Effect of Substrate Surface Roughness on Microstructure and Mechanical Properties of Cold-Sprayed Ti6Al4V Coatings on Ti
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Effect of Substrate Surface Roughness on Microstructure and Mechanical Properties of Cold‑Sprayed Ti6Al4V Coatings on Ti6Al4V Substrates Adrian Wei‑Yee Tan1,2 · Wen Sun1,2 · Ayan Bhowmik1,2 · Jun Yan Lek3 · Xu Song4 · Wei Zhai5 · Han Zheng2,5 · Feng Li1,6 · Iulian Marinescu1,6 · Zhili Dong7 · Erjia Liu1,2
Submitted: 4 June 2019 / in revised form: 30 July 2019 © ASM International 2019
Abstract Surface condition, especially surface roughness of substrates, critically influences the adhesion of coldsprayed titanium alloy coatings. To study this, Ti6Al4V (Ti64) coatings were deposited on Ti64 substrates with increasing surface roughness (Ra) from 0.05 µm (polished surface) to 5.4 µm (water-jet cut surface). It was found that the substrate surface roughness did not significantly affect the porosity, hardness and coating surface roughness because these properties were dependent on the deposition parameters such as propellant gas pressure and temperature and nozzle traverse speed. The adhesion test results showed that smoother substrate surfaces improved the coating bond strength of the cold-sprayed Ti64 coatings from about 7.1 MPa (Ra: 5.4 µm, interface failure) to 68.7 MPa (Ra: 0.05 µm, glue failure). The fracture characteristics of the debonded coating/substrate interfaces revealed that there were more adiabatic shear-induced craters observed on the smoother substrate surfaces. Finite element modeling also Electronic supplementary material The online version of this article (https://doi.org/10.1007/s11666-019-00926-5) contains supplementary material, which is available to authorized users. * Adrian Wei‑Yee Tan [email protected] * Erjia Liu [email protected] 1
Rolls‑Royce@NTU Corporate Lab, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
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School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore
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Facility for Analysis, Characterisation, Testing and Simulation (FACTS), Nanyang Technological University, Singapore 639798, Singapore
showed that the substrate surface features (i.e., peaks and valleys) possibly prevented the intimate contact between the particles and substrate and thus induced the non-uniform distributions of temperature, stress and strain at the particle/ substrate interface. Keywords finite element analysis · high-pressure cold spray · mechanical properties · substrate surface condition · Ti6Al4V powder/coating/substrate
Introduction Ti6Al4V (Ti64) is a particularly attractive alloy for highperformance structural applications due to its high specific strength, low density, high corrosion resistance and great thermal stability up to 400 °C (Ref 1). However, aerospace components made of Ti64 often suffer from wear, erosion and tear over their service periods due to harsh operation conditions. Repair of the damaged Ti64 components is
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School of Mechanical and Automation Engineering, Chinese University of Hong Kong, William M.W. Mong Engineering Building, Sh
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