Investigation of Deposition Behavior of Cold-Sprayed Magnesium Coating
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.K. Suo, X.P. Guo, W.Y. Li, M.P. Planche, and H.L. Liao (Submitted September 14, 2011; in revised form February 29, 2012)
Two types of magnesium powders with different particle size distributions were deposited by cold spraying at different main gas temperatures. The effects of gas temperature and particle size distribution on the deposition efficiency of particles were studied. The microstructure of coatings was observed, and the porosity of coatings was evaluated. The deposition efficiency of particles increased, and the porosity of coatings decreased with the increase of gas temperature. The deposition efficiency of particles increased when using the powder with a smaller particle size distribution. Stainless steel and aluminum plates were used as substrates. The bonding strength and mechanism between the coating and substrate were studied. The commercial finite element software ABAQUS was used to help us better understand the deformation behavior of particles and substrates. The mean bonding strength slightly increased when aluminum plates were used as substrates. The bonding mechanism of Mg coatings on stainless steel and aluminum substrates was discussed.
Keywords
bonding strength, cold spraying, deposition efficiency, magnesium coating, particle size
1. Introduction Magnesium (Mg), as the lightest one of all the commonly used structural metals, is one of the most abundant elements in earthÕs crust, amounting to about 2.5 wt.%. It has some advantageous properties, such as recoverability, good thermal conductivity, high dimensional stability, good electromagnetic shielding, and high damping characteristics along with good machinability. These properties make it an ideal candidate for engineering applications, especially in aerospace and automotive industries (Ref 1). Casting in vacuum or protective atmosphere is a primary technique employed to produce Mg workpieces (Ref 2, 3). This technique is relatively complex and expensive, especially for producing large workpieces; nevertheless, it can efficiently avoid the oxidation of Mg. On the other hand, there are some defects on cast workpieces, and it is difficult to repair these defects with TIG and MIG welding technologies because Mg can absorb impurity gases easily and lead to voids in the joint zone. Thermal spraying is a common
X.K. Suo, M.P. Planche, and H.L. Liao, LERMPS, Universite´ de Technologie de Belfort-Montbe´liard, Site de Se´venans, 90010 Belfort Cedex, France; X.P. Guo, Marine Engineering College, Jimei University, Xiamen 361021, Fujian, PeopleÕs Republic of China; and W.Y. Li, State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, XiÕan 710072, Shaanxi, PeopleÕs Republic of China. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
technology used to restore workpieces; however, it is unsuitable for Mg workpieces due to its high temperature activity. Therefore, it is necessary to develop an effective and low-cost technique to build
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