Skip to main content
SpringerLink
Log in

Peening Effect of Glass Beads in the Cold Spray Deposition of Polymeric Powders

  • PEER REVIEWED
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Cold spray is a green additive manufacturing method that accelerates micron-size particles to supersonic speeds. At these high speeds, the particles deposit upon impact with a desired surface. High-density polyethylene, polyurethane, polyamide-12, polystyrene, and ultra-high molecular weight polyethylene particles were cold-sprayed onto a low-density polyethylene substrate under different process conditions. Glass beads with diameters between 20 and 120 µm were added to each batch to study the effect of non-adhesive peening particles on the deposition efficiency and the quality of the final deposited layer of a series different polymeric powders. The successful deposition window was compared for the cold spray process with and without the addition of glass beads. Adding the glass beads to the polymer powders was found to widen the successful windows of deposition to both higher and lower impact velocities at a given temperature for all the polymer powder studied. In addition, adding peening particles were found to make deposition possible at lower particle temperatures where deposition had not been successful previously. This was especially important for ultra-high molecular weight polyethylene particles for which deposition in the absence of peening particles was not possible below 60 °C, but with peening particles was successful even at room temperature. Peening particles were found to increase deposition efficiency by as much as 50% for a given set of deposition conditions. The appropriate size of the added glass beads to maximize the deposition efficiency was found to be comparable to the size of the depositing particles. The addition of glass beads was also found to reduce the surface roughness of the deposited layer by more than 50%. Finally, for processing conditions with particle velocities below a Mach number of one, no glass beads were found to adhere to the resulting cold-sprayed substrates.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. F.S. da Silva, N. Cinca, S. Dosta, I.G. Cano, J.M. Guilemany, C.S.A. Caires, A.R. Lima, C.M. Silva, S.L. Oliveira, A.R.L. Caires, and A.V. Benedetti, Corrosion Resistance and Antibacterial Properties of Copper Coating Deposited by Cold Gas Spray, Surf. Coat. Technol., 2019, 361, p 292-301

    Article  Google Scholar 

  2. A. Papyrin, V. Kosarev, S. Klinkov, A. Alkhimov, and V.M. Fomin, Cold Spray Technology, Elsevier, Amsterdam, 2007

    Google Scholar 

  3. T.P. Bush, Z. Khalkhali, V.K. Champagne, D.P. Schmidt, and J.P. Rothstein, Optimization of Cold Spray Deposition of High-Density Polyethylene Powders, Therm. Spray Technol., 2017, 26(7), p 1548-1564

    Article  CAS  Google Scholar 

  4. Z. Khalkhali, W. Xie, V.K. Champagneb, J.-H. Lee, and J.P. Rothstein, A Comparison of Cold Spray Technique to Single Particle Micro-ballistic Impacts for the Deposition of Polymer Particles on Polymer Substrates, Surf. Coat. Technol., 2018, 351, p 99-107

    Article  CAS  Google Scholar 

  5. A. Astarita, L. Boccarusso, M. Durante, A. Viscusi, R. Sansone, and L. Carrino, Study of the Production of a Metallic Coating on Natural Fiber Composite Through the Cold Spray Technique, Mater. Eng. Perform., 2018, 27(2), p 739-750

    Article  CAS  Google Scholar 

  6. G. Archambault, B. Jodoin, S. Gaydos, and M. Yandouzi, Metallization of Carbon Fiber Reinforced Polymer Composite by Cold Spray and Lay-Up Molding Processes, Surf. Coat. Technol., 2016, 300, p 78-86

    Article  CAS  Google Scholar 

  7. 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

    Article  CAS  Google Scholar 

  8. M. Gardon, A. Latorre, M. Torrell, S. Dosta, J. Fernandez, and J.M. Guilemany, Cold Gas Spray Titanium Coatings Onto a Biocompatible Polymer, Mater. Lett., 2013, 106, p 97-99

    Article  CAS  Google Scholar 

  9. A.M. Vilardell, N. Cinca, A. Concustell, S. Dosta, I.G. Cano, and J.M. Guilemany, Cold Spray as an Emerging Technology for Biocompatible and Antibacterial Coatings: State of Art, Mater. Sci., 2015, 50, p 4441-4462

    Article  CAS  Google Scholar 

  10. X. Zhou and P. Mohanty, Electrochemical Behavior of Cold Sprayed Hydroxyapatite/Titanium Composite in Hanks’ Solution, Electrochim. Acta, 2012, 65, p 134-140

    Article  CAS  Google Scholar 

  11. N. Cinca, A.M. Vilardell, S. Dosta, A. Concustell, I. Garcia Cano, J.M. Guilemany, S. Estrade, A. Ruiz, and F. Peiro, A New Alternative for Obtaining Nanocrystalline Bioactive Coatings: Study of Hydroxyapatite Deposition Mechanisms by Cold Gas Spraying, Am. Ceram. Soc., 2016, 99, p 1420-1428

