Abstract
In this work, the cold-spray technique was used to deposit Inconel 718–nickel (1:1) composite coatings on stainless steel substrate. A general full factorial design was adopted to identify the statistically significant operating variables, i.e., impingement angle, erodent size, and feed rate on the coating erosion response. Erodent feed rate, impingement angle, and the interaction between impingement angle and erodent size were identified as the highly significant variables on the erosion rate. Then, a model correlating the identified variables with the erosion rate was derived. The best combination of control variables for minimum erosion loss with respect to erodent feed rate, erodent size, and impingement angle was 2 mg/min, 60 μm, and 90°, respectively. To analyze the erosion mechanism, the erodent samples were finally observed using Scanning Electron Microscope (SEM).
Highlights
Solid Particle Erosion (SPE) is the loss of material resulting from the repeated impact of small solid particles
cold spray (CS) is a low-temperature particle deposition process that has emerged as a powerful technique for its several advantages over other thermal spray processes including the minimization of potential phase changes, the preservation of the original feedstock properties, and the prevention of coating defects such as surface oxides and other inclusions [9,10,11,12]
From the analysis and optimization of the model reported in Equation (2) and the related surface plots illustrated in Figure 7, the combination of process variables optimizing the response for the cold-sprayed Inconel 718 (IN718)-Ni composite coating was obtained
Summary
Solid Particle Erosion (SPE) is the loss of material resulting from the repeated impact of small solid particles. The results indicated that, depending on the aluminum alloy substrate used, AA1050 and AA5083, the important sequences of the control parameters changed In both cases, the impact velocity was recognized as the highest contributing parameter, followed by the impingement angle [6]. Alidokht et al [26] studied the erosive wear performance of Ni and Ni-WC composite coatings produced by cold-spray; they did not follow a planned experimentation. A planned experimentation that is capable of creating reproducible results was performed in order to assess the erosion performance of a cold sprayed IN718-Ni composite coating This particular composite coating was selected to investigate its SPE response since in a recent study of Kazasidis et al [27], it revealed a promising resistance against another type of erosion: the cavitation erosion. Flexibility [25,28,29]
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