Abstract
Process optimization and quality control are important issues in cold spraying and coating development. Because the cold spray processing is based on high kinetic energy by high particle velocities, online spray monitoring of particle inflight properties can be used as an assisting process tool. Particle velocities, their positions in the spray jet, and particle size measurements give valuable information about spraying conditions. This, in turn, improves reproducibility and reliability of coating production. This study focuses on cold spraying of Al6061 material and the connections between particle inflight properties and coating characteristics such as structures and mechanical properties. Furthermore, novel 2D velocity scan maps done with the HW CS2 online spray monitoring system are presented as an advantageous powder and spray condition controlling tool. Cold spray processing conditions were similar using different process parameters, confirmed with the online spray monitoring prior to coating production. Higher particle velocities led to higher particle deformation and thus, higher coating quality, denser structures, and improved adhesions. Also, deposition efficiency increased significantly by using higher particle velocities.
Highlights
Cold spraying has shown its potential for producing high-quality coatings with different industrial requirements
This is because the cold spraying is the solid-state coating processing method, where coating formation is based on a high kinetic energy instead of thermal energy compared to other thermal spray technologies, e.g., arc and flame spray processes
This study focuses on the optimization of cold spraying of Al6061 by using novel online spray monitoring for the spray parameter selection and as the quality control tool
Summary
Cold spraying has shown its potential for producing high-quality coatings with different industrial requirements. For corrosion protection and repairing possibilities, Al and Al-based alloy coatings have received a lot of interest due to their good material properties and high suitability for cold spraying as the feedstock materials [1,2,3,4,5]. Low melting point materials such as Al alloys can be sprayed without oxidation This is because the cold spraying is the solid-state coating processing method, where coating formation is based on a high kinetic energy instead of thermal energy compared to other thermal spray technologies, e.g., arc and flame spray processes. [6,7,8,9,10,11] During the impacts, particles need to undergo a high plastic deformation in order to achieve high-quality coating structures. This, in turn, depends on the particle velocity. [12] Assadi et al [12] have well summarized the influences of several factors
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