Abstract
In cold spraying, formation and adhesion of the coating is mainly due to the kinetic impact of the powders as they impinge on the substrate, at velocities above the critical value, causing substantial plastic deformation of both the particles and substrate. Most of the research around cold spraying focuses on preheating the gas before spraying; however, this article is aimed at preheating the substrate only and evaluating its effect on the microstructure of the coating. Before deposition the substrate was preheated at different temperatures to understand its effect on the corrosion behavior. The analysis shows that the powder particle could efficiently deposit, by increasing the substrate temperature up to at least 250 °C. The corrosion current density extracted from the Tafel plot shows a decreasing trend than bare 1020 steel in 3.5 wt.% NaCl solution. However, at higher temperatures the corrosion behavior detriments due to an increase in the oxygen content of the coating during deposition. An estimation of the gas velocity shows that substrate heating is beneficial in obtaining high deposition efficiencies even with low gas velocities, much below the theoretical critical velocity for nickel.
Similar content being viewed by others
References
M.F. Smith, The Cold Spray Deposition Process: Fundamentals and Applications, Woodhead Publishing Series in Metals and Surface Engineering, pp. 43–61 (2007).
A. Moridi, S.M. Hassani-Gangaraj, M. Guagliano and M. Dao, Cold Spray Coating: Review of Material Systems and Future Perspectives, Surf. Eng., 2014, 36(6), p 369.
M. Grujici, C. Zhao, W. Resset and D. Helfritch, Adiabatic Shear Instability Based Mechanism for Particles/Substrate Bonding in the Cold-Gas Dynamic-Spray Process, Mater Des., 2004, 25, p 681.
A.S. Alhulaifi, G.A. Buck and W.J. Arbegast, Numerical and Experimental Investigation of Cold Spray Gas Dynamic Effects for Polymer Coating, J. Therm. Spray Technol., 2012, 21(5), p 852–862.
L. Venkatesh, N.M. Chavan and G. Sundararajan, The Influence of Powder Particle Velocity and Microstructure on the Properties of Cold Sprayed Copper Coatings, J. Thermal Spray Technol., 2011, 20, p 1009–1021.
K. Ogawa, K. Ito, K. Ichimura, Y. Ichikawa, S. Ohno and N. Onda, Characterization of Low-Pressure Cold-Sprayed Aluminum Coatings, J. Therm Spray Technol., 2008, 17(5–6), p 728–735.
F. Gartner, C. Borchers, T. Stoltenhoff, H. Kreye and H. Assadi, Microstructural and Macroscopic Properties of Cold Sprayed Copper Coatings, J. Therm. Spray, 2003, 93(12), p 64–70.
Y. Xie, M. Planche, C. Chen, R. Raoelison, P. Hervé, X. Suo, P. He and H. Liao, Cold Spraying of Thermally Softened Ni-Coated FeSiAl Composite Powder: Microstructure Characterization, Tribological Performance and Magnetic Property, Mater. Des., 2018, 160, p 270–283.
J.G. Legoux, E. Irissou and C. Moreau, Effect of Substrate Temperature on the Formation Mechanism of Cold-Sprayed Aluminum, Zinc and Tin Coatings, J. Therm. Tech., 2007, 16(5–6), p 619–626.
S. Yin, X. Suo, Y. Xie, W. Li, R. Lupoi and H. Liao, Effect of Substrate Temperature on Interfacial Bonding for Cold Spray of Ni onto Cu, J. Mat. Sci., 2015, 50, p 7448–7457.
M. Fukumoto, H. Wada, K. Tanabe, M. Yamada, E. Yamaguchi, A. Niwa, M. Sugimoto and M. Izawa, Effect of Substrate Temperature on Deposition Behavior of Copper Particles on Substrate Surfaces in the Cold Spray Process, J. Therm. Tech., 2007, 16(5–6), p643.
W. Giurlani, G. Zangari, F. Gambinossi, M. Passaponti, E. Salvietti, F. Di Benedetto, S. Caporali and M. Innocenti, Electroplating for Decorative Applications: Recent Trends in Research and Development, Coatings, 2018, 8, p p260-285.
B. Navinšek, P. Panjan and I. Milošev, PVD Coatings as an Environmentally Clean Alternative to Electroplating and Electroless Processes, Surf. Coat. Technol., 1999, 116–119, p p476-487.
J.M. Amado, M.J. Tobar, A. Yáñez, V. Amigó and J.J. Candel, Crack Free Tungsten Carbide Reinforced Ni(Cr) Layers obtained by Laser Cladding, Phys. Procedia, 2011, 12(Part A), p 338–344.
T. Schopphoven, A. Gasser and K. Wissenbach, Investigations on Ultra-High-Speed Laser Material Deposition as Alternative for Hard Chrome Plating and Thermal Spraying, J. Laser Appl., 2016, 28(2), p 1–9.
S. Pathak and G. Saha, Development of Sustainable Cold Spray Coatings and 3D Additive Manufacturing Components for Repair/Manufacturing Applications: A Critical Review, Coatings, 2017, 7(8), p 122–148.
M. Winnicki, Advanced Functional Metal-Ceramic and Ceramic Coatings Deposited by Low-Pressure Cold Spraying: A Review, Coatings, 2021, 11(9), p 1044.
B.S. De-Force, T.J. Eden and J.K. Potter, Cold Spray Al-5% Mg Coatings for the Corrosion Protection of Magnesium Alloys, J. Ther. Spray Tech., 2011, 20(6), p 1352–1358.
T. Marrocco, T. Hussain, D.G. McCartney and P.H. Shipway, Corrosion Performance of Laser Post-Treated Cold Sprayed Titanium Coatings, J. Therm. Spray Technol., 2011, 20(4), p 909–917.
