Abstract
Thermal spray (TS) coatings have been extensively utilized for various surface modifications such as enhancing wear/erosion resistance and thermal protection. In the present study, a new function of TS material is explored by studying its load-carrying capability. Due to the inherent microstructures containing voids and interfaces, it has been presumed TS materials were not suitable to bear loads. However, the recent advances in TS technology to manufacture near fully dense TS coatings have expanded their potential applications. In the current experiments, TS nickel coatings are deposited onto metallic substrates, and their mechanical behaviors are closely examined. Based on the measured data, the estimated elastic modulus of TS Ni is about 130 GPa (35% less than bulk value), and the maximum tensile strength is about 500 MPa (comparable to bulk value). It was found that such a high value is attainable because the coating is deposited onto a substrate, enabling a load-transfer mechanism and preventing coating failure at a much lower stress level. Three distinct deformation stages are identified to describe this behavior. Such a clarification is critical for enabling TS process to restore structural parts as well as to additively manufacture load-bearing components.
Similar content being viewed by others
References
H. Herman, S. Sampath, and R. McCune, Thermal Spray: Current Status and Future Trends, MRS Bull., 2000, 25(7), p 17-25
A. Kumar, J. Boy, R. Zatorski, and L. Stephenson, Thermal Spray and Weld Repair Alloys for the Repair of Cavitation Damage in Turbines and Pumps: A Technical Note, J. Therm. Spray Technol., 2005, 14(2), p 177-182
J. Santa, L. Espitia, J. Blanco, S. Romo, and A. Toro, Slurry and Cavitation Erosion Resistance of Thermal Spray Coatings, Wear, 2009, 267(1), p 160-167
M. Thorpe and H. Richter, A Pragmatic Analysis and Comparison of HVOF Processes, J. Therm. Spray Technol., 1992, 1(2), p 161-170
R.C. Dykhuizen, M.F. Smith, D.L. Gilmore, R.A. Neiser, X. Jiang, and S. Sampath, Impact of High Velocity Cold Spray Particles, J. Therm. Spray Technol., 1999, 8(4), p 559-564
A. Verstak and V. Baranovski, Activated Combustion HVAF Coatings for Protection Against Wear and High Temperature Corrosion, Therm. Spray Adv. Sci. Appl. Technol., 2003, 2003, p 5-8
W.B. Choi, L. Li, V. Luzin, R. Neiser, T. Gnaupel-Herold, H.J. Prask, S. Sampath, and A. Gouldstone, Integrated Characterization of Cold Sprayed Aluminum Coatings, Acta Mater., 2007, 55(3), p 857-866
S. Kuroda, M. Watanabe, K. Kim, and H. Katanoda, Current Status and Future Prospects of Warm Spray Technology, J. Therm. Spray Technol., 2011, 20(4), p 653-676
A. Savarimuthu, H. Taber, I. Megat, J. Shadley, E. Rybicki, W. Cornell, W. Emery, D. Somerville, and J. Nuse, Sliding Wear Behavior of Tungsten Carbide Thermal Spray Coatings for Replacement of Chromium Electroplate in Aircraft Applications, J. Therm. Spray Technol., 2001, 10(3), p 502-510
J. Kawakita, T. Fukushima, S. Kuroda, and T. Kodama, Corrosion Behaviour of HVOF Sprayed SUS316L Stainless Steel in Seawater, Corros. Sci., 2002, 44(11), p 2561-2581
P.D. Eason, J.A. Fewkes, S.C. Kennett, T.J. Eden, K. Tello, M.J. Kaufman, and M. Tiryakioğlu, On the Characterization of Bulk Copper Produced by Cold Gas Dynamic Spray Processing in as Fabricated and Annealed Conditions, Mater. Sci. Eng. A, 2011, 528(28), p 8174-8178
M. B. Beardsley, and J. L. Sebright, Structurally Integrated Coatings for Wear and Corrosion, 2008, No. DOE/GO14037
C. Weyant and S. Sampath, Engineered Thermal Spray Coatings for Bridge Repair and Reclamation, Adv. Mater. Process., 2011, 169(5), p 64-65
M. Jackson, J. Rairden, J. Smith, and R. Smith, Production of Metallurgical Structures by Rapid Solidification Plasma Deposition, JOM, 1981, 33(11), p 23-27
