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Proceedings Papers
ITSC2025, Thermal Spray 2025: Proceedings from the International Thermal Spray Conference, 68-73, May 5–8, 2025,
Abstract
View Papertitled, Surface Strengthening of Steel by High-Velocity Cold Spray Shot Peening
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for content titled, Surface Strengthening of Steel by High-Velocity Cold Spray Shot Peening
In this work, cold spray shot peening was used to treat interstitial-free (IF) steel. Different numbers of impact passes were evaluated and the microstructure and hardness evolution in IF steel were analyzed. Based on the experimental results, the potential of CSSP to achieve surface strengthening and properties enhancement in metallic materials is demonstrated.
Proceedings Papers
Multi-Purpose Additives Towards a Better Polymer Cold Spray Process
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ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 273-279, May 22–25, 2023,
Abstract
View Papertitled, Multi-Purpose Additives Towards a Better Polymer Cold Spray Process
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for content titled, Multi-Purpose Additives Towards a Better Polymer Cold Spray Process
Polymers have proven to be challenging to cold spray, particularly with high efficiency and quality when using inexpensive nitrogen (N 2 ) and air propellants. Helium (He) when used as a process propellant can improve spray deposit properties but is often undesirable due to its limited availability and high cost. In this study, additives of multiple particle sizes and materials were mixed with polymer powder in an effort to improve the performance of polymer sprays using mainly N 2 as a process propellant. The effects of additives on deposit microstructure were investigated by precise ion-beam polishing of deposit cross sections and subsequent electron microscope imaging. Additional metrics including the density and post - spray composition of deposits were investigated to quantify the peening effect and the amount of embedded additive. Additives, regardless of size, were observed to embed in the spray deposits. Additionally, hard-phase additives demonstrated nozzle-cleaning properties that continually remove polymer fouling on the nozzle walls. Inversely, sprays with polymer powder and no additives tended to clog the nozzle throat and diverging section as a result of continual fouling.
Proceedings Papers
Enhanced Antibacterial Properties of Copper Surfaces Using Cold Spray Shot Peening
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ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 268-273, May 24–28, 2021,
Abstract
View Papertitled, Enhanced Antibacterial Properties of Copper Surfaces Using Cold Spray Shot Peening
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for content titled, Enhanced Antibacterial Properties of Copper Surfaces Using Cold Spray Shot Peening
Metal surface characteristics play a significant role in interacting with their biological environment. Copper surfaces have been identified for their antimicrobial properties. Improvement of antibacterial and antiviral performances can be tailored by surface microstructure modification. Severe plastic deformation is an effective surface modification procedure to improve the mechanical performance of metal surfaces. This technique can be adapted to obtain surface grain refinement and induce surface roughness. In this work, cold spray shot peening is used to modify copper substrate surfaces and study the effects on their antibacterial properties. To modify the grain structure of copper, different shot-peening parameters were examined. The surface roughness and microstructure were investigated by employing optical and scanning electron microscopy. The bactericidal activity of copper substrates after shot peening treatment is discussed and a comparison between the bacterial load on treated (shot-peened surface and cold sprayed copper coating) and untreated surfaces (as-received) is provided. Testing of the surfaces after their exposure to the biological environment demonstrated improved microbial inactivation performances for surfaces that had undergone grain refinement without exceeding a certain roughness value.
Proceedings Papers
Mechanical and Microstructural Properties of Post-Treated Zn4Al Sprayed Coatings Using Twin Wire Arc Spraying
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ITSC 2021, Thermal Spray 2021: Proceedings from the International Thermal Spray Conference, 750-757, May 24–28, 2021,
Abstract
View Papertitled, Mechanical and Microstructural Properties of Post-Treated Zn4Al Sprayed Coatings Using Twin Wire Arc Spraying
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for content titled, Mechanical and Microstructural Properties of Post-Treated Zn4Al Sprayed Coatings Using Twin Wire Arc Spraying
Metal structures in offshore facilities are usually protected from corrosion using Zn-Al coatings even though they are subjected to collective stress conditions. This paper evaluates a post-treatment called machine hammer peening and its effect on surface finish, induced residual stresses, and near-surface microstructure of thermally sprayed ZnAl4 coatings. As expected, coating roughness was reduced from about Rz = 53.5 μm in the as-sprayed condition to 10.4 μm after treatment and coating densification was revealed in the near-surface zone. Residual stresses, which were surprisingly compressive in the as-sprayed condition, were likewise affected by the peening process, reaching a maximum of 200 MPa. The influence of peening direction and other such parameters were also investigated as part of the study.
