Residual stress development in cold sprayed Al, Cu and Ti coatings

Suhonen, Tomi; Varis, Tommi; Dosta, S.; Torrell, Marc; Guilemany, J.M.

doi:10.1016/j.actamat.2013.06.033

Cited by 146 publications

(49 citation statements)

References 19 publications

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“…For example: Cu/Cu, Cu/Al, Al/Al, Al/Cu [5], Al/Mg, Al6061/Mg, Al7075/Mg [6]. (ii) Thermal mismatch dominant CS process, which is originated from quenching of the sprayed splats, owing to the different thermal contraction of the substrate and deposited material, and/or temperature gradient in multi-pass deposition process [6][7][8]10]. For example: Ti/Cu [21], Al/Mg [6].…”

Section: Mechanismsmentioning

confidence: 99%

“…Even though the experimental methods possess various advantages, modelling of residual stresses is an attractive alternative method as it is quicker, inexpensive, and allows parametric studies. Many researchers have used analytical methods [3][4][5][6][7][8][9][10][11], and numerical models [3,8,[11][12][13][14][15][16][17][18][19] for predicting residual stresses induced by the CS process.…”

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confidence: 99%

“…Most of the current analytical models are based on the bending deformation method (also known as the deflection method or curvature method) [3][4][5][6][7][8][9][10][11], originally developed for evaluating residual stresses in thin coatings (e.g. thermal spray coatings, electrolysis film deposits) or shot-peened parts.…”

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confidence: 99%

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Theoretical prediction of residual stresses induced by cold spray with experimental validation

Boruah

Zhang

Doré

2019

MMMS

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Purpose-This study aims to develop a simple analytical model for predicting the throughthickness distribution of residual stresses in a cold spray deposit-substrate assembly. Design/methodology/approach-Layer by layer build up of residual stresses induced by both the peening dominant and thermal mismatch dominant cold spray processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys.Findings-Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value-The proposed model provides a more thorough explanation of residual stress development mechanisms by the cold spray process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to cold spray process optimisation aiming at residual stress control.

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Section: Mechanismsmentioning

confidence: 99%

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confidence: 99%

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Theoretical prediction of residual stresses induced by cold spray with experimental validation

Boruah

Zhang

Doré

2019

MMMS

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“…Thus, the residual stress can be influenced by the heat input, spraying kinematics and the associated thermal history. Based on these factors, in addition to substrate and coating material properties and dimensions, the mean residual stress in the coating can be compressive or tensile [149,150].…”

Section: Residual Stressmentioning

confidence: 99%

Cold spraying – A materials perspective

et al. 2016

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Cold spraying is a solid-state powder deposition process with several unique characteristics, allowing production of coatings or bulk components from a wide range of materials. The process has attracted much attention from academia and industry over the past two decades.The technical interest in cold spraying is twofold: first as a coating process for applications in surface technology, and second as a solid-state additive manufacturing process, offering an alternative to selective laser melting or electron beam melting methods. Moreover, cold spraying can be used to study materials behaviour under extremely high strain rates, high pressures and high cooling rates. The cold spraying process is thus considered to be relevant for various industrial applications, as well as for fundamental studies in materials science.This article aims to provide an overview of the cold spray process, the current understanding of the deposition mechanisms, and the related models and experiments, from a materials science perspective. IntroductionCold spraying (CS) is a solid-state material deposition technique, where micron-sized particles of a powder bond to a substrate as a result of high-velocity impact and the associated severe plastic deformation. Acceleration of particles to high velocities is obtained via expansion of a pressurised and (ironically) 'hot' gas through a diverging-converging nozzle.Despite heating the process gas -which is to provide higher acceleration of the gas and also to facilitate particle deformation through thermal softening -the feedstock remains in the solid state throughout the entire process; hence the name 'cold' spraying. This is to underline the contrast to conventional thermal spraying where particles are completely or partially molten upon impact onto the substrate. Alternative terminology includes cold gas spray, micro cold spray, cold gas dynamic spray, kinetic spray, supersonic particle deposition and metal powder application (MPA), all of which refer to the same principle of solid-state powder deposition as described above. CS is used for coating and repair. It is also used for additive manufacturing (AM) at relatively high deposition rates as compared to the methods based on selective laser or electron beam melting. The main advantage of CS is that it alleviates the problems associated with high temperature processing of materials, such as oxidation and unfavourable structural changes. It is possibly the only continuous method to produce bulk components of metastable materials that are available only in the powder form, e.g. as obtained from mechanical attrition or gas atomisation. The aim of the present paper is to provide an overview of CS from a materials perspective, particularly for a broader audience in materials research, e.g. with interest in dynamic phenomena, plasticity and phase transformations. In terms of application and properties, CS is perhaps best to be compared to thermal spraying processes, as in [24,25]. In view of relevant physical phenomena, however, CS is mos...

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“…Only the upper layer of the coating exhibits a lower density resulting in higher porosity close to the surface. This phenomenon is well known in cold spraying as a tamping effect, describing the process of additional deformation of deposited particles by impacting ones [11]. When the coated samples were flat rolled without previous annealing, some cracks were observed in normal direction/rolling direction (ND/RD) cross sections.…”

Section: Microstructurementioning

confidence: 99%