K. Murakami, H. Asako, T. Okamoto, and Y. Miyamoto, Microstructure and Mechanical Properties of Rapidly Solidified Deposited Layers of Fe-C-Cr Alloys Produced by Low Pressure Plasma Spraying, Mater. Sci. Eng. A, 1990, 123(2), p 261-270
S. Sampath, R. Gansert, and H. Herman, Plasma-Spray Forming Ceramics and Layered Composites, JOM, 1995, 47(10), p 30-33
R. Tiwari, S. Sampath, B. Gudmundsson, G. Halada, C. Clayton, and H. Herman, Microstructure and Tensile Properties of L12—Type Ni-Cr-Al Alloy Prepared by Vacuum Plasma Spray Forming, Scr. Metall. Mater., 1995, 33(7), p 1159-1162
A. Valarezo, W.B. Choi, W.G. Chi, A. Gouldstone, and S. Sampath, Process Control and Characterization of NiCr Coatings by HVOF-DJ2700 System: A Process Map Approach, J. Therm. Spray Technol., 2010, 19(5), p 852-865
S. Kuroda and T. Clyne, The Quenching Stress in Thermally Sprayed Coatings, Thin Solid Films, 1991, 200(1), p 49-66
G. Dwivedi, T. Wentz, S. Sampath, and T. Nakamura, Assessing Process and Coating Reliability Through Monitoring of Process and Design Relevant Coating Properties, J. Therm. Spray Technol., 2010, 19(4), p 695-712
S. Kuroda, T. Fukushima, and S. Kitahara, Simultaneous Measurement of Coating Thickness and Deposition Stress During Thermal Spraying, Thin Solid Films, 1988, 164, p 157-163
Y.C. Tsui and T.W. Clyne, An Analytical Model for Predicting Residual Stresses in Progressively Deposited Coatings. 1. Planar Geometry, Thin Solid Films, 1997, 306(1), p 23-33
J. Matejicek and S. Sampath, In Situ Measurement of Residual Stresses and Elastic Moduli in Thermal Sprayed Coatings—Part 1: Apparatus and Analysis, Acta Mater., 2003, 51(3), p 863-872
T. Varis, T. Suhonen, A. Ghabchi, A. Valarezo, S. Sampath, X. Liu, and S.-P. Hannula, Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps, J. Therm. Spray Technol., 2016, 23, p 1-10
S. Kuroda, Y. Tashiro, H. Yumoto, S. Taira, H. Fukanuma, and S. Tobe, Peening Action and Residual Stresses in High-Velocity Oxygen Fuel Thermal Spraying of 316L Stainless Steel, J. Therm. Spray Technol., 2001, 10(2), p 367-374
T. Suhonen, T. Varis, S. Dosta, M. Torrell, and J. Guilemany, Residual Stress Development in Cold Sprayed Al, Cu and Ti Coatings, Acta Mater., 2013, 61(17), p 6329-6337
J. Matejicek, S. Sampath, D. Gilmore, and R. Neiser, In Situ Measurement of Residual Stresses and Elastic Moduli in Thermal Sprayed Coatings—Part 2: Processing Effects on Properties of Mo Coatings, Acta Mater., 2003, 51(3), p 873-885
S. Sampath, V. Srinivasan, A. Valarezo, A. Vaidya, and T. Streibl, Sensing, Control, and In Situ Measurement of Coating Properties: An Integrated Approach Toward Establishing Process-Property Correlations, J. Therm. Spray Technol., 2009, 18(2), p 243-255
A. Valarezo and S. Sampath, An Integrated Assessment of Process-Microstructure-Property Relationships for Thermal-Sprayed NiCr Coatings, J. Therm. Spray Technol., 2011, 20(6), p 1244-1258
S. Sampath and H. Herman, Rapid Solidification and Microstructure Development During Plasma Spray Deposition, J. Therm. Spray Technol., 1996, 5(4), p 445-456
Acknowledgment
This research was supported through funding by the Innovations Deserving Exploratory Analysis (IDEA) program of the Transportation Research Board of the National Academy of Sciences, managed by Dr. I. Jawed (NCHRP IDEA 155). The authors also acknowledge support from the Stony Brook’s Industrial Consortium for Thermal Spray Technology.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Vackel, A., Nakamura, T. & Sampath, S. Mechanical Behavior of Spray-Coated Metallic Laminates. J Therm Spray Tech 25, 1009–1019 (2016). https://doi.org/10.1007/s11666-016-0404-x
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-016-0404-x