    Article  CAS  Google Scholar 

  12. M. Robotti, S. Dosta, C. Fernandez-Rodriguez, M.J. Hernandez-Rodriguez, I.G. Cano, E.P. Melian, and J.M. Guilemany, Photocatalytic Abatement of NOx by CTiO2/Polymer Composite Coatings Obtained by Low Pressure Cold Gas Spraying, Appl. Surf. Sci., 2016, 362, p 274-280

    Article  CAS  Google Scholar 

  13. L. Wang, F. Wang, S. Li, and Y. Wang, Microstructure and Application of Alumina-Supported Cu-Based Coating Prepared by Cold Spray, Surf. Coat. Technol., 2019, 362, p 113-123

    Article  CAS  Google Scholar 

  14. M.J. Vucko, P.C. King, A.J. Poole, Y. Hu, M.Z. Jahedi, and R. de Nys, Assessing the Antifouling Properties of Cold-Spray Metal Embedment Using Loading Density Gradients of Metal Particles, Biofouling, 2014, 30, p 651-666

    Article  CAS  Google Scholar 

  15. C. Stenson, K.A. McDonnell, S. Yin, B. Aldwell, M. Meyer, D.P. Dowling, and R. Lupoi, Cold Spray Deposition to Prevent Fouling of Polymer Surfaces, Surf. Eng., 2018, 34(3), p 1-11

    Article  Google Scholar 

  16. H. Che, P. Vo, and S. Yue, Investigation of Cold Spray on Polymers by Single Particle ImpactExperiments, Therm. Spray Technol., 2019, 28, p 135-143

    Article  Google Scholar 

  17. P.A. Podrabinnik and I.V. Shishkovsky, Laser Post Annealing of Cold-Sprayed Al-Ni Composite Coatings for Green Energy Tasks, Procedia IUTAM, 2017, 23, p 108-113

    Article  Google Scholar 

  18. F. Robitaille, M. Yandouzi, S. Hind, and B. Jodoin, Metallic Coating of Aerospace Carbon/Epoxy Composites by the Pulsed Gas Dynamic Spraying Process, Surf. Coat. Technol., 2009, 203(19), p 2954-2960

    Article  CAS  Google Scholar 

  19. H. Che, M. Gagne, P.S.M. Rajesh, J.E. Sapieha, F. Sirois, D. Therriault, and S. Yue, Metallization of Carbon Fibre Reinforced Polymer for Lightning Strike Protection, Mater. Eng. Perform., 2018, 27(10), p 5205-5211

    Article  CAS  Google Scholar 

  20. H. Che, P. Vo, and S. Yue, Metallization of Carbon Fibre Reinforced Polymers by Cold Spray, Surf. Coat. Technol., 2017, 313, p 236-247

    Article  CAS  Google Scholar 

  21. H. Che, X. Chu, P. Vo, and S. Yue, Cold Spray of Mixed Metal Powders on Carbon Fibre Reinforced Polymers, Surf. Coat. Technol., 2017, 329, p 232-243

    Article  CAS  Google Scholar 

  22. J. Affi, H. Okazaki, M. Yamada, and M. Fukumoto, Fabrication of Aluminum Coating onto CFRP Substrate by Cold Spray, Mater. Trans., 2011, 52(9), p 1759-1763

    Article  CAS  Google Scholar 

  23. P.S.M. Rajesh, F. Sirois, and D. Therriault, Damage Response of Composites Coated with Conducting Materials Subjected to Emulated Lightning Strikes, Mater. Des., 2018, 139, p 45-55

    Article  CAS  Google Scholar 

  24. R. Kromer, Y. Danlos, E. Aubignat, C. Verdy, and S. Costil, Coating Deposition and Adhesion Enhancements by Laser Surface Texturing—Metallic Particles on Different Classes of Substrates in Cold Spraying Process, Mater. Manuf. Process., 2017, 32(14), p 164

    Article  Google Scholar 

  25. B.K. Pant, A.H.V. Pavan, R.V. Prakash, and M. Kamaraj, Effect of Laser Peening and Shot Peening on Fatigue Striations During FCGR Study of Ti6Al4 V, Int. J. Fatigue, 2016, 93, p 38-50

    Article  CAS  Google Scholar 

  26. G.-Q. Chen, Y. Jiao, T.-Y. Tian, X.-H. Zhang, Z.-Q. Li, and W.-L. Zhou, Effect of Wet Shot Peening on Ti-6Al-4 V Alloy Treated by Ceramic Beads, Trans. Nonferrous Metals Soc. China, 2014, 24, p 690-696

    Article  CAS  Google Scholar 

  27. R. Ramos, N. Ferreira, J.A.M. Ferreira, C. Capela, and A.C. Batista, Improvement in Fatigue Life of Al 7475-T7351 Alloy Specimens by Applying Ultrasonic and Microshot Peening, Int. J. Fatigue, 2016, 92, p 87-95

