Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders
Cold gas dynamic spraying is a solid-state processing technique that is particularly attractive for surface coatings, 3D near-net shape additive manufacturing, and component repairs with an advantage of high-deposition efficiency. This technique has the sustainable potential to change the future ind...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-09-01
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| Series: | Engineering Proceedings |
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| Online Access: | https://www.mdpi.com/2673-4591/43/1/7 |
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| author | Jiashuo Qi Rija Nirina Raoelison Christophe Verdy Jishuai Li Mohamed Rachik |
| author_facet | Jiashuo Qi Rija Nirina Raoelison Christophe Verdy Jishuai Li Mohamed Rachik |
| author_sort | Jiashuo Qi |
| collection | DOAJ |
| description | Cold gas dynamic spraying is a solid-state processing technique that is particularly attractive for surface coatings, 3D near-net shape additive manufacturing, and component repairs with an advantage of high-deposition efficiency. This technique has the sustainable potential to change the future industrial and manufacturing environment, especially in the fabrication process of complex flight-critical components that are made of aluminum. This paper investigates the microstructure of aluminum coatings generated onto a commercial Al plate called FORTAL (Al 7075-T6) via cold spraying using helium as the propellant gas. Three Al coatings (pure Al, AlSi10Mg, and Scalmalloy) are compared under a similar deposition condition. The top view of the coating revealed the highest deformation (high flattening) in the case of pure Al powders, whereas both the AlSi10Mg and Scalmalloy powders exhibit less flattening. The cross sections show fine equiaxed grains within the pure Al coating and extremely fine grains for both the AlSi10Mg coating and the Scalmalloy coating, with more extremely refined grains within the Scalmalloy coating. These results suggested an onset of recrystallization within the Al coating that is attributed to the heat generated by the strong plastic deformation. Less thermally activated recrystallization occurred within both AlSi10Mg coating and Scalmalloy coating due to their stronger mechanical properties. The structure rather resulted from the dynamic due to the high strain rate collision. The extremely fine structure is mostly at the powder/powder interface within the Scalmalloy coating and is developed towards the powder region which is also within the AlSi10Mg coating. Better plastic deformation occurred within the AlSi10Mg powder compared to the Scalmalloy powder that have a higher mechanical resistance. Together, these results evidence a limited thermally activated recrystallization within the Al alloys despite the highest deposition condition being used. The pure Al powders can also achieve a state of equiaxed fine grain due to the better plastic deformation. |
| first_indexed | 2024-03-08T20:48:39Z |
| format | Article |
| id | doaj.art-4cc9cf42f6cb46f48363e91d9b37dcf5 |
| institution | Directory Open Access Journal |
| issn | 2673-4591 |
| language | English |
| last_indexed | 2024-03-08T20:48:39Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Engineering Proceedings |
| spelling | doaj.art-4cc9cf42f6cb46f48363e91d9b37dcf52023-12-22T14:06:21ZengMDPI AGEngineering Proceedings2673-45912023-09-01431710.3390/engproc2023043007Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy PowdersJiashuo Qi0Rija Nirina Raoelison1Christophe Verdy2Jishuai Li3Mohamed Rachik4Laboratoire Roberval, Université de Technologie de Compiègne, Alliance Sorbonne Université, Centre de Recherche Royallieu, CS 60319, 60203 Compiègne, FranceLaboratoire Interdisciplinaire Carnot de Bourgogne (ICB), Université de Technologie de Belfort-Montbéliard, CNRS, 21078 Dijon, FranceLaboratoire Interdisciplinaire Carnot de Bourgogne (ICB), Université de Technologie de Belfort-Montbéliard, CNRS, 21078 Dijon, FranceLaboratoire Roberval, Université de Technologie de Compiègne, Alliance Sorbonne Université, Centre de Recherche Royallieu, CS 60319, 60203 Compiègne, FranceLaboratoire Roberval, Université de Technologie de Compiègne, Alliance Sorbonne Université, Centre de Recherche Royallieu, CS 60319, 60203 Compiègne, FranceCold gas dynamic spraying is a solid-state processing technique that is particularly attractive for surface coatings, 3D near-net shape additive manufacturing, and component repairs with an advantage of high-deposition efficiency. This technique has the sustainable potential to change the future industrial and manufacturing environment, especially in the fabrication process of complex flight-critical components that are made of aluminum. This paper investigates the microstructure of aluminum coatings generated onto a commercial Al plate called FORTAL (Al 7075-T6) via cold spraying using helium as the propellant gas. Three Al coatings (pure Al, AlSi10Mg, and Scalmalloy) are compared under a similar deposition condition. The top view of the coating revealed the highest deformation (high flattening) in the case of pure Al powders, whereas both the AlSi10Mg and Scalmalloy powders exhibit less flattening. The cross sections show fine equiaxed grains within the pure Al coating and extremely fine grains for both the AlSi10Mg coating and the Scalmalloy coating, with more extremely refined grains within the Scalmalloy coating. These results suggested an onset of recrystallization within the Al coating that is attributed to the heat generated by the strong plastic deformation. Less thermally activated recrystallization occurred within both AlSi10Mg coating and Scalmalloy coating due to their stronger mechanical properties. The structure rather resulted from the dynamic due to the high strain rate collision. The extremely fine structure is mostly at the powder/powder interface within the Scalmalloy coating and is developed towards the powder region which is also within the AlSi10Mg coating. Better plastic deformation occurred within the AlSi10Mg powder compared to the Scalmalloy powder that have a higher mechanical resistance. Together, these results evidence a limited thermally activated recrystallization within the Al alloys despite the highest deposition condition being used. The pure Al powders can also achieve a state of equiaxed fine grain due to the better plastic deformation.https://www.mdpi.com/2673-4591/43/1/7cold spraycoatingmicrostructurealuminum alloys |
| spellingShingle | Jiashuo Qi Rija Nirina Raoelison Christophe Verdy Jishuai Li Mohamed Rachik Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders Engineering Proceedings cold spray coating microstructure aluminum alloys |
| title | Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders |
| title_full | Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders |
| title_fullStr | Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders |
| title_full_unstemmed | Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders |
| title_short | Comparative Microstructural Study of Cold Sprayed Coatings Using Pure Aluminum and Aluminum Alloy Powders |
| title_sort | comparative microstructural study of cold sprayed coatings using pure aluminum and aluminum alloy powders |
| topic | cold spray coating microstructure aluminum alloys |
| url | https://www.mdpi.com/2673-4591/43/1/7 |
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