Abstract
The traditional role of cold spray coatings lays in the dimensional restoration of assorted components and machine parts, but these repairs often result in coating mechanical properties that fall short when compared to the parent material. A potential solution to improve mechanical properties, while maintaining the benefits of a complete solid-state process where temperatures remain below the metallic melting point, is by incorporating ultrasonic consolidation as a post-treatment process in conjunction with the cold spray coating. In the work presented here, ultrasonic consolidation was applied upon two metal matrix composite cold spray coatings consisting of mechanically blended feedstock of Cu-38 wt.%Ni and Cr3C2-30 wt.%NiCr at 50:50 and 25:75 wt.%, respectively. Metallography and mechanical testing were performed to analyze coating response to the ultrasonic consolidation process, which included mean free path relationship of the reinforcing particles (Cr3C2-NiCr). The results demonstrated an increase in tensile and adhesion properties attributed to the ultrasonic consolidation step, as well as the influence of the increased Cr3C2-NiCr content. Ultrasonic consolidation applied as a post-treatment upon cold spray coatings was found to provide a unique approach to complete solid-state processing where coating mechanical properties can be improved and/or modified with carbide containing particle content within the metal matrix.
Similar content being viewed by others
References
Q. Wang and M.X. Zhang, Review on Recent Research and Development of Cold Spray Technologies, Key Eng. Mater., 2013, 533, p 1–52.
Schmelzle, J., E.V. Kline, C.J. Dickman, E.W. Reutzel, G. Jones, and T.W. Simpson, (Re)Designing for Part Consolidation: Understanding the Challenges of Metal Additive Manufacturing, J Mech Design, 2015, 137(11)
R.F. Brown, G.M. Smith, J. Potter and T.J. Eden, Parameter Development Via in Situ Residual Stress Measurement and Post-Deposition Analysis of Cold Spray Cuni Coatings, J. Therm. Spray Technol., 2020, 29(8), p 1876–1891.
T. Stoltenhoff, H. Kreye and H.J. Richter, An Analysis of the Cold Spray Process and Its Coatings, J. Therm. Spray Technol., 2002, 11(4), p 542–550.
V. Luzin, K. Spencer and M.X. Zhang, Residual Stress and Thermo-Mechanical Properties of Cold Spray Metal Coatings, Acta Mater., 2011, 59(3), p 1259–1270.
H. Assadi, F. Gartner, T. Stoltenhoff and H. Kreye, Bonding Mechanism in Cold Gas Spraying, Acta Mater., 2003, 51(15), p 4379–4394.
H. Assadi, T. Schmidt, H. Richter, J.O. Kliemann, K. Binder, F. Gartner, T. Klassen and H. Kreye, On Parameter Selection in Cold Spraying, J. Therm. Spray Technol., 2011, 20(6), p 1161–1176.
K. Binder, J. Gottschalk, M. Kollenda, F. Gartner and T. Klassen, Influence of Impact Angle and Gas Temperature on Mechanical Properties of Titanium Cold Spray Deposits, J. Therm. Spray Technol., 2011, 20(1–2), p 234–242.
X.T. Luo, Y.K. Wei, Y. Wang and C.J. Li, Microstructure and Mechanical Property of Ti and Ti6al4v Prepared by an in-Situ Shot Peening Assisted Cold Spraying, Mater. Des., 2015, 85, p 527–533.
P.A. Podrabinnik and I.V. Shishkovsky, Laser Post Annealing of Cold-Sprayed Al-Ni Composite Coatings for Green Energy Tasks, Proc. IUTAM, 2017, 23, p 108–113.
A. Sova, S. Grigoriev, A. Okunkova and I. Smurov, Cold Spray Deposition of 316l Stainless Steel Coatings on Aluminium Surface with Following Laser Post-Treatment, Surf. Coat. Technol., 2013, 235, p 283–289.
Y. Sano, K. Akita, K. Masaki, Y. Ochi, I. Altenberger and B. Scholtes, Laser Peening without Coating as a Surface Enhancement Technology, J. Laser Micro Nanoeng., 2006, 1(3), p 161–166.
P. Poza, C.J. Munez, M.A. Garrido, S. Vezzu, S. Rech and A. Trentin, Effect of Laser Remelting on the Mechanical Behaviour of Inconel 625 Cold-Sprayed Coatings, Procedia Eng., 2011, 10, p 3799–3804.