N. Bala, H. Singh and S. Prakash, Accelerated Hot Corrosion Studies of Cold Spray Ni–50Cr Coating on Boiler Steels, Mater. Des., 2010, 31, p 244–253.
G. Sundarajan, P. Phani, A. Jyothirmayi and R. Gundakaram, The Influence of Heat Treatment on the Microstructural, Mechanical and Corrosion Behaviour of Cold Sprayed SS 316L Coatings, J. Mat. Sci., 2009, 44, p 2320–2326.
M. Diaba, X. Pang and H. Jahed, The Effect of Pure Aluminum Cold Spray Coating on Corrosion and Corrosion Fatigue of Magnesium (3% Al-1% Zn) Extrusion, Surface Coat. Technol., 2017, 309, p 423–435.
D. Dzhurinskiy, E. Maeva, E. Leshchinsky and R.G. Maev, Corrosion Protection of Light Alloys Using Low Pressure Cold Spray, J Therm. Spray Technol., 2012, 21, p 304–313.
S.N. Abdullah, N. Sazali and A.S. Jamaludin, Study on Thickness of Low Carbon Steel in Rapid Cooling Process: A Short Review, J. Modern Manuf. Syst. Technol., 2020, 4(1), p 52–59.
H. Koivuluoto, H. Lagerbom, J. Kylmälahti and M. Vuoristo, Microstructure and Mechanical Properties of Low-Pressure Cold-Sprayed (LPCS) Coatings, J. Therm Tech., 2008, 17(5–6), p p721-727.
H. Assadi, F. Gartner, T. Stoltenhoff and H. Kreye, Bonding Mechanism in Cold Gas Spraying, Acta Mater., 2003, 51, p 4379–4394.
M. Karimi, A. Fartaj, G. Rankin, D. Vanderzwet, W. Birtch and J. Villafuerte, Numerical Simulation of the Cold Gas Dynamic Spray Process, J. Therm. Spray Technol., 2006, 15(4), p 518–532.
V.K. Champagne, D.J. Helfritch, S.P.G. Dinavahi and P.F. Leyman, Theoretical and Experimental Particle Velocity in Cold Spray, J. Therm. Spray Technol., 2010, 20(3), p 425–431.
M. Walker, Microstructure and Bonding Mechanisms in Cold Spray Coatings, Mater. Sci. Technol., 2018, 34(17), p 1–21.
E. Irissou, J.-G. Legoux, A.N. Ryabinin, B. Jodoin and C. Moreau, Review on Cold Spray Process and Technology: Part I—Intellectual Property, J. Thermal Spray Technol., 2008, 17(4), p p495-516.
D.L. Gilmore, R.C. Dykhuizen, R.A. Neiser, T.J. Roemer and M.F. Smith, Particle Velocity and Deposition Efficiency in the Cold Spray Process, J. Therm. Spray Technol., 1999, 8(4), p 576–582.
A.W.-Y. Tan, J.Y. Lek, W. Sun, A. Bhowmik, I. Marinescu, X. Song, W. Zhai, F. Li, Z. Dong, C.B. Boothroyd and E. Liu, Influence of Particle Velocity When Propelled Using N2 or N2-He Mixed Gas on the Properties of Cold-Sprayed Ti6Al4V, Coatings, 2018, 8, p 327–349.
X. Tao Luo, Y. Juan Li, C. Xin Li, G. Jun Yang and C. Jiu Li, Effect of Spray Conditions on Deposition Behavior and Microstructure of Cold Sprayed Ni Coatings Sprayed with a Porous Electrolytic Ni Powder, Surf. Coat. Tech., 2016, 289, p 85–93.
G. Bae, K. Kang, H. Na, J.-J. Kim and C. Lee, Effect of Particle Size on the Microstructure and Properties of Kinetic Sprayed Nickel Coatings, Surf. Coat. Technol., 2010, 204(20), p p3326-3335.
Y.-J. Ying-KangWei, Y. Zhang, X.-T. Luo and C.-J. Li, Corrosion Resistant Nickel Coating with Strong Adhesion on AZ31B Magnesium Alloy Prepared by an In-situ Shot-Peening-Assisted Cold Spray, Corros. Sci., 2018, 138(1), p 105–115.
S.M. Hassani-Gangaraj, A. Moridi and M. Guagliano, Critical Review of Corrosion Protection by Cold Spray Coatings, Surf. Eng., 2015, 31(11), p 803–815.
Funding
This was partly supported by funding (recipient Dr. S. Roy) by Science and Engineering Research Board, Dept. of Science and Technology, Govt. of India (Grant No 2016/EMR/002927).
Author information
Authors and Affiliations
Contributions
All authors have contributed to the study conception and design. S.T. was involved in coating material preparation, data collection and analysis. D.S. was involved with corrosion data collection and analysis. S.R. has secured funding and provided supervision. S.P. has provided resources and supervision. The first draft of the manuscript was written by S.T. and all authors have commented on the manuscript. All authors have read and approved the final manuscript.
Corresponding author
Ethics declarations
Conflict of interest
Dr. S. Roy acknowledges financial support from SERB, DST, Govt of India, toward this project. The other authors have no relevant financial or non-financial interests to disclose.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Tripathy, S., Sahoo, D., Roy, S. et al. Effect of Substrate Heating on Corrosion Behavior of Nickel Coated on AISI 1020 Steel by Cold Gas Dynamic Spraying. J. of Materi Eng and Perform 32, 5346–5352 (2023). https://doi.org/10.1007/s11665-022-07500-1
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-022-07500-1