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Improved Deposition Efficiency of Low-Pressure Cold-Sprayed Tin Coating Through Powder Recycling

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Abstract

Cold spray is an advanced 3D technique to build thick coatings using ductile powders. Plastic deformations and physical interactions induced by kinetic energy are mainly the origins of interparticle and particle–substrate adhesion. The deposition efficiency, i.e., the quantity of matter deposited compared to the amount propelled, is directly linked to the parameters used in the cold spray. To improve this aspect, parameters’ optimization is also required with other solutions such as using thermally treated powders or powder blending with hard particles. Another approach is recycling powder, though it has not yet been widely evaluated. When depositing a blend of fresh and recycled Sn powder, the results showed improved coating deposition efficiency compared to a batch of 100% fresh or recycled particles. This blend does not significantly change the coating thickness, although it decreases the porosity ratio because of the thermal–mechanical history of the recycled particles. Recycled particles present lower elastic modulus. Finally, coating/substrate adhesion force was unchanged for the blend of fresh and recycled particles, but this still depends on the nature of the powder used.

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Acknowledgments

L. Zarazúa-Villalobos acknowledges the National Council of Science and Technology of Mexico (CONACYT) for the grant provided for the development of this project. C. Bernard acknowledges the Institute of Fluid Science (Tohoku University) for sponsoring this research through the Lyon Center Collaborative Research Grant.

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Authors and Affiliations

  1. ELyTMaX IRL3757, CNRS, Univ Lyon, INSA Lyon, Centrale Lyon, Université Claude Bernard Lyon 1, Villeurbanne, France

    Liliana Zarazua-Villalobos, Nicolas Mary, Chrystelle Bernard & Kazuhiro Ogawa

  2. Tohoku University, Sendai, Japan

    Liliana Zarazua-Villalobos & Kazuhiro Ogawa

  3. Fracture and Reliability Research Institute, Tohoku University, Sendai, Japan

    Liliana Zarazua-Villalobos & Kazuhiro Ogawa

  4. Frontier Research Institute for Interdisciplinary Sciences, Tohoku University, Sendai, Japan

    Chrystelle Bernard

  5. APERAM Research Center, rue Roger Salengro BP15, 62330, Isbergues, France

    Clement Boissy

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  1. Liliana Zarazua-Villalobos
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  4. Kazuhiro Ogawa
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Correspondence to Nicolas Mary.

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Zarazua-Villalobos, L., Mary, N., Bernard, C. et al. Improved Deposition Efficiency of Low-Pressure Cold-Sprayed Tin Coating Through Powder Recycling. J Therm Spray Tech 31, 2577–2593 (2022). https://doi.org/10.1007/s11666-022-01447-4

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