Proceedings Papers
Surface Grain Refinement of AZ91D Magnesium Alloy by Cold Spraying Shot Peening Process
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ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 795-801, May 26–29, 2019,
Abstract
View Papertitled, Surface Grain Refinement of AZ91D Magnesium Alloy by Cold Spraying Shot Peening Process
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for content titled, Surface Grain Refinement of AZ91D Magnesium Alloy by Cold Spraying Shot Peening Process
In this work, a new cold-spray shot-peening process was used to achieve surface nanocrystallization on a magnesium alloy deposit. The results of various examinations and tests show that nanocrystalline layers up to 40 µm thick with an average grain size in range of 50-80 nm can be prepared on AZ91D deposits using the new process. The nanocrystalline layers also exhibit good microhardness and tribological properties.
Proceedings Papers
Grain Refinement of Pure Al Coating via In-Situ Shot-Peening-Assisted Cold Spray
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ITSC 2018, Thermal Spray 2018: Proceedings from the International Thermal Spray Conference, 233-237, May 7–10, 2018,
Abstract
View Papertitled, Grain Refinement of Pure Al Coating via In-Situ Shot-Peening-Assisted Cold Spray
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for content titled, Grain Refinement of Pure Al Coating via In-Situ Shot-Peening-Assisted Cold Spray
In this study, pure Al coating was deposited via in-situ shot-peening-assisted cold spray method in order to study the effect of the in-situ tamping effect which was caused by the impact of large sized shot-peening particles on grains size evolution of coatings. The microstructures of the as-sprayed Al coating were observed by using Scanning Electron Microscope and Electron Backscatter Diffraction. A commercial gas atomized Al powder with a grain size range of 10-20 μm was used as the spraying powder. The cross section of the as-sprayed Al particles presented elongated rectangular morphologies, which indicated that the nearly spherical particles experienced severe plastic deformation by the impact of large sized shot-peening particles. It was found that dynamic recrystallization of dislocations-ridden regions was responsible for the grain refinement of cold sprayed coating. Aluminum grains with size of several tens to several hundred of nanometers can be apparently recognized at the whole cross section of the particle. Therefore, in-situ shot-peening-assisted cold spray method can deposit completely nanocrystalline coating using micrometer-grain powder, and thus can be employed to develop high quality coatings of commercial importance.
Proceedings Papers
Isothermal Oxidation Behavior of HVAF-Sprayed NiCoCrAlY Coatings: Effect of Surface Treatment
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ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 456-461, June 7–9, 2017,
Abstract
View Papertitled, Isothermal Oxidation Behavior of HVAF-Sprayed NiCoCrAlY Coatings: Effect of Surface Treatment
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for content titled, Isothermal Oxidation Behavior of HVAF-Sprayed NiCoCrAlY Coatings: Effect of Surface Treatment
NiCoCrAlY coatings are widely used as bond coats for ceramic thermal barrier coatings (TBCs) and oxidation and corrosion protective overlay coatings in industrial gas turbines. High temperature oxidation behaviour of NiCoCrAlYs has a great influence on the coating performance and lifetime of TBCs. A promising route to decrease the oxidation rate of such coatings is post-coating surface modification which can facilitate formation of a uniform alumina scale with a considerably slower growth rate compared to the as-sprayed coatings. In this work, the effect of surface treatment by means of shot peening and laser surface melting (LSM) on the oxidation resistance of high velocity air-fuel (HVAF) sprayed NiCoCrAlY coatings was studied. Isothermal oxidation was carried out at 1000 °C for 1000h. Results showed that the rough surface of as-sprayed HVAF sprayed coatings was significantly changed after shot peening and LSM treatment, with a compact and smooth appearance. After the exposure, the oxide scales formed on surface-treated NiCoCrAlY coatings showed different morphology and growth rate compared to those formed on as-sprayed coating surface. The oxidation behaviour of surface treated HVAF-sprayed NiCoCrAlY coatings were revealed and discussed.
