Effects of processing on microstructure evolution and fatigue crack growth mechanisms in cold-spray 6061 aluminum alloy

Gavras, Anastasios G.; Lados, Diana A.; Champagne, Victor K.; Warren, Robert J.

doi:10.1016/j.ijfatigue.2018.01.006

Cited by 54 publications

(23 citation statements)

References 28 publications

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“…Furthermore, annealing increased ductility and diffusion occurred at the particle boundaries. Similarity, resistance to fatigue crack growth was increased with annealing [1]. In our study, the coating hardnesses were at a similar level as they were in the previous study, where the coatings were sprayed with laser-assisted cold spraying.…”

Section: Cold-sprayed Al6061 Coatings-mechanical Propertiessupporting

confidence: 86%

“…Hardness of cold-sprayed Al6061 coatings were much higher than Al6061-T4 but slightly lower than Al6061-T6, meaning that during the cold spray processing, high mechanical properties can be achieved without the need of an addition post-treatment such as annealing. Gavras et al [1] have produced Al6061 coatings with cold spraying by using He as the process gas. They achieved hardness for the as-sprayed coating as high as 105 HV 100 .…”

Section: Cold-sprayed Al6061 Coatings-mechanical Propertiesmentioning

confidence: 99%

“…For example, corrosion resistance, electrical conductivity, wear resistance, functional properties, and repairing possibilities are application fields for cold-sprayed coatings. Especially, for corrosion protection and repairing possibilities, Al and Al-based alloy coatings have received a lot of interest due to their good material properties and high suitability for cold spraying as the feedstock materials [1][2][3][4][5]. In cold spraying, low melting point materials such as Al alloys can be sprayed without oxidation.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Koivuluoto

Larjo²,

Marini

et al. 2020

Coatings

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Process optimization and quality control are important issues in cold spraying and coating development. Because the cold spray processing is based on high kinetic energy by high particle velocities, online spray monitoring of particle inflight properties can be used as an assisting process tool. Particle velocities, their positions in the spray jet, and particle size measurements give valuable information about spraying conditions. This, in turn, improves reproducibility and reliability of coating production. This study focuses on cold spraying of Al6061 material and the connections between particle inflight properties and coating characteristics such as structures and mechanical properties. Furthermore, novel 2D velocity scan maps done with the HW CS2 online spray monitoring system are presented as an advantageous powder and spray condition controlling tool. Cold spray processing conditions were similar using different process parameters, confirmed with the online spray monitoring prior to coating production. Higher particle velocities led to higher particle deformation and thus, higher coating quality, denser structures, and improved adhesions. Also, deposition efficiency increased significantly by using higher particle velocities.

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Section: Cold-sprayed Al6061 Coatings-mechanical Propertiessupporting

confidence: 86%

Section: Cold-sprayed Al6061 Coatings-mechanical Propertiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Koivuluoto

Larjo²,

Marini

et al. 2020

Coatings

View full text Add to dashboard Cite

show abstract

“…Combining the data in table 3 with that in figures 3(f)-(j), it can be seen that with increasing size of the highaluminum bronze particle in the sprayed powder, the micro cracks in the obtained coating are more obvious, as indicated by the yellow areas in figure 4. The smaller the particle velocity during cold spray, the greater the stress in the coating and the concentration [17], which leads to crack propagation [18]. Therefore, under the same spraying conditions, the low kinetic energy of the high-aluminum bronze particle having large particle size results in stress concentration and the larger the crack.…”

Section: ( )mentioning

confidence: 99%

Effect of powder particle size on microstructure and properties of low pressure cold sprayed high aluminium bronze coating

Feng

et al. 2020

Mater. Res. Express

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AbstrasctHigh-aluminum bronze alloy powder was mixed with 16 wt% Al 2 O 3 powder to prepare low-pressure gas dynamic spray coatings with different sized powder particles. The mechanical properties of coatings were tested and the surface, cross section and stretch section of coatings were observed by scanning electron microscopy. Uniform experiment was performed to analyze the effects of particle size of the high-aluminum bronze and Al 2 O 3 powder on coating performance. Experimental results shows that the degree of deformation of the high-aluminum bronze particle in the coating increased with decreasing particle size in the high-aluminum bronze and Al 2 O 3 in the mixed powder. The degree of deformation of the high-aluminum bronze particle in the coating affected the mechanical properties of the coating showing a linear relationship between powder size and coating performance. When the particle size of Al 2 O 3 and high-aluminum bronze particle ranged between 23-25 μm, the coating has the outstanding mechanical properties. OPEN ACCESS RECEIVED

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“…A previous study by the authors investigated the long fatigue crack growth mechanisms in bulk deposited cold-spray 6061 aluminum. [24] This study was designed to expand the previous work by examining the microstructurally small to physically small fatigue crack growth behavior in bulk cold-spray 6061 deposits, as well as cold-spray 6061 coatings on substrates. Thus, the controlling fatigue crack growth mechanisms in early stages are determined, and the strength at the coating-substrate interface is investigated.…”

Section: Introductionmentioning

confidence: 99%

Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings

Gavras

Champagne

Warren

et al. 2018

Metall Mater Trans A

Self Cite

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Cold-spray-processed aluminum alloys have static mechanical properties superior to those of aerospace cast alloys, and similar to those of their wrought counterparts, making them good candidates for structural applications. However, their broad and confident use relies upon systematic fatigue crack growth studies to investigate and demonstrate the materials' performance in critical high-integrity components. In this work, the fatigue crack growth behavior in early stages (small crack growth regime) was investigated for cold-spray processed 6061 aluminum alloys and coatings, at stress ratio R = 0.1, in room temperature laboratory air. The effects of the characteristic microstructure and initial flaw size on the fatigue crack growth response were systematically examined, and the crack growth mechanisms at the microstructural scale were established and compared to those of long cracks. The mechanical interfacial stability of coatings was examined in cold-spray 6061-rolled 6061-T6 couples. An original method of quantifying the deposition-substrate interfacial strength, and correlating it to the response under cyclic loading via crack-interface stability maps, was developed. The proposed methodology is based on combined scratch testing and fracture mechanics formulations, and failure at the coating-substrate interface can be predicted for any crack growth scenario under cyclic loading. The method can be broadly used for the design and optimization of cold-spray and other coatings, as well as in structural repair.

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Effects of processing on microstructure evolution and fatigue crack growth mechanisms in cold-spray 6061 aluminum alloy

Cited by 54 publications

References 28 publications

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Effect of powder particle size on microstructure and properties of low pressure cold sprayed high aluminium bronze coating

Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings

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