Influence of spray angle in cold spray deposition of Ti-6Al-4V coatings on Al6061-T6 substrates

Influence of spray angle in cold spray deposition of Ti-6Al-4V coatings on Al6061-T6 substrates

Surface and Coatings Technology

10.1016/j.surfcoat.2021.128068

http://dx.doi.org/10.1016/j.surfcoat.2021.128068

Debbie Hwee Leng Seng, Zheng Zhang, Zhi-Qian Zhang, Tzee Luai Meng, Siew Lang Teo, Boon Hee Tan, Qizhong Loi, Jisheng Pan

General Chemistry, Condensed Matter Physics, Surfaces, Coatings and Films, Materials Chemistry, Surfaces and Interfaces

04 January 2022

SENG, D. H. L., ZHANG, Z., ZHANG, Z.-Q., MENG, T. L., TEO, S. L., TAN, B. H., LOI, Q., & PAN, J. (2022). Influence of spray angle in cold spray deposition of Ti-6Al-4V coatings on Al6061-T6 substrates. Surface and Coatings Technology, 432, 128068. https://doi.org/10.1016/j.surfcoat.2021.128068

Cold spray (CS) has been deployed to deposit compact and well bonded Ti-6Al-4 V (Ti64) coatings. While the effects of gas pressure, gas temperature and powder feed rate have been well studied, the influence of spray angle during CS deposition of Ti64 powders is less understood. As actual components frequently have uneven or curved surfaces, it is critical to understand the impact of spray angle to design an efficient toolpath for repair or additive manufacturing of 3D freeform objects. In this work, off-normal spray angles were studied to elucidate their impact on the coating quality when depositing spherical Ti64 powders by CS on Al6061-T6 substrates using nitrogen as process gas. Evaluation of deposition efficiency and the coatings' surface roughness, cross-sectional microstructure, thickness and residual stress were performed to provide insight on the effects of spray angle. Finite Element Method (FEM) simulations were also performed in order to understand the dominant Ti64 deformation mode and development of residual stress in the coatings. Spray angle is identified to be an effective process parameter to control porosity, pore alignment and extent of surface compressive residual stress in the CS deposited materials.

Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0)

This research / project is supported by the A*STAR - Machining Learning Assisted Control of Metal Cold Spray and Shot Peening Processes
Grant Reference no. : A1894a0032

This research / project is supported by the A*STAR - Structural Metal Alloy Program
Grant Reference no. : A18b1B0061

This research / project is supported by the A*STAR - Singapore Aerospace Program
Grant Reference no. : A1915a0073

This research / project is supported by the A*STAR - Singapore Aerospace Program
Grant Reference no. : A1915a0082

This research / project is supported by the A*STAR - High-strength Lightweight Metals and Soft Magnetic Materials
Grant Reference no. : A1898b0043

https://oar.a-star.edu.sg/communities-collections/articles/18234

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