R.F. Li, Z.G. Li, Y.Y. Zhu and K. Qi, Structure and Corrosion Resistance Properties of Ni-Fe-B-Si-Nb Amorphous Composite Coatings Fabricated by Laser Processing, J. Alloys Compd., 2013, 580, p 327–331.
A. Astarita, S. Genna, C. Leone, F.M.C. Minutolo, F. Rubino and A. Squillace, Study of the Laser Remelting of a Cold Sprayed Titanium Layer, Procedia CIRP, 2015, 33, p 452–457.
M.H. Bocanegra-Bernal, Hot Isostatic Pressing (Hip) Technology and Its Applications to Metals and Ceramics, J. Mater. Sci., 2004, 39(21), p 6399–6420.
M. Khomutov, P. Potapkin, V. Cheverikin, P. Petrovskiy, A. Travyanov, I. Logachev, A. Sova and I. Smurov, Effect of Hot Isostatic Pressing on Structure and Properties of Intermetallic Nial-Cr-Mo Alloy Produced by Selective Laser Melting, Intermetallics, 2020, 120, p 106766.
D.R. White, Ultrasonic Consolidation of Aluminum Tooling, Adv. Mater. Process., 2003, 161(1), p 64–65.
D.R. Foster, M.J. Dapino and S.S. Babu, Elastic Constants of Ultrasonic Additive Manufactured Al 3003–H18, Ultrasonics, 2013, 53(1), p 211–218.
P.J. Wolcott, A. Hehr, C. Pawlowski and M.J. Dapino, Process Improvements and Characterization of Ultrasonic Additive Manufactured Structures, J. Mater. Process. Technol., 2016, 233, p 44–52.
G.D.J. Ram, Y. Yang and B.E. Stucker, Effect of Process Parameters on Bond Formation During Ultrasonic Consolidation of Aluminum Alloy 3003, J. Manuf. Syst., 2006, 25(3), p 221–238.
J.H. Ouyang, E. Yarrapareddy and R. Kovacevic, Microstructural Evolution in the Friction Stir Welded 6061 Aluminum Alloy (T6-Temper Condition) to Copper, J. Mater. Process. Technol., 2006, 172(1), p 110–122.
H.J. Aval, Microstructural Evolution and Mechanical Properties of Friction Stir-Welded C71000 Copper-Nickel Alloy and 304 Austenitic Stainless Steel, Int. J. Miner. Met. Mater., 2018, 25(11), p 1294–1303.
R.W. Fonda, J.F. Bingert and K.J. Colligan, Development of Grain Structure During Friction Stir Welding, Scr. Mater., 2004, 51(3), p 243–248.
V. Fartashvand, A. Abdullah and S.A.S. Vanini, Effects of High Power Ultrasonic Vibration on the Cold Compaction of Titanium, Ultrason. Sonochem., 2017, 36, p 155–161.
I.S. Lee, C.J. Hsu, C.F. Chen, N.J. Ho and P.W. Kao, Particle-Reinforced Aluminum Matrix Composites Produced from Powder Mixtures Via Friction Stir Processing, Compos. Sci. Technol., 2011, 71(5), p 693–698.
C.J. Huang, W.Y. Li, Z.H. Zhang, M.S. Fu, M.P. Planche, H.L. Liao and G. Montavon, Modification of a Cold Sprayed Sicp/Al5056 Composite Coating by Friction Stir Processing, Surf. Coat. Technol., 2016, 296, p 69–75.
P.J. Wolcott, A. Hehr and M.J. Dapino, Optimized Welding Parameters for Al 6061 Ultrasonic Additive Manufactured Structures, J. Mater. Res., 2014, 29(17), p 2055–2065.
A. Hehr, P.J. Wolcott and M.J. Dapino, Effect of Weld Power and Build Compliance on Ultrasonic Consolidation, Rapid Prototyp. J., 2016, 22(2), p 377–386.
C.D. Hopkins, M.J. Dapino and S.A. Fernandez, Statistical Characterization of Ultrasonic Additive Manufacturing Ti/Al Composites, J. Eng. Mater. Trans. ASME, 2010, 132(4), p 041006–1.
N. Sridharan, M. Gussev, R. Seibert, C. Parish, M. Norfolk, K. Terrani and S.S. Babu, Rationalization of Anisotropic Mechanical Properties of Al-6061 Fabricated Using Ultrasonic Additive Manufacturing, Acta Mater., 2016, 117, p 228–237.
