Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

Abstract

Copper-coated graphite and copper mixture powders were deposited on AZ31B magnesium alloy and 6061 T6 aluminum alloy substrates under different process parameters by a solid-state cold spray technique. The microstructure of the copper-coated graphite and copper composite coatings was visually examined using photographs taken with an optical microscope and a scanning electron microscope. The surface roughness of the coatings was investigated with a 3D profilometer. The thickness of the coatings was determined through the analysis of the microstructure images, while the adhesion of the coatings was characterized using the scratch test method. The results indicate that the surface roughness of the coatings sprayed on the two different substrates gradually decreases as gas temperature and gas pressure increase. Additionally, the thickness and adhesion of the coatings deposited on the two different substrates both increase with an increase in gas temperature and gas pressure. Comparing the surface roughness, thickness, and adhesion of the coatings deposited on the two different substrates, the surface roughness and adhesion of the coatings on the soft substrate are greater than those of the coatings on the hard substrate, while the thickness of the coatings is not obviously affected by the hardness of the substrate. Furthermore, it is noteworthy that the surface roughness, thickness, and adhesion of the copper-coated graphite and copper composite coatings sprayed on the two different substrates exhibit a distinct linear relationship with particle velocity.

3D fractal model with experimental analysis for assessing surface topography in EDM

“…Optimization algorithms will be link with the fractal model to fine-tune machining parameters automatically. Another approach is to extend the fractal model to the hybrid manufacturing combining additive and subtractive manufacturing such as EDM to analyze the phase transformation and mechanical properties [46,47]. These enhancements aim to establish the fractal model as a versatile tool for optimizing EDM processes and advancing precision manufacturing.…”

Machinability studies of Al–4Mg/in-situ MgAl2O4 nano composites: measurement of cutting forces and machined surface roughness

“…Studies have proved that the morphology of chips has a major role in defining the life of cutting tool and workpiece [36][37][38]. During the chip removal process, a part of the temperature removed is taken away with the thrown away chip and any variation in the formation of chip size and shape would affect the life of cutting tool and workpiece [39][40][41].…”

Multiscale Simulation of Microstructure Evolution during Preparation and Service Processes of Physical Vapor Deposited c-TiAlN Coatings

“…The microstructure of these raw coatings predominantly determines the performance of PVD coatings, while performance responses under service conditions for the coatings are influenced by the observed microstructure evolution. Enhancing the service performance of coatings [4,5] necessitates a thorough understanding of the coatings' microstructure, which is influenced by specific process parameters, and developing robust methodologies to monitor the patterns of microstructure evolution during the service process. Challenges are likely encountered in converting, merging, and transferring information across different scales because the transfer of multi-scale information is required to characterize the complete preparation and service processes, which are both time-intensive and costly.…”