Exploring thermal dynamics and porosity of cold-sprayed Ti-6Al-4V coatings on Al6061-T6 substrates: A pulsed thermography and numerical modeling approach

Exploring thermal dynamics and porosity of cold-sprayed Ti-6Al-4V coatings on Al6061-T6 substrates: A pulsed thermography and numerical modeling approach

International Journal of Thermal Sciences

10.1016/j.ijthermalsci.2023.108732

http://dx.doi.org/10.1016/j.ijthermalsci.2023.108732

Sreedhar Unnikrishnakurup, Zheng Zhang, Debbie Hwee Leng Seng, Zhi-Qian Zhang, Jisheng Pan, Vinod Kumar, Jonathan Zheng, Carlos Manzano, Andrew Ngo

Condensed Matter Physics, General Engineering

27 October 2023

Unnikrishnakurup, S., Zhang, Z., Seng, D. H. L., Zhang, Z., Pan, J., Kumar, V., Zheng, J., Manzano, C., & Ngo, A. (2024). Exploring thermal dynamics and porosity of cold-sprayed Ti-6Al-4V coatings on Al6061-T6 substrates: A pulsed thermography and numerical modeling approach. International Journal of Thermal Sciences, 196, 108732. https://doi.org/10.1016/j.ijthermalsci.2023.108732

In this investigation, we use pulsed thermography and a multilayer analytical model to critically evaluate the thermal diffusivity and inherent porosity in cold-sprayed Ti-6Al-4V coatings on Al6061-T6 substrates. These coatings are of importance in deploying cold spray as an additive manufacturing technique for the restoration of high-cost alloy components. Our study draws upon experimental data obtained at spray angles from 50°to 90°, illustrating the relationship among the spray angle, porosity within the coating, and the resultant thermal diffusivity. Our results reveal a decrease in porosity and an increase in thermal diffusivity as the spray angle increases from 50°to 90°. In conjunction with our experimental approach, a numerical model was developed, incorporating binary images derived from optical micrographs to simulate transient heat diffusion during pulsed thermography experiments. The congruence between our empirical findings and simulation data affirms the effectiveness of the applied methodology, shedding light on the complex interplay between processing parameters and the resulting thermal properties. This study explores the effects of porosity and thermal gradients introduced during pulsed thermography, providing a profound understanding of the thermal dynamics of cold-sprayed coatings.

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

This research / project is supported by the Agency for Science, Technology, and Research (A*STAR) - Machining Learning Assisted Control of Metal Cold Spray and Shot Peening Processes Program
Grant Reference no. : A1894a0032

This research / project is supported by the Agency for Science, Technology, and Research (A*STAR) - Structural Metal Alloy Program
Grant Reference no. : A18b1B0061

This research / project is supported by the Agency for Science, Technology, and Research (A*STAR) - Singapore Aerospace Programs
Grant Reference no. : M2115a0091, M2115a0093, and M2115a0094

This research / project is supported by the Agency for Science, Technology, and Research (A*STAR) - High-strength Lightweight Metals and Soft Magnetic Materials
Grant Reference no. : A1898b0043

https://oar.a-star.edu.sg/communities-collections/articles/19498

1290-0729

Institute of Materials Research and Engineering