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The Effect of Low Temperature Range Heat Treatment on the Residual Stress of Cold Gas Dynamic Sprayed Inconel 718 Coatings via Neutron Diffraction

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Abstract

There has been considerable interest in the application of cold gas dynamic spray (CGDS) to deposit nickel-based superalloy coatings for the repair and development of high-value components that operate under extreme environmental conditions. The CGDS process introduces residual stresses in the coating layers, but inherently effects the subsurface of the substrate in a similar manner. The present study investigates the effect of low temperature range heat treatments (100-400 °C) on the residual stress of CGDS Inconel® 718 deposited onto a presolution-treated Al7075-T651 substrate. High spatial resolution nondestructive residual stress measurements were carried out via neutron diffraction on both the CGDS deposit and substrate. The low temperature range heat treatments displayed a significant effect on both the substrate and coatings. Residual stress relaxation was exhibited in coatings that were heat-treated at the lowest temperature, whereas an increased heat treatment temperature displayed an opposite effect, increasing both the compressive residual stress in the IN718 coating and the residual tensile stress in the substrate. It is proposed the difference in thermal expansion coefficient of the two materials was the main factor responsible for the residual stresses. The effect of post-heat treatment on coating microhardness and porosity is also presented.

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Acknowledgments

The authors would like to thank Dr. Peter Lock and Dr. Julian Ratcliffe from the La Trobe Institute of Molecular Science (LIMS) Bioimaging Platform for their assistance. The authors would also like to express their gratitude to The Australian Institute of Nuclear Science and Engineering (AINSE) for their support in funding travel and accommodation to undertake the neutron diffraction residual stress experiment through proposal P3628.

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Authors and Affiliations

  1. Department of Engineering, School of Engineering and Mathematical Sciences, La Trobe University, Bundoora, VIC, Australia

    Sun Yung Kim & Mitchell L. Sesso

  2. Department of Mechanical Engineering and Product Design Engineering, Swinburne University of Technology, Hawthorn, VIC, Australia

    Sun Yung Kim

  3. The Australian Centre for Neutron Scattering, Australian Nuclear Science and Technology Organisation, Lucas Heights, NSW, Australia

    Vladimir Luzin

  4. School of Engineering, The University of Newcastle, Callaghan, NSW, Australia

    Vladimir Luzin

  5. Aerospace Division, Defence Science and Technology Group, Fishermans Bend, VIC, Australia

    John Thornton

  6. Commonwealth Scientific and Industrial Research Organisation, Manufacturing Flagship, Clayton, VIC, Australia

    Stefan Gulizia

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Residual Stresses Credit Line: 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.

This work is based on a thesis submitted by Sun Yung Kim in partial fulfilment of the requirements for the degree of Doctor of Philosophy in mechanical/materials engineering, Swinburne University of Technology, June 2017.

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Kim, S.Y., Luzin, V., Sesso, M.L. et al. The Effect of Low Temperature Range Heat Treatment on the Residual Stress of Cold Gas Dynamic Sprayed Inconel 718 Coatings via Neutron Diffraction. J Therm Spray Tech 29, 1477–1497 (2020). https://doi.org/10.1007/s11666-020-01080-z

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