https://bura.brunel.ac.uk/bitstream/2438/13101/1/FullText.pdf

Cold spraying - A materials perspective

This paper provides a review of recent developments in the field of Mg corrosion and puts those into context. This includes considerations of corrosion manifestations, material influences, surface treatment, anodization, coatings, inhibition, biodegradable medical applications, stress corrosion cracking, flammability, corrosion mechanisms for HP Mg, critical evaluation of corrosion mechanisms, and concluding remarks. There has been much research recently, and much research continues in this area. This is expected to produce significantly better, more-corrosion-resistant Mg alloys.

Review of Recent Developments in the Field of Magnesium Corrosion

In the cold spray (CS) process, deposits are produced by depositing powder particles at high velocity onto a substrate. Powders deposited by CS do not undergo melting before or upon impacting the substrate. This feature makes CS suitable for deposition of a wide variety of materials, most commonly metallic alloys, but also ceramics and composites. During processing, the particles undergo severe plastic deformation and create a more mechanical and less metallurgical bond with the underlying material. The deformation behavior of an individual particle depends on multiple material and process parameters that are classified into three major groups—powder characteristics, geometric parameters, and processing parameters, each with their own subcategories. Changing any of these parameters leads to evolution of a different microstructure and consequently changes the mechanical properties in the deposit. While cold spray technology has matured during the last decade, the process is inherently complex, and thus, the effects of deposition parameters on particle deformation, deposit microstructure, and mechanical properties remain unclear. The purpose of this paper is to review the parameters that have been investigated up to now with an emphasis on the existent relationships between particle deformation behavior, microstructure, and mechanical properties of various cold spray deposits.

Review of Relationship Between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray

In the cold spray process, deposition of particles takes place through intensive plastic deformation upon impact in a solid state at temperatures well below their melting point. Therefore, spray particles experience little oxidation or decomposition during this process. As a result, cold-sprayed coatings have excellent mechanical, electrical and thermal properties. In this work, pure Al, Cu, Ti and stainless steel 316 were deposited by cold spray. The tensile strength and elongation of these coatings were also measured. The results showed that the as-sprayed coatings of the four materials have poor ductility and almost no elongation. However, heat treatment can improve the mechanical properties of the cold-sprayed coatings to some extent. Here, the effects of heat treatment conditions on the mechanical properties of the four cold-sprayed materials are discussed.

/pdf/the-effects-of-heat-treatment-on-the-mechanical-properties-3ckd9tpegm.pdf

The effects of heat treatment on the mechanical properties of cold-sprayed coatings

In this paper, the application of cold spray (CS) coating deposition technology as additive manufacturing technique is discussed. Absence of material melting during CS deposition permits to obtain deposits with low value of residual stresses and to preserve the phase composition of source material which is a very important advantage. In this paper, the latest developments in the field of cold spray such as micronozzle device and new multimaterial deposition approach permitting to significantly enlarge the potential of cold spray as additive manufacturing technology is discussed.

Potential of cold gas dynamic spray as additive manufacturing technology

In the current work, a series of coatings produced by cold spray using varying materials were studied with neutron diffraction. The through-thickness residual stress was evaluated in a number of substrate-coating systems, typically at a scale of several millimetres. By combining neutron stress and texture analysis, optical and electron microscopy and numerical simulations of the high strain rate deformation, a multi-scale analysis approach is presented herein to provide insights into the mechanism of residual stress accumulation in cold spray coatings and to help establish a solid framework to understand the mechanisms of splat/coating formation.

Residual Stresses in Cold Spray Coatings

Cold spray technology is used to produce metal coatings with a variety of functions, including surface corrosion protection, improvement of wear resistance, etc. Cold sprayed materials exhibit a wide range of behaviours resulting in large variation of spraying efficiency, coating properties, quality and performance in service. Residual stress, being a result and attribute of the deposition process, can be studied to test whether the coating is in tension/compression stress state and also to provide information about the thermo-mechanical history of the material during the deposition process. Residual stress distributions in a variety of coating materials have been studied by neutron diffraction. Through-thickness residual stress profiles show that the stress magnitude varies significantly and depends mainly on the mechanical properties of the coating material.

Residual Stress in Coatings Produced by Cold Spray

Al and Al alloy cold spray coatings were deposited on Mg substrates using two different cold spray systems - a Kinetic Metallization system (convergent barrel, sonic nozzle) and a CGT system (convergent-divergent barrel, supersonic nozzle). The residual stress profiles in the coatings were measured using neutron diffraction with high spatial resolution. In the first part of the study, the residual stress profile in pure Al coatings was compared when sprayed using the Kinetic Metallization system (using both helium and nitrogen as the driving gas), and with the CGT system using nitrogen gas. In this way the effect of impact velocity and process temperature was studied. In the second part of the study, the residual stress profile was compared in coatings of pure Al, 7075 Al and 6061 Al sprayed using the same process conditions in the CGT system. The residual stress profiles depend more on the alloy content, i.e. intrinsic resistance to plastic deformation, than on the processing conditions, and this is interpreted using a simple model that incorporates the effect of peening stresses in the cold spray process.

Residual stresses in cold spray Al coatings: The effect of alloying and of process parameters

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Residual Stresses in Cold Spray Coatings

Residual Stress in Coatings Produced by Cold Spray

Residual stresses in cold spray Al coatings: The effect of alloying and of process parameters