Proceedings Papers
Fe-based Powder Alloys Deposited by HVOF and HVAF Spraying – A Salt Spray Test Ranking
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ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 669-674, June 7–9, 2017,
Abstract
View Papertitled, Fe-based Powder Alloys Deposited by HVOF and HVAF Spraying – A Salt Spray Test Ranking
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for content titled, Fe-based Powder Alloys Deposited by HVOF and HVAF Spraying – A Salt Spray Test Ranking
Three Fe-based powder alloys, Höganäs Fe SP529, Fe SP586 and 6AB, have been deposited by HVOF and HVAF spraying onto mild steel plates. The sprayed samples were first ground and then shot peened using glass shot in order to seal the surface interconnected pores and other surface imperfections. The samples as ground and ground/glass shot peened were tested by salt spray (fog) exposition for 238 h according to ASTM B117/ISO 9227. FeSP586, HVOF and HVAF sprayed and glass shot peening samples achieved surface sealing enough to pass the test with appearance rating RA = 9 according to ISO 10289. All other samples achieved moderate to excessive pitting and/or moderate to excessive staining types of corrosion defects.
Proceedings Papers
Fatigue Strength of Mg Alloy Coated with Al Coatings via In-Situ Shot-Peening Assisted Cold Spray
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ITSC 2017, Thermal Spray 2017: Proceedings from the International Thermal Spray Conference, 772-776, June 7–9, 2017,
Abstract
View Papertitled, Fatigue Strength of Mg Alloy Coated with Al Coatings via In-Situ Shot-Peening Assisted Cold Spray
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for content titled, Fatigue Strength of Mg Alloy Coated with Al Coatings via In-Situ Shot-Peening Assisted Cold Spray
In this study, pure Al coatings were deposited on ZK60-T5 Mg alloy substrates via in-situ shot-peening assisted cold spray in order to study the effect of the Al coating on fatigue behavior of coated samples. Fatigue behavior of the coated and un-coated samples has been investigated through experimental tests. The size and shape distribution of powders, microstructural characteristics of coatings and fractography of fatigue test samples have been studied using scanning electron microscopy. The average microhardness of pure Al coating is higher than 70 HV50. In order to obtain the fatigue S-N diagram for each set, coated and un-coated samples have been tested in a load-controlled condition. The tension-compression fatigue experiments reveal that the fatigue property of ZK60-T5 alloy coated with pure Al coatings has significantly deteriorated compared with un-coated samples.
Proceedings Papers
Wear Behavior of Post-Treated Arc Sprayed Cermet Coatings by Means of Hammer Peening
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ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 484-489, May 10–12, 2016,
Abstract
View Papertitled, Wear Behavior of Post-Treated Arc Sprayed Cermet Coatings by Means of Hammer Peening
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for content titled, Wear Behavior of Post-Treated Arc Sprayed Cermet Coatings by Means of Hammer Peening
This study evaluates the effect of hammer peening on the wear behavior of cermet coatings. WC-FeCMnSi coatings were produced by twin wire arc spraying and post-treated on a five-axis machining center equipped with pneumatic peen. The surface topography of the peened coatings was examined and compared to as-sprayed and polished samples. Dry sliding friction and abrasive wear tests showed that the treated coatings had lower friction coefficients, but were less wear resistant than non-treated samples. Likewise, strain hardening effects revealed by nanoindentation testing were offset by process-induced cracking of embedded carbides, which contributes to break-outs and third-body wear.
