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Surface Modification of a Cold Gas Dynamic Spray-Deposited Titanium Coating on Aluminum Alloy by using Friction-Stir Processing

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Abstract

In this research, the parameters of the cold spray process were initially assessed for deposition of a pure titanium coating layer with the thickness in the range of 800-850 µm on an AA5083 alloy substrate. Thereafter, to enhance the structural integrity of Ti-coating layer and decrease the coating porosity, friction-stir processing was employed as a post-modification technique by using a flat cylindrical tungsten carbide tool. The plunge depth of the friction-stir tool (in the range of 0.3-0.5 mm) was found to significantly affect the densification of the porous titanium coating layer. Optical microscopy, field emission-scanning electron microscopy, electron backscattering diffraction, transmission electron microscopy analysis and indentation Vickers micro-hardness testing were conducted on the thickness cross-sections of cold-sprayed coatings to characterize the microstructural features and mechanical properties before and after friction-stir modification performed using two different plunge depths. Furthermore, residual stress profiles on the surface were determined by using x-ray diffraction analysis technique. Significant grain refinement, from an initial cold-sprayed coating grain size of less than 25 µm to grain sizes < 1 µm, was observed across the thickness section of modified samples with a gradient profile from the coating surface toward the interface depending on the plunge depth. After friction-stir processing, the hardness of a thin layer close to the surface of coating increased up to seven times higher as compared to the cold-sprayed material.

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Authors and Affiliations

  1. School of Metallurgical and Materials Engineering, College of Engineering, University of Tehran, P.O. Box 11155-4563, Tehran, Iran

    F. Khodabakhshi

  2. Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, Canada

    B. Marzbanrad, H. Jahed & A. P. Gerlich

  3. Faculty of Mechanical and Manufacturing Engineering, Universiti Malaysia Pahang, 26600, Pekan, Pahang, Malaysia

    L. H. Shah

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  1. F. Khodabakhshi
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  2. B. Marzbanrad
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  3. L. H. Shah
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  4. H. Jahed
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  5. A. P. Gerlich
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Correspondence to F. Khodabakhshi.

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Khodabakhshi, F., Marzbanrad, B., Shah, L.H. et al. Surface Modification of a Cold Gas Dynamic Spray-Deposited Titanium Coating on Aluminum Alloy by using Friction-Stir Processing. J Therm Spray Tech 28, 1185–1198 (2019). https://doi.org/10.1007/s11666-019-00902-z

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