D.E. Schick, R.M. Hahnlen, R. Dehoff, P. Collins, S.S. Babu, M.J. Dapino and J.C. Lippold, Microstructural Characterization of Bonding Interfaces in Aluminum 3003 Blocks Fabricated by Ultrasonic Additive Manufacturing, Weld J., 2010, 89(5), p 105s–115s.
C.Y. Kong, R.C. Soar and P.M. Dickens, Characterisation of Aluminium Alloy 6061 for the Ultrasonic Consolidation Process, Mater. Sci. Eng. A Struct., 2003, 363(1–2), p 99–106.
H.S. Kim and M.B. Bush, The Effects of Grain Size and Porosity on the Elastic Modulus of Nanocrystalline Materials, Nanostruct. Mater., 1999, 11(3), p 361–367.
G.M. Smith, M. Resnick, B. Kjellman, J. Wigren, G. Dwivedi and S. Sampath, Orientation-Dependent Mechanical and Thermal Properties of Plasma-Sprayed Ceramics, J. Am. Ceram. Soc., 2018, 101(6), p 2471–2481.
M. Kouzeli and A. Mortensen, Size Dependent Strengthening in Particle Reinforced Aluminium, Acta Mater, 2002, 50(1), p 39–51.
S. Usmani, S. Sampath, D.L. Houck and D. Lee, Effect of Carbide Grain Size on the Sliding and Abrasive Wear Behavior of Thermally Sprayed Wc-Co Coatings, Tribol. Trans., 1997, 40(3), p 470–478.
P. Chivavibul, M. Watanabe, S. Kuroda and K. Shinoda, Effects of Carbide Size and Co Content on the Microstructure and Mechanical Properties of Hvof-Sprayed Wc-Co Coatings, Surf. Coat. Technol., 2007, 202(3), p 509–521.
W.M. Zhao, C. Liu, L.X. Dong and Y. Wang, Effects of Arc Spray Process Parameters on Corrosion Resistance of Ti Coatings, J. Therm. Spray Technol., 2009, 18(4), p 702–707.
X.T. Luo, G.M. Smith and S. Sampath, On the Interplay between Adhesion Strength and Tensile Properties of Thermal Spray Coated Laminates-Part I: High Velocity Thermal Spray Coatings, J. Therm. Spray. Technol., 2018, 27(3), p 296–307.
G. Munday, J. Hogan and A. McDonald, On the Microstructure-Dependency of Mechanical Properties and Failure of Low-Pressure Cold-Sprayed Tungsten Carbide-Nickel Metal Matrix Composite Coatings, Surf. Coat. Technol., 2020, 396, p 125947.
G.M. Smith and S. Sampath, Sustainability of Metal Structures Via Spray-Clad Remanufacturing, JOM, 2018, 70(4), p 512–520.
G.M. Smith, O. Higgins and S. Sampath, In-Situ Observation of Strain and Cracking in Coated Laminates by Digital Image Correlation, Surf. Coat. Technol., 2017, 328, p 211–218.
X.T. Luo, M.L. Yao, N. Ma, M. Takahashi and C.J. Li, Deposition Behavior, Microstructure and Mechanical Properties of an in-Situ Micro-Forging Assisted Cold Spray Enabled Additively Manufactured Inconel 718 Alloy, Mater. Des., 2018, 155, p 384–395.
T.W. Gustafson, P.C. Panda, G. Song and R. Raj, Influence of Microstructural Scale on Plastic Flow Behavior of Metal Matrix Composites, Acta Mater., 1997, 45(4), p 1633–1643.
P. Chen, W.B. Liao, L.H. Liu, F. Luo, X.Y. Wu, P.J. Li, C. Yang, M. Yan, Y. Liu, L.C. Zhang and Z.Y. Liu, Ultrafast Consolidation of Bulk Nanocrystalline Titanium Alloy Through Ultrasonic Vibration, Sci. Rep., 2018, 8, p 1–9.
Author information
Authors and Affiliations
Corresponding author
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
Brown, R.F., Smith, G.M., Hehr, A. et al. Ultrasonic Consolidation Post-Treatment of CuNi:Cr3C2-NiCr Composite Cold Spray Coatings: A Mechanical and Microstructure Assessment. J Therm Spray Tech 30, 2069–2082 (2021). https://doi.org/10.1007/s11666-021-01262-3
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-021-01262-3