Proceedings Papers
Tribological Behavior of Arc Sprayed and Compressed Coatings with Different Carbide Grain Size Fraction
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ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 1019-1024, May 10–12, 2016,
Abstract
View Papertitled, Tribological Behavior of Arc Sprayed and Compressed Coatings with Different Carbide Grain Size Fraction
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for content titled, Tribological Behavior of Arc Sprayed and Compressed Coatings with Different Carbide Grain Size Fraction
This study assesses the effect of machine hammer peening (MHP) and carbide grain size fraction on the friction and wear behavior of arc-sprayed WC-W 2 C FeCMnSi coatings. SEM examination shows that post-treatment by MHP compresses the coating, reducing both thickness and porosity, particularly in coatings with ultrafine carbides. The treatments also cause cracking, however, especially in carbide phases. Ball-on-disk tests were carried out on as-sprayed and treated samples to determine sliding wear and friction properties, and dry sand rubber wheel tests were used to evaluate abrasion resistance. SEM and EDX analyses before and after wear testing show how coating microstructure and grain size correlate with the friction and wear test results obtained and the given surface treatments.
Proceedings Papers
Improving Corrosion Resistance of Al6061 Coating Deposited by an In-Situ Shot-Peening Assisted Cold Spray
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ITSC2016, Thermal Spray 2016: Proceedings from the International Thermal Spray Conference, 1046-1051, May 10–12, 2016,
Abstract
View Papertitled, Improving Corrosion Resistance of Al6061 Coating Deposited by an In-Situ Shot-Peening Assisted Cold Spray
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for content titled, Improving Corrosion Resistance of Al6061 Coating Deposited by an In-Situ Shot-Peening Assisted Cold Spray
This study demonstrates a novel method for improving the corrosion resistance of cold sprayed Al6061 coatings. Large stainless steel particles were added to a commercial Al6061 powder and the mixture was deposited on Mg alloy AZ31B substrates using nitrogen gas at low working pressure and temperature. It is shown that the stainless steel particles had a shot-peening effect, thus increasing the density as well as the corrosion resistance of Al6061 coatings. SEM examination showed that no stainless steel particles were incorporated in the coating.
Proceedings Papers
Development of the Microstructure and Mechanical Properties of Cold-Sprayed IN718 Alloy Coating by a Novel In-Situ Shot Peening Process
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ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 293-298, May 11–14, 2015,
Abstract
View Papertitled, Development of the Microstructure and Mechanical Properties of Cold-Sprayed IN718 Alloy Coating by a Novel In-Situ Shot Peening Process
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for content titled, Development of the Microstructure and Mechanical Properties of Cold-Sprayed IN718 Alloy Coating by a Novel In-Situ Shot Peening Process
In this study, in-situ shot-peening approach was introduced by mixing large stainless steel (SS) shots with diameters over 150 μm with IN718 spray powders to aim at developing a novel approach to achieve dense coating. Effect of mixed stainless steel shot content on the microstructure and mechanical properties of the IN718 coating was examined. Results show that IN718 coating can be deposited without any shot peening particle inclusions for their relatively low velocity. It was revealed that the deposition efficiency of the IN 718 powders is improved by the in-situ shot peening effect. With increasing shot fraction in the powder mixture from 0% to 50 vol.%, the coating porosity decreased from 5.6% to 0.2% only by using N 2 accelerating gas. Remarkable work hardening induced by impact of the shot peening particles was detected.
