Laser texturing as an alternative to grit blasting for improved coating adhesion on AZ91D magnesium alloy

Substrate preparation plays an important role in the performance of thermal spray coating, especially on softer materials like magnesium and aluminium alloys. Conventional substrate preparation methods such as grit blasting may not be the most suitable choice due to grit embedding, lower coating adhesion strength and environmental concerns. Laser texturing can be an attractive alternative to the grit blasting method for such materials. AZ91D substrate was prepared for thermal spray coating using grit blasting and laser texturing techniques. WC-12Co powder was thermally sprayed on AZ91D magnesium alloy using the high-velocity oxygen fuel technique. The adhesion strength of the coating, thus produced, was determined using the ASTM 633C adhesion strength test. Scanning electron microscopy was used to investigate substrate morphology and to qualitatively analyse substrate and coating interface. X-ray diffraction was used to identify phase compositions. The coating was characterised for roughness, porosity, micro-hardness and fracture toughness. Laser texturing as a substrate preparation technique has been able to produce well-adhered coatings, with adhesion strength of 45.6?MPa, and comparable coating characteristics with those of the grit blasting technique.     

Residual stress development in cold sprayed Al,Cu and Ti coatings

Residual stresses play an important role in the formation and performance of thermal spray coatings. A curvature-based approach where the substrate–coating system deflection and temperature are monitored throughout the coating deposition process was used to determine residual stress formation during cold spray deposition of Al, Cu and Ti coatings. The effect of substrate material (carbon steel, stainless steel and aluminium) and substrate pre-treatment (normal grit blasting, grit blasting with the cold spray system and grinding for carbon steel substrate) were studied for all coating materials with optimized deposition parameters. Mainly compressive stresses were expected because of the nature of cold spraying, but also neutral as well as tensile stresses were formed for studied coatings. The magnitudes of the residual stresses were mainly dependent on the substrate/coating material combination, but the surface preparation was also found to have an effect on the final stress stage of the coating.     

Surface preparation and thermal spray in a single step: The PROTAL process—Example of application for an aluminum-base substrate

Thermal spray techniques can fulfill numerous industrial applications. Coatings are thus applied to resist wear and corrosion or to modify the surface characteristics of the substrate (e.g., thermal conductivity/thermal insulation). However, many of these applications remain inhibited by some deposit characteristics, such as a limited coating adhesion or pores or by industrial costs because several nonsynchronized and sequential steps (that is, degreasing, sand blasting, and spraying) are needed to manufacture a deposit. The PROTAL process was designed to reduce the aforementioned difficulties by implementing simultaneously a Q-switched laser and a thermal spray torch. The laser irradiation is primarily aimed to eliminate the contamination films and oxide layers, to generate a surface state enhancing the deposit adhesion, and to limit the contamination of the deposited layers by condensed vapors. From PROTAL arises the possibility to reduce, indeed suppress, the preliminary steps of degreasing and grit blasting. In this study, the benefits of the PROTAL process were investigated, comparing adhesion of different atmospheric plasma spray coatings (e.g., metallic and ceramic coatings) on an aluminum-base substrate. Substrates were coated rough from the machine shop, for example, manipulated barehanded and without any prior surface preparation. Results obtained this way were compared with those obtained using a classical procedure; that is, degreasing and grit blasting prior to the coating deposition.     

Ablation laser and heating laser combined to cold spraying

Cold spraying is particularly suitable for the elaboration of coatings sensitive to heat and oxidation. As spraying particles are not subjected to melting, the adhesion and formation of the coating is due to the kinetic energy transmitted to the particles by accelerating gas. Bonding mechanisms are not only strongly dependent on the particle velocity but also on the state of the substrate surface. The presence of surface pollutants inhibits the coating elaboration. Surface modifications are necessary to reach a high adhesion between the coating and the substrate. A laser ablation and a laser heat treatment are proposed to prepare the substrate prior to cold spraying. Ablation laser is used to eliminate adsorbed pollutant molecules and heating laser is employed to improve the contact between substrate and particles and coating substrate adherence. The bonding of aluminium coating on aluminium 2017 alloy was evaluated by tensile adhesion tests and demonstrated the strong influence of the laser treatments in comparison with conventional processes (grit blasting and degreasing).     

