introduced. Based on this knowledge, the key structure-property mechanisms of CS Ni superalloys are elucidated with suggestions on how knowledge gaps in the field can be filled in the near future.

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“…Without etching, it is evident that the number of micro pores drastically decreases as a function of process gas temperature with the lowest recorded porosity at 0.16%. Given the explanation of the increased thermal softening of the powders particles during CS process, the gradual densification of the coating suggests that there will be an improvement in particle cohesion, which can imply a greater wear resistance as porosity defects can result in early crack propagation during sliding [86,87]. Figure 8 depicts the XRD patterns of the as-sprayed coatings on Al6061 alloy substrate.…”

Section: Microstructure Of the Coatingsmentioning

confidence: 99%

“…Their intensities gradually become sharper as the loads increase, insinuating a dominant abrasive wear mechanism. Considering that S1 had a greater amount of pores, the stress concentration at the point of tribological contact which can induce fatigue cracks from the influence of circular stress due to the brittle nature of CS coatings [31,86,112]. This increases the chance of enabling a fatigue wear mechanism of which brittle fractures occur from the buildup of microslips along the contacting asperities.…”

Section: Wear Of the Bare And Coated Al6061 Alloysmentioning

confidence: 99%

Effect of Gas Propellant Temperature on the Microstructure, Friction, and Wear Resistance of High-Pressure Cold Sprayed Zr702 Coatings on Al6061 Alloy

et al. 2022

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For the first time, Zr702 coatings were deposited onto an Al6061 alloy using a high-pressure cold spray (HPCS) system. In this work, five different N2 process gas temperatures between 700 and 1100 °C were employed to understand the formation of cold sprayed (CS) Zr coatings and their feasibility for enhanced wear resistance. Results indicated that the N2 processing gas temperature of about 1100 °C enabled a higher degree of particle thermal softening, which created a dense, robust, oxide- and defect-free Zr coating. Across all CS Zr coatings, there was a refinement of crystallinity, which was attributed to the severe localized plastic deformation of the powder particles. The enhanced thermal boost up zone at the inter-particle boundaries and decreased recoverable elastic strain were accountable for the inter-particle bonding of the coatings at higher process gas temperatures. The flattening ratio (ε) increased as a function of temperature, implying that there was a greater degree of plastic deformation at higher N2 gas temperatures. The microhardness readings and wear volume of the coatings were also improved as a function of process gas temperature. In this work, the wear of the Al6061 alloy substrate was mainly plowing-based, whereas the Zr CS substrates demonstrated a gradual change of abrasive to adhesive wear. From our findings, the preparation of CS Zr coatings was a feasible method of enhancing the wear resistance of Al-based alloys.

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Wear and Fretting Behavior of Cold Sprayed IN625 Superalloy

Cited by 8 publications

References 34 publications

Fretting Wear and Scratch Resistance of Cold-Sprayed Pure Cu and Ti

Fretting Wear and Scratch Resistance of Cold-Sprayed Pure Cu and Ti

Solid-State Cold Spray Additive Manufacturing of Ni-Based Superalloys: Processing–Microstructure–Property Relationships

Effect of Gas Propellant Temperature on the Microstructure, Friction, and Wear Resistance of High-Pressure Cold Sprayed Zr702 Coatings on Al6061 Alloy

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