A Review of the Mechanical and Tribological Behavior of Cold Spray Metal Matrix Composites
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REVIEW
A Review of the Mechanical and Tribological Behavior of Cold Spray Metal Matrix Composites Lewei He1 • Mostafa Hassani1
Submitted: 16 April 2020 / in revised form: 31 July 2020 / Published online: 24 September 2020 ASM International 2020
Abstract Cold spray is an effective solid-state process for the fabrication of metal matrix composites where metallic, ceramic, or intermetallic reinforcements are embedded in a metallic matrix. Cold-sprayed metal matrix composites (CS MMCs) enable combining favorable properties of their constituent phases. Combinations of the ductility of metals with the high strength of ceramics or with the creep resistance of intermetallics are two typical examples. Here, we review recent advances in the understanding of the mechanical and tribological behavior of CS MMCs, with particular emphasis on the physical mechanisms and predictive understanding. We start the review with deposition mechanisms, defects, and microstructural features in CS MMCs. We continue the discussion with the mechanical behavior of CS MMCs, including elastic modulus, hardness, strength, ductility, as well as adhesive and cohesive failures. We also explore various aspects of the tribology of CS MMCs, from frictional response to abrasive and erosive wear. We discuss the effect of cold spray parameters and post-spray thermal and mechanical treatments on the microstructure and properties of CS MMCs. We connect experimental findings on the mechanics and tribology of CS MMCs with theoretical frameworks to the extent possible. Finally, we propose several critical unresolved issues in the field as future research directions. Keywords cold spray mechanical properties metal matrix composites tribological properties review
& Mostafa Hassani [email protected] 1
Sibley School of Mechanical and Aerospace Engineering, Cornell University, Ithaca, NY 14853, USA
Introduction Cold spray is a solid-state process in which micrometersized particles (5-50 lm) are accelerated by a supersonic carrier gas in a de Laval nozzle to high velocities (3001200 m/s) and impact a substrate material. If the impact velocity of the particles exceeds a threshold, referred to as critical velocity, the particles bond to the substrates in solid state without having to induce high homologous temperatures or melt either material. As a result, limitations associated with high temperatures such as phase transformation, tensile residual stresses, and significant distortion can be avoided, making cold spray a competitive deposition technology for different classes of materials. Ever since the first ‘‘cold’’ deposition of metallic particles onto metallic substrates was reported after Papyrin et al.’s classic two-phase flow experiments (Ref 1), cold spray has proven successful in the deposition of not only pure metals and engineering alloys, but also metallic glasses (Ref 2, 3), ceramics (Ref 4-7), high entropy alloys (Ref 8), and composites (Ref 9-11) onto a variety of substrates including metals, ceramics (Ref 12), polymers (Ref 13), and metall
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