热喷涂基体表面前处理技术的研究进展

热喷涂涂层与基体机械咬合的结合机理决定了基体表面前处理是热喷涂涂层中非常重要的处理工艺。文中概述了当前广泛应用的喷砂处理的工艺特点,指出砂粒易在基体表面镶嵌和对基体造成损伤是喷砂工艺的主要缺点,讨论了喷砂对高温合金单晶材料和超高强钢疲劳性能的影响,研究了软质基体表面超音速火焰喷涂WC涂层的免喷砂工艺。同时介绍了近年来其他热喷涂基体表面前处理方面的研究热点,包括高压水射流处理技术、机械粗化技术以及激光表面前处理,并重点阐述了其基本原理、特点及应用情况。     

Untergrundeinflüsse auf das Verhalten von Korrosionsschutzbeschichtungen bei stoßartiger Belastung

Influence of the substrate on the behaviour of corrosion protection coatings under impact load Loading by impact produces two types of stress at the interface between coating and steel substrate. While the compressive stress remains essentially ineffective, the shear stress may lead to detachment of the coating in a circular area. The risk of damage, caused by loss of adhesion, can be modified, if special forms of profile are provided for at the steel substrate, particularly by blasting procedures. Shot blasting, however, leads to a structure, that hardly will improve the strength of adhesion. The treatment of the surface by grit blasting is by far more effective because the anti-corrosive coating can then virtually become clamped into the surface profile obtained in this way.     

Erosion testing and surface preparation using abrasive water-jetting

Erosion testing and surface preparation are studied using a 3-axis Computer Numerical Control (CNC) abrasive water jetting (AWJ) apparatus. The effects of erosion time t, impingement angle α and pressure p on the erosion rate E, average surface roughness R _a, and surface hardness Rockwell C Hardness (HRC) were investigated in detail. Compared with conventional grit blasting, AWJ can reduce grit embedment in the target material due to the action of the high-pressure water. AWJ also has the advantage of generating a higher average surface roughness R _a over water jetting (WJ) due to the action of abrasive particles. In addition, AWJ increases the surface hardness HRC of the substrate material. The obtained higher degree of average surface roughness is helpful for improving the bonding strength between the coating and the substrate material. The erosion testing and the surface preparation are numerically controlled by a 3-axis CNC system; therefore precise and detailed results for various operating parameters can be obtained.     

Fatigue behavior of a SAE 1045 steel coated with Colmonoy 88 alloy deposited by HVOF thermal spray

An investigation has been conducted in order to study the fatigue behavior of a SAE 1045 steel substrate coated with a Ni-base alloy known commercially as Colmonoy 88, deposited by HVOF spray technique. Fatigue tests were conducted under axial conditions (R = 0.1), employing samples of the substrate material in the as-polished condition, after grit blasting with alumina particles and after grit blasting and coating with a deposit of about 250 μm thick. The fatigue tests were conducted at maximum stresses in the range of 380-533 MPa, depending on the condition of the material. A detailed fractographic analysis of some selected samples tested at different stresses was carried out, aimed mainly at determining the crack nucleation and propagation sequence. The results indicate that the deposition of such a coating leads to a fatigue strength debit of the substrate in the range of 10-20% and a similar debit in fatigue limit of ∼ 11-13%. It has been found that grit blasting is the process responsible for the fatigue strength debit observed in the coated samples. Fatigue cracks have been observed to initiate at the substrate-coating interface and at the free surface of the coating, mainly close to alumina particles embedded on the substrate and sharp notches produced during the process. The fractographic analysis of the fracture surface of the coated specimens points out the characteristic heterogeneous nature of the coating, particularly regarding some of its mechanical properties, such as fracture toughness.     

Examination of a grit-blasting process for thermal spraying using statistical methods

An experimental study was conducted to develop an understanding of how the grit blasting process, prior to plasma spray coating, affects various properties of the substrate and coatings. A statistical design of experiment approach was used and the results were analyzed using both the linear regression method and average response of factors calculations. The following process variables were studied: grit size (20, 36, 54), blasting pressure (20, 35, 50 psi), blasting duration (4, 6, 8 passes), blasting distance (4, 6 in.), and blasting angle (45°, 90°). Properties such as bond strength, grit contamination, surface roughness, and substrate distortion were evaluated and correlated to the process variables. Based on multiple linear regression results, it was shown that the bond strength can be improved by increasing all of the parameters within the range studied here. No relationship between the surface roughness and bond strength was observed. Grit contamination is mostly influenced by grit size, blasting pressure, and number of blasting passes. The average response method provided indications to the direction of modifying the required properties as a function of process variables. While the average response method agreed mostly with the linear regression predication, some differences are further discussed in the study.     