    Article  CAS  Google Scholar 

  28. H. Kovaci, Y.B. Bozkurt, A.F. Yetim, M. Aslan, and A. Celik, The Effect of Surface Plastic Deformation Produced by Shot Peening on Corrosion Behavior of a Low-Alloy Steel, Surf. Coat. Technol., 2019, 360, p 78-86

    Article  CAS  Google Scholar 

  29. Q. Wu, D.-J. Xie, Z.-M. Jia, Y.-D. Zhang, and H.-Z. Zhang, Effect of Shot Peening on Surface Residual Stress Distribution of SiCp/2024Al, Compos. B, 2018, 154, p 382-387

    Article  CAS  Google Scholar 

  30. C. Wang, C. Jiang, F. Cai, Y. Zhao, K. Zhu, and Z. Chai, Effect of Shot Peening on the Residual Stresses and Microstructure of Tungsten Cemented Carbide, Mater. Des., 2016, 95, p 159-164

    Article  CAS  Google Scholar 

  31. A. Moridi, S.M. Hassani-Gangaraj, S. Vezzu, L. Trsko, and M. Guagliano, Fatigue Behavior of Cold Spray Coatings: The Effect of Conventional and Severe Shot Peening as Pre-/Post-treatment, Surf. Coat. Technol., 2015, 283, p 247-254

    Article  CAS  Google Scholar 

  32. 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

    Article  CAS  Google Scholar 

  33. H. Lee, H. Shin, S. Lee, and K. Ko, Effect of Gas Pressure on Al Coatings by Cold Gas Dynamic Spray, Mater. Lett., 2008, 62(10–11), p 1579-1581

    Article  CAS  Google Scholar 

  34. K. Ravi, T. Deplancke, K. Ogawa, J.-Y. Cavaille, and O. Lame, Understanding Deposition Mechanism in Cold Sprayed Ultra High Molecular Weight Polyethylene Coatings on Metals by Isolated Particle Deposition Method, Addit. Manuf., 2018, 21, p 191-200

    CAS  Google Scholar 

  35. Z. Khalkhali and J.P. Rothstein, Characterization of the Cold Spray Deposition of a Wide Variety of Polymeric Powders, Surf. Coat. Technol., 2019, 383, p 125251

    Article  Google Scholar 

  36. A.S. Alhulaifi, G.A. Buck, and W.J. Arbegast, Numerical and Experimental Investigation of Cold Spray Gas Dynamic Effects for Polymer Coating, Therm. Spray Technol., 2012, 21, p 852-862

    Article  CAS  Google Scholar 

  37. A. Shapiro, The Dynamics and Thermodynamics of Compressible Fluid Flow, The Ronald Press Company, New York, 1953

    Google Scholar 

  38. V.K. Champagne, D.J. Helfritch, S.P.G. Dinavahi, and P.F. Leyman, Theoretical and Experimental Particle Velocity in Cold Spray, Therm. Spray Technol., 2011, 20, p 425-431

    Article  CAS  Google Scholar 

Download references

Acknowledgments

This research was accomplished through a cooperative research agreement with the US Army Research Laboratory, Contract: W911NF-15-2-0024, P00003 ‘Intelligent Processing of Materials by Design.’ The authors would also like to thank Peter van Puyvelde of KU Leuven for kindly supplying us with the PS, PA, and PU powders used in this study. The contributions from Zimu Zhu who provided the AFM studies are also appreciated.

Author information

Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, University of Massachusetts, Amherst, MA, 01003, USA

    Zahra Khalkhali, Kashyap Sundara Rajan & Jonathan P. Rothstein

Authors
  1. Zahra Khalkhali
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kashyap Sundara Rajan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jonathan P. Rothstein
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zahra Khalkhali.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Appendix

Appendix

Figure 9 shows the optical microscopy of deposition of HDPE particles (a) on HDPE substrate with smooth surface and (b) on a roughened HDPE surface. The experiment of depositing HDPE particles on a smooth and a roughened surface of HDPE showed that the deposition efficiency was improved by 22% when depositing on a smooth surface compared to depositing on a rough surface of HDPE substrate. This information is not visible the optical images. Rather, the measurement was done by weighing the substrate before an after deposition to calculate the deposition efficiency. Therefore, as a response to the reviewer’s comment, we provided these images in the Appendix not in the results and discussion section.

Fig. 9
figure 9

Optical microscopy of deposition of HDPE particles (a) on HDPE substrate with smooth surface and (b) on a roughened HDPE surface

Full size image

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Khalkhali, Z., Rajan, K.S. & Rothstein, J.P. Peening Effect of Glass Beads in the Cold Spray Deposition of Polymeric Powders. J Therm Spray Tech 29, 657–669 (2020). https://doi.org/10.1007/s11666-020-01001-0

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-020-01001-0

Keywords

Search

Navigation