Microstructure and Mechanical Properties of Warm-Sprayed Titanium Coating on Carbon Fiber-Reinforced Plastic
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JTTEE5 25:788–796 DOI: 10.1007/s11666-016-0392-x 1059-9630/$19.00 Ó ASM International
Microstructure and Mechanical Properties of Warm-Sprayed Titanium Coating on Carbon Fiber-Reinforced Plastic Amirthan Ganesan, Okada Takuma, Motohiro Yamada, and Masahiro Fukumoto (Submitted October 28, 2015; in revised form February 8, 2016) Polymer materials are increasingly dominating various engineering fields. Recently, polymer-based composite materialsÕ surface performances—in particular, surface in relative motion—have been improved markedly by thermal spray coating. Despite this recent progress, the deposition of high-strength materials—producing a coating thickness of the order of more than 500 lm—remains highly challenging. In the present work, a highly dense and thick titanium coating was successfully deposited onto the carbon fiber-reinforced plastic (CFRP) substrate using a newly developed high-pressure warm spray (WS) system. The coating properties, such as hardness (300 ± 20 HV) and adhesion strength (8.1 ± 0.5 MPa), were evaluated and correlated with the microstructures of the coating. In addition, a wipe-test and in situ particle velocity and temperature measurement were performed to validate the particle deposition behavior as a function of the nitrogen flow rate in the WS system. It was found that the microstructures, deposition efficiency, and mechanical properties of the coatings were highly sensitive to nitrogen flow rates. The coating porosity increased with increasing nitrogen flow rates; however, the highest density was observed for nitrogen flow rate of 1000 standard liters per minute (SLM) samples due to the high fraction of semi-molten particles in the spray stream.
Keywords
adhesion strength, aerospace, interlayer, microhardness, porosity of coating, titanium
1. Introduction CFRP materials are considered as a potential manufacturing material for fuel-efficient aircraft and automobiles, despite their poor surface performance. The CFRP structures in aircraft and automobiles are easily eroded by sand, fine dust, and volcanic ash, resulting in massive material losses (Ref 1). Over the next few years, CFRP is destined to become an important component in various heavy industries, where components most often experience relative motion, and thus the phenomenon of sliding wear is inevitable (Ref 1-3). CFRP is used in erosioncritical areas such as the leading edges of airplanes, the turbine fans of aero engines and in applications where the components are in relative motion; as such, the materials must be protected against erosion/sliding wear in order to avoid severe damage and consequential high maintenance costs. Numerous solutions have been proposed to protect CFRP surfaces, such as polymer-based anti-erosion paints, metal- or ceramic-based coatings by physical vapor deposition, and chemical vapor deposition (Ref 1, 3). Amirthan Ganesan, Okada Takuma, Motohiro Yamada, and Masahiro Fukumoto, Department of Mechanical Engineering, Toyohashi University of Technology, Toyohashi 441-8580, Japan. Contact e-mail
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