Modeling of Erosion Response of Cold-Sprayed In718-Ni Composite Coating Using Full Factorial Design

Abstract

In this work, the cold-spray technique was used to deposit Inconel 718–nickel (1:1) composite coatings on stainless steel substrate. A general full factorial design was adopted to identify the statistically significant operating variables, i.e., impingement angle, erodent size, and feed rate on the coating erosion response. Erodent feed rate, impingement angle, and the interaction between impingement angle and erodent size were identified as the highly significant variables on the erosion rate. Then, a model correlating the identified variables with the erosion rate was derived. The best combination of control variables for minimum erosion loss with respect to erodent feed rate, erodent size, and impingement angle was 2 mg/min, 60 μm, and 90°, respectively. To analyze the erosion mechanism, the erodent samples were finally observed using Scanning Electron Microscope (SEM).

Study on the Effect of Powder-Bed Fusion Process Parameters on the Quality of as-Built IN718 Parts Using Response Surface Methodology

“…The compositional analysis using XRD revealed the presence of γ, γ', and γ" phases in the as-built specimens. For example, the γ" of the samples decreased from 19.06% to 13.60% as the energy decreased from Ev = 91.6 J/mm 3 to Ev = 75.0 J/mm 3 as the scan speed increased from 1056 mm/s to 864 mm/s. As the energy density increases, the Nb present in the IN718 alloy forms precipitates (Ni 3 Nb), which is the strength-hardening phase.…”

“…With the help of Table 4, it can be observed that the width of the fabricated IN718 as-built samples increases with an increase in the amount of energy density applied similar to the trend seen in the length of the samples. For example, the width of the samples increased from 4.993 mm to 5.000 mm as the energy density increased from Ev = 57.8 J/mm 3 to Ev = 67.5 J/mm 3 as the scan speed decreased from 1121.5 mm/s to 960 mm/s. This deviation in length and width can be attributed to the influence of various process parameters on the energy density of the specimens.…”

“…IN718, with an exceptional weldability property, is found to be indifferent to strain-age cracking. IN718 has the ability to maintain good chemical and mechanical properties at high temperatures, and the working temperature of IN718 is between −257 • C to 704 • C [3]. IN718 is also known for its corrosion-resistance properties, creep-resistance behavior, and high strength [4].…”

Review of Application and Research Based on Cold Spray Coating Materials

“…Regarding the application of Ni as a spray material in cold spray technology, Elisa [23] and other researchers used Inconel 718-Ni (1: 1) as a spray material, and used high-pressure cold spray technology with Nitrogen as an accelerating medium on stainless steel substrates. In the coating, only 30 wt % of Inconel 718 was retained in the coating.…”

Wear-Fatigue Study of Carbon Steels

“…Erosive wear is frequently caused by the impact of solid particles entrained in a gas or liquid stream. Another form of erosion is caused by the impact of liquid droplets onto material surface [6][7][8]. The site of solid particle impact experiences high stresses and strains.…”