Residual Stress Generation in Laser-Assisted Cold Spray Deposition of Oxide Dispersion Strengthened Fe 91 Ni 8 Zr 1
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Residual Stress Generation in Laser-Assisted Cold Spray Deposition of Oxide Dispersion Strengthened Fe91Ni8Zr1 Dallin J. Barton1 • Venkata Satish Bhattiprolu1 • Billy Chad Hornbuckle2 Clio M. Batali1 • Kristopher A. Darling2 • Gregory B. Thompson1 • Luke N. Brewer1
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Submitted: 3 December 2019 / in revised form: 8 July 2020 Ó ASM International 2020
Abstract This paper examines the residual stresses generated by laser-assisted cold spray deposition of an ironbased oxide dispersion strengthened alloy (Fe91Ni8Zr1 at.%) on an AISI 1018 mild steel substrate, as well as studies of the effect of the laser heating on the substrate alone. The in-plane residual stress values were determined by X-ray diffraction-based measurements. In the top section of the layers, established at a raster deposition rate of 25 mm/s and simultaneous surface heating temperatures of 650 and 950 °C, stresses were compressive ranging from - 170 to - 440 MPa. For the substrate only study, a larger span of surface temperatures from 350 to 950 °C and scan rates of 5 and 25 mm/s were investigated. Here, the stresses in the laser tracks were tensile, of the order of ? 400 MPa, with both ‘‘W’’- and ‘‘M’’- shaped profiles about the laser centerline. It was found that the stress profile shape was influenced by the Gaussian power distribution across the laser spot diameter which correlated
This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & Luke N. Brewer [email protected] 1
Department of Metallurgical and Materials Engineering, The University of Alabama, Box 870202, Tuscaloosa, AL 35401-0200, USA
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United States Army Research Laboratory, Weapons and Materials Research Directorate, RDRL-WMM-B, Aberdeen Proving Grounds, MD 21005-5069, USA
with microstructural changes (martensite formation) in the substrate. Keywords cold spray diode laser laser-assisted cold spray laser surface treatment optical microscopy phase analysis residual stress
Introduction Cold gas dynamic spray (Ref 1), now commonly shortened to the term cold spray (CS), is a solid-state bonding process that additively deposits metal powders at temperatures much lower than their melting temperatures. This is achieved by spraying the powder at supersonic velocities whereupon its cold weld bonds to either a substrate or to prior deposited material upon contact. This allows CS deposit microstructures (and its resultant properties) to largely be retained, albeit highly deformed. This contrasts with higher temperature coating processes where the material undergoes solidification phase transformation that may degrade the properties. Certain cases of CS additive repair and additive manufacturing are now cons
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