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Effect of the Cold-Sprayed Aluminum Coating-Substrate Interface Morphology on Bond Strength for Aircraft Repair Application

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Abstract

This article is dealing with the effects of surface preparation of the substrate on aluminum cold-sprayed coating bond strength. Different sets of AA2024-T3 specimens have been coated with pure Al 1050 feedstock powder, using a conventional cold spray coating technique. The sets were grit-blasted (GB) before coating. The study focuses on substrate surface topography evolution before coating and coating-substrate interface morphology after coating. To study coating adhesion by LASAT® technique for each set, specimens with and without preceding GB treatment were tested in load-controlled conditions. Then, several techniques were used to evaluate the effects of substrate surface treatment on the final coating mechanical properties. Irregularities induced by the GB treatment modify significantly the interface morphology. Results showed that particle anchoring was improved dramatically by the presence of craters. The substrate surface was characterized by numerous anchors. Numerical simulation results exhibited the increasing deformation of particle onto the grit-blasted surface. In addition, results showed a strong relationship between the coating-substrate bond strength on the deposited material and surface preparation.

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Notes

  1. Surface Engineering Research Laboratory based in Belfort, France.

  2. Available on the Material Center from MINES ParisTech based in Evry, France.

  3. Available on the LERMPS based in Belfort, France.

Abbreviations

AA2024-T3:

Aluminum Alloy 2024-T3

GB:

Grit-Blasted

CS:

Cold Spray

XRD:

X-Ray Diffraction

SEM:

Scanning Electron Microscopy

LASAT:

LAser Shock Adhesion Testing

Al:

Aluminum

EOS:

Equation of State

FEA:

Finite Element Analysis

AIL:

Additional Interface Length

RPL:

Representative Profile Length

R a :

Arithmetic average of absolute values (µm)

R z :

Average distance between the highest peak and lowest valley in each sampling length (µm)

V p :

Particle velocity (m s−1)

σ :

Yield strength (MPa)

E :

Young’s modulus (MPa)

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Acknowledgments

This work was carried out within the “C-SAR” FUI program. The authors would like to thanks all the members of the program consortium, i.e., Airbus Industries Group, Safran Helicopter Engines, Lifco Industrie, APS Coating, UTBM, Dassault Aviation and Trochet, for valuable discussion, and OSEO, “Pôle ASTech Paris Région”, “Pôle des microtechniques” and “Pôle Pégase” for financial support. Many thanks also to Mrs. N. De Dave-Fabrègue from MINES ParisTech for its precious help in microscopic characterization and metallographic samples preparation.

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Authors and Affiliations

  1. Centre des Matériaux, CNRS UMR 7633, Competence Center for Spray Processing (C2P), MINES ParisTech, Evry, Île-de-France, France

    Quentin Blochet, Francesco Delloro, François Borit & Michel Jeandin

  2. Centre de Morphologie Mathématique, Mathématique et Systèmes, MINES ParisTech, Fontainebleau, Île-de-France, France

    Franck N’Guyen & Dominique Jeulin

Authors
  1. Quentin Blochet
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  2. Francesco Delloro
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  3. Franck N’Guyen
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  4. Dominique Jeulin
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  5. François Borit
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  6. Michel Jeandin
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Correspondence to Quentin Blochet.

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Blochet, Q., Delloro, F., N’Guyen, F. et al. Effect of the Cold-Sprayed Aluminum Coating-Substrate Interface Morphology on Bond Strength for Aircraft Repair Application. J Therm Spray Tech 26, 671–686 (2017). https://doi.org/10.1007/s11666-017-0548-3

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  • DOI: https://doi.org/10.1007/s11666-017-0548-3

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