Fatigue behavior of a 4140 steel coated with a NiMoAl deposit applied by HVOF thermal spray

The fatigue behavior of a quenched and tempered AISI 4140 steel has been investigated in three different conditions: as-polished, as-grit blasted with Al₂O₃ particles and as-coated, after grit blasting, with a deposit of Ni–Al–Mo alloy (Metco 447) of approximately 300 μm in thickness, applied by HVOF thermal spraying. It has been determined that after grit blasting with particles of 20 mesh (83 μm) at a pressure of 345 kPa, a significant decrease in the fatigue properties of the material takes place. It has also been observed that such particles, are retained at the substrate surface during blasting and become stress concentrators that enhance the nucleation of fatigue cracks. The latter give rise to a decrease in the fatigue strength of the blasted material. Further coating of the grit blasted specimens with a deposit of Metco 447 of approximately 300 μm thick, applied by HVOF thermal spraying, leads to a further reduction in the fatigue strength of the material. Under these conditions, the fatigue cracks are also nucleated at the alumina particles retained after blasting. It is believed that such a further decrease is mainly associated with two different causes. Firstly, the extensive fracture and delamination of the coating from the substrate which has been observed from the microscopic analysis. Secondly, the possible existence of tensile residual stresses in the substrate, in the vicinity of the substrate–deposit interface, which would assist in the propagation of the fatigue cracks nucleated at the alumina particles. The fatigue properties of the steel substrate in the three different conditions investigated, has been described in terms of the simple parametric relationship earlier proposed by Basquin.     

Influence of the Surface State on the Adherence of the Coating: Case of an Alumina Coating Plasma Sprayed on SiC Composites

In thermal spraying, adherence between the coating and the substrate appears as the fundamental point. To favor a good interaction between both, it is often necessary to clean and prepare the substrate surface. Conventionally, solvents and sand blasting are applied to remove the contaminants and increase the surface roughness for a mechanical anchorage. However, according to the substrate nature (ceramic) or the substrate morphology, it can be prejudicial to apply a mechanical treatment because of peeling of the surface or a decrease in the global properties. Then, to obtain an appropriate preparation, several techniques can be investigated, such as water jet, ice blasting, and heat treatment; as well, laser ablation can be an interesting technology to prepare the substrate surface. The aim of this work was to study the modifications induced by 10 ns single or cumulative pulses of a Q-switched Nd:YAG near-infrared laser and its influence on the interface adhesion. The case of an alumina coating sprayed on a ceramic matrix composite (CMC) was studied. In these conditions, the laser treatment seems favorable from the adherence viewpoint according to the mechanical effect (induced by a conelike structure) and the chemical effect.     

Deposition and characterization of flame-sprayed aluminum on cured glass and basalt fiber-reinforced epoxy tubes

An oxy-acetylene flame spray torch was used to deposit thin layers of aluminum onto cured glass and basalt fiber-reinforced epoxy tubes. The composite specimens were fabricated by filament winding. Surface coatings embedded in composite laminates were produced. The composite substrates were grit blasted to promote adhesion of the molten aluminum particles. It was found that adhesion increased significantly when the composite substrate was lightly grit blasted, with no adhesion on smooth composite surfaces. The number of passes of the flame spray torch was varied to change the coating thickness and uniformity over the substrate. The electrical resistance of the coatings was measured to assess the suitability of a coating as a conductor. It was found that uniform, electrically conductive coatings were produced with a minimum of two torch passes. Optical images were captured to characterize the coating microstructure and thickness. This investigation did not reveal any visible evidence of damage to the composite substrate. To assess possible degradation effects from the grit blasting and flame spraying processes, the tube specimens were subjected to mechanical testing by applying internal pressurization with hydraulic oil. The tests indicated that the grit blasting and flame spraying processes must be carefully executed to mitigate degradation of the strength of the composite material substrate.     

