Improving the Wear and Corrosion Resistance of Maraging Part Obtained by Cold Gas Spray Additive Manufacturing

Rodolpho F Vaz,Javier Sanchez,Alessio Silvello,Irene García Cano,Vicente Albaladejo

doi:10.3390/met11071092

Abstract

The use of the cold gas spray (CGS) process as a metal additive manufacturing (MAM) technique for metallic part production has been deeply studied recently, mainly due to its advantages over other MAM techniques. CGS MAM is a high-productivity technique with a very low level of particle oxidation, microstructural changes, phase transformations, or deleterious residual thermal stresses in the part. The use of CGS MAM to produce maraging parts represents a gain for the industry by saving machining time and preventing raw material waste. Its wear resistance and corrosion behavior were evaluated in this work and were compared with cermet coatings deposited by high-velocity oxy-fuel (HVOF) on the CGS MAM maraging. This work presents the innovative and effective combination of different thermal spraying processes and materials to obtain MAM maraging parts with higher wear resistance, evaluating abrasion, sliding, and water erosion wear types.

Highlights

Metal additive manufacturing (MAM) as a category encompasses a series of processes to produce components layer-by-layer as an alternative to the conventional methods, such as machining, rolling, or stamping, or formative methods such as injection molding.MAM’s main advantages are the possibility of producing parts with complex geometries and added functionalities, avoiding material waste, and the savings coming from a distributed production and less stock required, among others
cold gas spray (CGS) produces parts with very high density, due to the very high velocity and kinetic energy imposed on the particles, deforming them at the impact and consolidating the MAM part
This work aimed to evaluate the performance of CGS MAM maraging under different wear conditions and compare it with the performance of cermets high-velocity oxy-fuel (HVOF) sprayed on this maraging

Summary

Introduction

Metal additive manufacturing (MAM) as a category encompasses a series of processes to produce components layer-by-layer as an alternative to the conventional methods, such as machining, rolling, or stamping, or formative methods such as injection molding.MAM’s main advantages are the possibility of producing parts with complex geometries and added functionalities, avoiding material waste, and the savings coming from a distributed production and less stock required, among others. The MAM technology has drawn much attention and has been the focus of many publications regarding the different techniques, such as powder bed fusion (PBD), binder jetting, metal material extrusion, and direct energy deposition processes (e.g., laser, electron beam, and welding processes) [1,2,3,4,5]. An alternative for MAM freeform part production is the cold gas spray (CGS) thermal spray process, which operates by accelerating powder particles by a supersonic gas jet, under the material melting point, preventing severe oxidation, microstructural changings, phase transformations, and thermal stresses typical in high-temperature fabrication processes [6,7,8]. CGS produces parts with very high density, due to the very high velocity and kinetic energy imposed on the particles, deforming them at the impact and consolidating the MAM part. The particles’ energy at the impact on the substrate can break the thin oxide film on the substrate surface, promoting the intimate contact with the fresh metal surface, which can lead to a strong metallurgical bonding, the adiabatic shear instability (ASI) [12,13,14]

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