Proceedings Papers
Shot Peening Effect on the Morphology and Roughness of HVOF Coatings
Available to PurchaseGustavo Bavaresco Sucharski, Ramón Sigifredo Cortés Paredes, Anderson Geraldo Marenda Pukasiewicz, Rodolpho Fernando Vaz
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 856-862, May 11–14, 2015,
Abstract
View Papertitled, Shot Peening Effect on the Morphology and Roughness of HVOF Coatings
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for content titled, Shot Peening Effect on the Morphology and Roughness of HVOF Coatings
The HVOF process is characterized by the deposition of a low porosity and oxide content coating and the particles projected by this process have high kinetic energy, resulting in a high density coating. However, the presence of non-melted particles can affect the porosity, tensile adhesion, hardness and surface finishing. In this article, the influence of the shot peening treatment on morphology, porosity, tensile adhesion and roughness of some FeMnCrSi(Ni/B) HVOF coatings have been studied. High carbon steel particles with spherical geometry were used for shot peening. The results show that the shot peening reduces the porosity, mainly in the coatings with higher porosity level, and generates an increase of hardness with no phase transformations. The increase in adherence is also a benefit generated by the treatment. The surface quality analyses show a significant roughness reduction. With shot peening a compressive residual stress state was achieved in the coating, improving mechanical properties.
Proceedings Papers
The Effect of Severe Shot Peening as Pre/Post Treatment on Fatigue Behavior of Cold Spray Coating
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ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 611-616, May 21–23, 2014,
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View Papertitled, The Effect of Severe Shot Peening as Pre/Post Treatment on Fatigue Behavior of Cold Spray Coating
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for content titled, The Effect of Severe Shot Peening as Pre/Post Treatment on Fatigue Behavior of Cold Spray Coating
This study evaluates the influence of shot peening on the fatigue life of cold spray aluminum alloy 6082 coatings. A pneumatic blast machine with standard steel shot was used to peen both uncoated and coated substrates. Six test groups representing different treatment protocols were characterized in terms of residual stress, roughness, and rotating bending fatigue. The results show that the best fatigue performance is obtained by intense shot peening prior to cold spraying. Post-treatment shot peening, in contrast, had a detrimental effect as a large portion of the kinetic energy is absorbed in the coating, resulting in surface damage rather than further work hardening.
Proceedings Papers
Densification of Low Temperature HVOF Ti Coating
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ITSC 2011, Thermal Spray 2011: Proceedings from the International Thermal Spray Conference, 1193-1196, September 27–29, 2011,
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View Papertitled, Densification of Low Temperature HVOF Ti Coating
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for content titled, Densification of Low Temperature HVOF Ti Coating
Fundamental properties of Titanium coating prepared by low temperature HVOF process aided by injection of water had been published by our research group. The results showed that low temperature HVOF process provided as a good means for the deposition of comparatively dense Ti coating, however the interconnected pores observed in Ti coating degraded corrosion resistance of Ti coating, therefore it was necessary to manufacture denser Ti coating. Two processes were respectively applied for the densification of Ti coating. One process was to perform post heat treatment for as-sprayed Ti coating with conventional Ti powder as feedstock. The other process was to modify thermal spray powder. Ti powder mixing with spherical glass powder was used to deposit denser Ti coating as a result of shot peening effect of hard glass powder. Finally the corrosion resistance for densified Ti coatings was evaluated by electrochemical characterization.
Proceedings Papers
Residual Stress Distribution in HVOF Inconel 718 Coatings for Aerospace Repair Applications
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ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 778-784, June 2–4, 2008,
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View Papertitled, Residual Stress Distribution in HVOF Inconel 718 Coatings for Aerospace Repair Applications
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for content titled, Residual Stress Distribution in HVOF Inconel 718 Coatings for Aerospace Repair Applications
Residual stress build up in thick thermal spray coatings is a property of concern. The adhesion of these coatings to the substrate is strongly influenced by the residual stress generation during the coating deposition process. In the HVOF spray process, due to lower processing temperature and higher particle velocity as compared to plasma spraying, significant peening stresses are generated during the impact of semi molten particles on the substrate. The combination of these peening stresses together with quenching and cooling stresses that arise after deposition can be of significant importance. In this paper both a numerical finite element analysis (FEA) method, to calculate peening, quenching and cooling residual stresses, and experimental methods, as Modified Layer Removal Method (MLRM) and Neutron Diffraction analysis, are applied. The investigation is performed for thick Inconel 718 coatings on Inconel 718 substrates. Combined, these numerical and experimental techniques yield a deeper understanding of residual stress formation and a tool for process optimisation. The relationship between the stress state and deposit/substrate thickness ratio is given particular interest.
