On the evolution of substrate's residual stress during cold spray process: A parametric study

Marzbanrad, Bahareh; Jahed, Hamid; Toyserkani, Ehsan

doi:10.1016/j.matdes.2017.10.062

Cited by 51 publications

(20 citation statements)

References 28 publications

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“…Also, columnar grains were detected in the interfacial region ( Figure 4a). A similar type of TEM microstructure obtained through CS of the AZ31B alloy was reported in [46].…”

Section: Tensile and Corrosion-fatigue Testingsupporting

confidence: 79%

“…Also, columnar grains were detected in the interfacial region ( Figure 4a). A similar type of TEM microstructure obtained through CS of the AZ31B alloy was reported in [46]. Figure 3 shows the SEM micrographs of the polished cross-section of the specimens e-painted on the substrate and CS AA7075.…”

Section: Tensile and Corrosion-fatigue Testingsupporting

confidence: 71%

“…Usually, small grains positively affect the corrosion resistance in NaCl corrosive media by forming a uniform passive film [62]. Moy et al [63] and others [46,64] identified a significant grain refinement through dynamic recrystallization in the CS metallic coatings. In CS coatings, the refined grains were identified at the coating/substrate interface (as seen in Figure 4), which is limited.…”

Section: Grain Refinement and Dislocation Densitymentioning

confidence: 99%

“…Compressive residual stresses also play a role in the corrosion resistance specifically the pits formation. The residual stresses are formed in CS coatings because of peening effect by higher particle impact velocity [27] and the thermal expansion mismatch of the coating and the substrate [46]. As the impact velocity and carrier gas temperature are very high, the striking of the CS coating particles on the AZ31B substrate induced plastic deformation due to the adiabatic shear instability adjacent to the surface of the impacted particles, resulting in the formation of residual stress [20,59,70].…”

Section: Residual Stressmentioning

confidence: 99%

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Improving Corrosion and Corrosion-Fatigue Resistance of AZ31B Cast Mg Alloy Using Combined Cold Spray and Top Coatings

et al. 2018

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In this paper, we report the application of zinc phosphate electrostatic-painting top coating on cold sprayed AA7075 leading to a significant improvement in corrosion-fatigue performance. High strength AA7075 powder was sprayed on AZ31B substrate, followed by the application of the top coating. The electrochemical corrosion and corrosion-fatigue tests of the coated and uncoated specimens were performed in 3.5% NaCl solution. Transmission electron microscopy (TEM) analysis showed that a continuous nanolayered mixture of Mg/Al was formed at the cold spray coating/substrate interface leading to high bonding strength. The results showed that the combined coatings improved the corrosion resistance remarkably, and significantly increased the fatigue life, with a fatigue strength of 80 MPa at 107 cycles, as compared to the as-cast specimen. Surface topographic analysis of the corrosion-fatigue-tested specimens demonstrated the presence of deep macro-pits on the cold sprayed AA7075 coating after 3.7 million cycles, while there were no such pits on the top-coated specimens, even after 107 cycles when tested at 30 Hz. The fractographic analysis of the fatigue-fractured specimens showed that the formation of pits allowed the NaCl solution to penetrate in the AZ31B substrate, creating localized corrosion pits resulting in premature failure, which eventually reduced the fatigue life.

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“…Also, columnar grains were detected in the interfacial region ( Figure 4a). A similar type of TEM microstructure obtained through CS of the AZ31B alloy was reported in [46].…”

Section: Tensile and Corrosion-fatigue Testingsupporting

confidence: 79%

Section: Tensile and Corrosion-fatigue Testingsupporting

confidence: 71%

Section: Grain Refinement and Dislocation Densitymentioning

confidence: 99%

Section: Residual Stressmentioning

confidence: 99%

See 2 more Smart Citations

Improving Corrosion and Corrosion-Fatigue Resistance of AZ31B Cast Mg Alloy Using Combined Cold Spray and Top Coatings

et al. 2018

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“…In contrast, the surface modified samples show significantly higher YS values of 110 MPa where the coating surface was delaminated and cracked (marked by red arrow). The obtained higher YS was basically due the combination of peening effect, covering of porosity and higher strength of coating materials as mentioned in [7,23]. There were many studies reported the tensile fracture surface of the AZ31B alloys; e.g., [10].…”

Section: Behavior Of Coating In Tensile Loadingmentioning

confidence: 85%

Fatigue life enhancement of cast Mg alloy by surface modification in cold spray process

2018

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Abstract. To improve the fatigue life of Mg alloy, high strength AA7075 spherical powder was deposited on AZ31B samples in nitrogen carrier gas environment at 400°C temperature in cold spray process followed by electrostatic painting with zinc phosphate. The fully reverse four-point rotating-bending fatigue tests were conducted on the coated and uncoated samples in different environmental conditions. It is seen that the cold sprayed AA7075 improved the yield strength of the AZ31B cast alloy. Similarly, a significant fatigue enchantment was observed in the coated samples, reaching a fatigue strength of 90 MPa compared to as-cast fatigue strength of 70 MPa at 10 7 cycles when tested in air, and fatigue strength of 80 MPa under a 3.5%NaCl testing environment. The SEM analysis at the interface of the tensile tested sample exhibited the interfacial fracture followed by delamination of the coating. Similarly, delamination of coating was merely detected in the fatigue fracture sample tested in the air, while the sample tested in the corrosive environment showed pits which allowed the solution to penetrate in the AZ31B substrate results delamination and premature failure. However, the presence of e-paint forms a passive layer which is hindering the pit formation and extending the fatigue life.

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Residual Stress in Engineering Materials: A Review

et al. 2021

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The accurate determination of residual stresses has a crucial role in understanding the complex interactions between microstructure, mechanical state, mode(s) of failure, and structural integrity. Moreover, the residual stress management concept contributes to industrial applications, aiming to improve the product's service performance and life cycle. In this regard, the industry requests rapid, efficient, and modern methods to identify and control the residual stress state. This review article contains three main sections. The first section covers different residual stress determination methods and reports the advancements over the recent decade. The second section includes the role of residual stresses in the performance of a broad range of materials including metallic alloys, polymers, ceramics, composites, and biomaterials. This is presented by classifying different science areas dealing with residual stresses into two main groups, including “origins” and “effects” of residual stresses. The range of topics covered are “welding, machining, curing/cooling, and spray coating processes,” “medical and dental sciences,” and “fatigue and fracture mechanisms.” The third section summarizes various strategies to effectively control residual stresses through different manufacturing procedures. It is hoped that the data provided herein serves as a valuable up‐to‐date reference for engineers and scientists in the field of residual stress.

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On the evolution of substrate's residual stress during cold spray process: A parametric study

Cited by 51 publications

References 28 publications

Improving Corrosion and Corrosion-Fatigue Resistance of AZ31B Cast Mg Alloy Using Combined Cold Spray and Top Coatings

Improving Corrosion and Corrosion-Fatigue Resistance of AZ31B Cast Mg Alloy Using Combined Cold Spray and Top Coatings

Fatigue life enhancement of cast Mg alloy by surface modification in cold spray process

Residual Stress in Engineering Materials: A Review

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