Purpose The purpose of this paper is to propose cold spraying and laser cladding processes as alternatives to cadmium and chromium electroplating, respectively. There are many substances or chemicals within the coating technology that can be identified as substances of very high concern because of their carcinogenic or mutagenic nature. Cadmium and chromium undoubtedly belong to these items and are the basic constituents of electrolytic coating processes. Finding an alternative and adapting to the existing restrictions of the usage of such hazardous products stands for many to be or not to be in the market. Design/methodology/approach The research work was focused on down selecting the appropriate materials, producing the coating samples, testing their properties and optimizing process parameters by statistical method. On the one hand, the high-pressure cold spray system and spraying of the titanium coating on the landing gear component, and on the other hand, the high-energy laser cladding facility and the wear resistant cobalt-based coating deposited onto the shock absorber piston. Substrates of these two applications were made of the same material, 4330 – high-strength low-carbon steel. Findings Meeting the requirements of Registration, Evaluation, Authorization and Restriction of Chemicals implies undertaking research and implementation work to identify alternative processes. The work provides the technical characteristics of new coatings justifying application readiness of the researched processes. Originality/value Taguchi’s design of experiment method was combined with the measurements and analysis of specified coating properties for the optimization of the cold spray process parameters. There is also laser cladding process development presented as a fast rate technology generating coatings with the unique properties.
In this research, the cold spray process as an additive manufacturing method was applied to deposit thick titanium coatings onto 7075 aluminium alloy. An analysis of changes in the microstructure and mechanical properties of the coatings depending on the standoff distance was carried out to obtain the maximum deposition efficiency. The process parameters were selected in such a way as to ensure the spraying of irregular titanium powder at the highest velocity and temperature and changing the standoff distance from 20 to 100 mm. Experimental studies demonstrated that the standoff distance had a significant effect on the microstructure of the coatings and their adhesion. Moreover, its rise significantly increased the deposition efficiency. The standoff distance also significantly affected the coating microstructure and their adhesion to the substrate, but did not cause any changes in their phase composition. The standoff distance also influenced the coating porosity, which first decreased to a minimum level of 0.2% and then increased significantly to 9.8%. At the same time, the hardness of the coatings increased by 30%. Numerical simulations confirmed the results of the tests.
The article presents the results of corrosion resistance tests of cold-sprayed aluminum coatings onto 4330 steel and Al 7075 aluminum alloy. The coatings were sub-jected to corrosion tests in a salt chamber.The obtained coatings are characterized by low porosity and very good anticorrosion properties.
The aluminum alloy Al7075 is commonly used in aircraft industry due to its high mechanical resistance to weight ratio. Nevertheless when the structure is being serviced upon the severe environmental conditions or loads degradation mechanisms could often been found in the material. To improve its behavior the cold spray process with various titanium powders (e.g. CP Ti, Ti-64) deposited onto Al7075 was investigated. The spraying of angular titanium powder was performed in the presence of nitrogen and helium supplied at process parameters (temperature, pressure), which were the maximum values attainable by the CS system used. The deposits were sprayed while maintaining a standoff distance in the range from 20 to 100 mm increased by 10 mm. The experimental data indicated that the deposition efficiency had increased significantly with increasing standoff distance. The coating porosity first decreased to minimum 0.6% and then increased significantly to 9.8%. The mechanical properties of the coatings reached the highest values when the porosity was minimum. No new phases were reported in the cold sprayed titanium coatings when compared with the starting feedstock. The same process parameters were transferred to Ti6Al-4V coral like powder deposition process. The shear strength between Ti coating material and Al7075 substrate was measured. Additionally the tensile strength of the deposit only, previously disintegrated from the substrate, was checked out. The data obtained indicate that the consolidation of Ti powder with Al7075 substrate made by cold spray could be served for both: materials integration and building a component by materials disintegration, where Al substrate is removed on spraying and machining; and simply used as a technological support for additive manufacturing of a self-standing real life component.
The work concerns a study of the properties of cold sprayed Ti coatings. This material is an attractive choice for many applications because it exhibits high strength-to-weight ratios, very good oxidation resistance, corrosion resistance and biocompatibility. Cold spraying is applied to deposit Ti coatings and elements as additive manufacturing process, however it needs higher critical velocity for deposition than other, more ductile metals. Nowadays nitrogen as cheap gas is used as working gas in cold spray process, however application helium as accelerating gas allows to obtain elements with higher strength. It allows to understand the mechanism of cohesion between sprayed particles. In carried out experiment Ti powder with angular shape was applied in the cold spraying process. The coatings were sprayed by means of Impact Innovations 5/8 system with nitrogen and addition of helium onto 7075 Al alloy. The investigations revealed that the cold sprayed Ti coatings with addition of helium as working gas exhibit better mechanical properties, lower porosity and roughness.
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