Abstract
Metal Cold Spray (MCS) is currently under evaluation for its suitability for aerospace applications. However, before this technology can be implemented into the jet engine, the mechanical performance and structural integrity of this novel process must be fully understood. Limited data is currently available to determine key materials properties given the discrete and transient nature of a MCS component. Furthermore, it is extremely challenging to produce uniaxial test coupons that are truly representative of the in-service geometry. As such, the small punch (SP) test offers an attractive alternative, since miniature disc SP specimens can be extracted from localised discrete locations. This paper will report the findings from an experimental collaborative programme of work currently being undertaken by Swansea University, Rolls-Royce Singapore and Nanyang Technological University Corp Lab to understand the contrasting modes of failure in a Ti-6Al-4V coating sprayed on to a Ti-6Al-4V substrate, which is expected to have properties akin to a forged variant. This will include a series of SP tests to assess the integrity and performance across the substrate, bond line and coating. Results will be supported by additional microstructural and fractographic investigations.
Highlights
Performance, cost and time are among the main drivers of material technology in the aerospace industry
This paper aims to report results from the characterisation of mechanically tested Ti-6Al-4V Metal Cold Spray (MCS) samples using small punch (SP) testing
The failure modes of cold spray Ti-6Al-4V coating on a TI-6Al-4V substrate has been studied and elucidated in this paper
Summary
Performance, cost and time are among the main drivers of material technology in the aerospace industry. As novel materials and processes are developed and incorporated in gas turbine engines, repair technologies are evolving simultaneously to ensure that aerospace components can still operate in optimal condition during service in a cost-effective approach. Traditional repair methods such as welding or hot spraying can lead to a number of deleterious effects on the component being repaired. The deposition of sufficiently thick coatings is prohibited by thermal stresses generated within the component [2] These effects can potentially reduce the service life of components and lead to premature failure
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