Journal ArticleDOI
Influence of coating thickness on residual stress and adhesion-strength of cold-sprayed Inconel 718 coatings
TLDR
In this article, a powder based on the chemical composition of IN 718 was cold-sprayed on IN718 substrates by using nitrogen gas for an application as a repair tool for aero engine components.Abstract:
In the cold spray process, deposition of particles takes place through intensive plastic deformation upon impact in a solid state at the temperatures well below their melting point. The high particle impact velocity causes high local stresses which lead to deforming the particles and the substrate plastically in the proximity of the particle–substrate interface. As a result, high residual stresses are introduced in cold spray coatings due to the peening effect of the particles collisions with the substrate. In this study, a powder based on the chemical composition of IN 718 was cold-sprayed on IN 718 substrates by using nitrogen gas for an application as a repair tool for aero engine components. The magnitude of the residual stress and its distribution through the thickness were measured by using the hole-drilling and the bending methods. Residual stress was also estimated by using an approach based on the physical process parameters. Mainly compressive residual stresses were observed in cold-sprayed IN 718 coatings. Accumulation of residual stresses in the coatings is highly affected by peening during deposition and it decreases with increase in thickness. It has been observed that the adhesion-strengths of cold-sprayed IN 718 coatings are highly influenced by coating thickness and residual stress states of the coating/substrate system. In the presence of residual stresses in the coatings, adhesion-strength decreases with increasing coating thickness. The energy-release-rate criterion has been used to predict adhesion-strength with increasing coating thickness. Predicted bond-strength values are close to the measured adhesion-strength values and decrease with increase in coating thickness.read more
Citations
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Journal ArticleDOI
Recent progress of machinability and surface integrity for mechanical machining Inconel 718: a review
TL;DR: In this paper, the machinability and surface integrity of Inconel 718 (IN-718) components were evaluated from the viewpoint of geometrical structure of the part to be machined.
Journal ArticleDOI
Numerical modelling of particle impact and residual stresses in cold sprayed coatings: A review
TL;DR: In this article, a review of the experimental techniques used for residual stress measurements; such as X-ray diffraction, neutron diffraction and material removal, curvature measurement and deformation techniques, are concisely reviewed from the context of being applied to cold spray deposits.
Journal ArticleDOI
Evaluation of residual stresses induced by cold spraying of Ti-6Al-4V on Ti-6Al-4V substrates
Dibakor Boruah,Bilal Ahmad,Tung Lik Lee,Saurabh Kabra,Abdul Khadar Syed,Philip McNutt,Matthew Doré,Xiang Zhang +7 more
TL;DR: In this paper, the effects of geometrical variables (i.e., the number of CS layers, CS layer thickness, and substrate thickness) and track pattern on the magnitude and distribution of residual stresses in CS deposit-substrate assemblies were measured experimentally by neutron diffraction and contour method.
Journal ArticleDOI
Factors governing static properties and fatigue, fatigue crack growth, and fracture mechanisms in cold spray alloys and coatings/repairs: A review
TL;DR: In this paper, a literature review that comprehensively discusses the state-of-the-art in cold spray materials and their properties is necessary for the adoption and implementation of the technology.
Journal ArticleDOI
Investigation of Coatings, Corrosion and Wear Characteristics of Machined Biomaterials through Hydroxyapatite Mixed-EDM Process: A Review.
Al-Amin,Ahmad Majdi Abdul-Rani,Mohd Danish,Saeed Rubaiee,Abdullah Bin Mahfouz,Harvey M. Thompson,Sadaqat Ali,Deepak Rajendra Unune,M. H. Sulaiman +8 more
TL;DR: In this paper, a comparative analysis of machined surface properties using the existing deposition methods and the EDM technique employing Hydroxyapatite powder (HAp), yielding Ca, P, and O, is presented.
References
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Journal ArticleDOI
A finite element calculation of stress intensity factors by a modified crack closure integral
E.F. Rybicki,M. F. Kanninen +1 more
TL;DR: In this article, an efficient technique for evaluating stress intensity factors is presented, based on the crack closure integral, which can be used with a constant strain finite element stress analysis and a coarse grid.
Journal ArticleDOI
Gas Dynamic Principles of Cold Spray
R. C. Dykhuizen,M. F. Smith +1 more
TL;DR: In this paper, an analytical model of the cold-spray process is presented, where analytical equations are solved to predict the spray particle velocities, demonstrating the interaction between the numerous geometric and material properties.
Journal ArticleDOI
An analysis of the cold spray process and its coatings
TL;DR: In this paper, computational fluid dynamics (CFD) and extensive spray tests were performed for detailed analyses of the cold spray process, and the modeling of the gas and particle flow field for different nozzle geometries and process parameters in correlation with the results of the experiments reveal that adhesion only occurs when the powder particles exceed a critical impact velocity that is specific to the spray material.
Journal ArticleDOI
From Particle Acceleration to Impact and Bonding in Cold Spraying
Tobias Schmidt,Hamid Assadi,Hamid Assadi,Frank Gärtner,H.J. Richter,H.J. Richter,Thorsten Stoltenhoff,Heinrich Kreye,Thomas Klassen +8 more
TL;DR: In this article, the authors summarized the state of the art in these theoretical studies, alongside a comprehensive description of the process, and also discussed the prediction of coating properties in the light of modeling combined with experimental investigations.