Proceedings Papers
Short-Pulse Laser Post Processing of PTA and Thermal Sprayed Wear and Corrosion Resistant Coatings
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ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 332-336, May 2–4, 2005,
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View Papertitled, Short-Pulse Laser Post Processing of PTA and Thermal Sprayed Wear and Corrosion Resistant Coatings
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for content titled, Short-Pulse Laser Post Processing of PTA and Thermal Sprayed Wear and Corrosion Resistant Coatings
Laser post treatment is a well known procedure in order to homogenize the geometry, the microstructure and aspect of the surface of thermal sprayed coatings. Furthermore the properties of coatings, as for example corrosion resistance can be improved, as a sealing layer is induced by remelting. High power laser sources as CO 2 -, Nd:YAG as well as diode laser are used for this aim. They allow a very deep remelting zone in a depth-range between 0,2-2 mm. Contemporarily the hard phases as well carbides in the coating degenerate due to the very high heat input and the wear resistance of the coating decreases. Short-pulse laser are very advantageous for processing surfaces in a very narrow band (under 50 µm). Applications are nowadays developed for the surface treatment of aluminium cylinder running surfaces and of titanium implants. The short-pulse laser post processing can be a very profitable methods to improve the behaviour of coatings without damaging hard phases. Investigations on remelting of PTA- and thermal sprayed coatings with a Nd:YAG-short-puls laser and with an excimer laser are reported in this paper. Surface quality as for example roughness of PTA-coatings with tungsten carbides (NiCrBSi+60%WSC) could be improved and a slight surface sealing layer was induced. Depending on the adopted laser system, different surface roughness profiles can be reached. In further investigations the suitability of the method was proven for thermally sprayed coatings of NiCrBSi
Proceedings Papers
Laser Shock Flier Impact Simulation of Particle-Substrate Interactions in Cold Spray
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ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 343-350, May 2–4, 2005,
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View Papertitled, Laser Shock Flier Impact Simulation of Particle-Substrate Interactions in Cold Spray
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for content titled, Laser Shock Flier Impact Simulation of Particle-Substrate Interactions in Cold Spray
Coating-substrate adhesion in cold spray is a paramount property, the mechanisms of which are not yet well elucidated. These mechanisms are governed by metallurgical and morphological phenomena occuring when cold-sprayed particles impinge on the substrate. To go into these mechanisms, due to the intrinsic characteristics of the cold spray process, i.e. the low-temperature and high velocity of the particles, direct observation and control of inflight particles and related phenomena (especially when impinging) cannot be done easily. For this reason, an experimental simulation of the particle-substrate reactions at the particle impingement was developed. This simulation is based on original filter impact experiments from laser shock acceleration of plates/foils (fliers). These were applied to the Cu-Al metallurgically-reactive system to simulate Cu cold-sprayed onto Al. The velocity of the plate was selected in the range of actual cold spray velocities. Relevant Cu-Al interaction phenomena were featured and studied as a function of filter impact conditions, i.e., primarily, shearing, plastic deformation, phase transformation (including rapid melting/solidification and formation of intermetallics). These phenomena were shown to be similar to those involved in cold spray. This was ascertained by a parallel study of cold-sprayed Cu coating of Al using SEM, TEM, EPMA, and an energy balance and diffusion calculations. In addition, this simulation can be used to feed FE modeling of cold spray particle impingement on the substrate. Preliminary results are discussed from modeling using the “RADIOSS®” code. More generally, laser shock flier impact experiments were demonstrated to result in a powerful tool capable of simulating cold spray coating-substrate interface mechanisms. Major assets rest on their high significance, reproducibility, flexibility and potential for substituting for direct laborious cold spray optimization testing.