Abstract
Protective coatings based on an Al-Al2O3 metal matrix composite (MMC) were sprayed using dynamic metallization (DM), a low-pressure cold spray variant. A series of samples approximately 1 mm in thickness were sprayed using different spray process parameters (temperature, velocity) and different feedstock powder compositions (Al, Zn, Al2O3). This resulted in MMCs of different phase compositions and slightly different physical conditions of coating formation. The through-thickness residual stresses that accumulate in coatings during the spray process were studied using neutron diffraction in all phases comprising the MMCs. The overall residual stress in the coating (macrostress) was compressive, which is in good agreement with the data on residual stress observed in other cold spray coatings, accumulating as a result of the peening process. However, due to the slightly elevated spray temperature characteristic of DM in comparison with other cold spray variants, thermal stresses are also present and play an equally important role in the accumulation of residual stress in each phase. Because of the multi-phase composition and thermal mismatch between the metal and ceramic components of the MMC, inter-phase microstresses also accumulate. A micro-mechanical explanation of the observed tensile microstress in Al/Zn versus compressive stress in Al2O3 is proposed.
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Abbreviations
- \(\sigma_{\text{M}}\) :
-
Macrostress (tensor)
- \(\sigma_{\mu }\) :
-
Microstress (tensor)
- \(\sigma_{\mu }^{\alpha }\) :
-
Microstress of phase α
- \(\sigma_{\text{tot}}^{\alpha }\) :
-
Total (phase) stress of phase α
- \(f\) :
-
Volume fraction of hard particle (inclusion) phase
- \(\sigma\) :
-
Stress averaged over the gauge volume
- \(E\) :
-
Young’s modulus
- \(E_{||}, E_{\bot}\) :
-
Young’s modulus for the in-plane (||) and normal (\(\bot\)) directions in coatings
- \(d^{\alpha }\) :
-
d-spacing of phase α
- \(d_{||}, d_{\bot}\) :
-
Measured d-spacing in-plane (||) and normal (\(\bot\)) directions
- \(d_{0}\) :
-
Reference (macrostress-free) d-spacing
- \(\left( {hkl} \right)\) :
-
The Miller indices of certain reflection (crystal plane)
- \(2\theta\left({hkl}\right)\) :
-
Bragg’s (scattering) angle of (hkl) reflection
- \(S_{1}^{\alpha}\left({hkl}\right), \raise.5ex\hbox{$\scriptstyle 1$}\kern-.1em/ \kern-.15em\lower.25ex\hbox{$\scriptstyle 2$} S_{2}^{\alpha}\left({hkl}\right)\) :
-
Two (hkl)-dependent diffraction elastic constants of phase α
- \(\varSigma^{\alpha }\) :
-
Experimentally determined phase stress of phase α
- \(D^{\alpha }\) :
-
Deviatoric part of the microstress of phase α
- \(\Delta \varepsilon_{\text{th}}\) :
-
Thermal mismatch strain
- \(\alpha\left({\text{material}}\right)\) :
-
Thermal expansion coefficient of material
- \(\Delta T\) :
-
Temperature drop from spraying to room
- \(\sigma_{\text{d}}\) :
-
Deposition stress
- ϱ:
-
Material’s density
- \(p\) :
-
Porosity
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Acknowledgments
V.L. would like to thank Dr. Max Avdeev (ANSTO) for his assistance with the x-ray diffraction phase analysis, Dr. Joel Davis (ANSTO) for assisting with scanning electron microscopy and Mr. Karl Toppler (ANSTO) for carrying out the four-point bending test.
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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.
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Luzin, V., Spiridonov, P., Spencer, K. et al. Neutron Diffraction Study of Macrostress and Microstress in Al-Al2O3-Based Corrosion Protection Coating Obtained by Cold Spray (Dynamic Metallization). J Therm Spray Tech 29, 1437–1454 (2020). https://doi.org/10.1007/s11666-020-01077-8
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DOI: https://doi.org/10.1007/s11666-020-01077-8