喷砂预处理对HVOF喷涂TiAl-Nb/NiCrAl涂层结合强度的影响

采用不同的喷砂压力对基体表面进行喷砂预处理,研究了基体表面状态的变化对HVOF喷涂TiAl-Nb/NiCrAl涂层结合强度的影响。结果表明：随着喷砂压力的增大,基体粗糙度及表面凹坑的深度和宽度增大,NiCrAl层与基体结合界面处孔洞等缺陷增多,同时基体表面残余砂粒的面积分数增加;涂层结合强度随基体粗糙度的增大,先增大后减小,当基体粗糙度为8.33μm时,结合强度达到最大值44.5 MPa。     

A method of etching and powder blasting for microholes on brittle materials

Brittle materials such as semiconductors, ceramics, glasses, piezoelectric etc., are difficult to machine by traditional machining methods. This paper provides an approach to create holes or grooves more efficiently via powder blasting process. Instead of one protective layer for mask that is conventionally used, two layers are coated on the surface of the substrate material. The inner layer is water-soluble resin with excellent adhesion to the substrate but having weak resistance to powder erosion, and the second layer is a photosensitive oligomer that is adhered well to the first layer and has very high resistance to powder erosion. Such a protective coating possesses two contrary characteristics: high resistance to powder blasting and easy removal from substrate after powder erosion. Once the openings of the second layer are formed at the desired positions via a photo-etching method, a printing method, or other methods, the holes or grooves can be obtained by etching through the openings of the second layer to the first layer and the substrate by a powder blasting process. Then the whole protective coating is easily and smoothly stripped off without any damage to the substrate by dissolving the first layer with water. Due to easy removal of the mask plus the good resistance to powder blasting and a much higher erosion rate than the one obtainable by wet and dry etching processes, the proposed process can be applied to create holes or grooves on brittle material, instead of chemical etching process, so as to achieve a good quality and superior rate of production.     

Surface treatment effects on ceramic matrix composites: Case of a thermal sprayed alumina coating on SiC composites

High-temperature-resistant ceramics are already used for many industrial applications. In response to the growing demand, the need for further research considering the final application and the global behaviour of the material is becoming increasingly apparent. In general, it is possible to comply with many specifications, just by treating the surface of the ceramics. For instance, it is possible to achieve an adequate mechanical strength by depositing a protective layer with different structure and/or chemical composition. Regardless to the specification, the adhesion coating/substrate is the most crucial property to be considered. Conventionally, surface degreasing (applying solvents to remove organic impurities) and grit blasting (corundum) are carried out as a two steps pretreatment prior to the thermal-spraying operation to guarantee a mechanical anchorage of the molten particles to the substrate. However, some substrates are grit-blasting sensitive and therefore, alternative treatments should be considered. In these cases, the adherence of the coating must be attained by others means, either from a chemical point of view by modifying the surface wettability, or from a photonic one.Within this context, this study aims to explore the surface modifications induced on SiC composites (Ceramic Matrix Composites, CMC) before plasma spraying of alumina coatings. The effect of two different pre-treatments, deposition of a silicon bonding layer and short-pulse laser treatment (Nd:YAG), on the coating-substrate interface is investigated. A better chemical affinity between the alumina coating and the silicon carbide CMC has been observed with the silicon bond coating. On the other hand, a mixture of chemical and mechanical interaction induced by a cone-like structure occurs when treating the SiC CMC surface by laser prior thermal-spraying.     

HVOF碳化钨金属陶瓷涂层对基体疲劳性能影响的研究现状

由超音速火焰喷涂（HVOF）制备的碳化钨金属陶瓷涂层,具有接近完全致密、结合强度高、硬度高等优势。本文综述了金属表面HVOF碳化钨金属陶瓷涂层疲劳寿命影响的研究现状,并分析了产生疲劳裂纹的原因,影响疲劳寿命的原因有涂层与基体的性能差异、喷砂引入的缺陷、残余应力及涂层制备工艺等的影响。改进措施有涂层设计、基体不做喷砂或喷丸替代喷砂等改变前处理工艺、获得或提高涂层压应力、减少碳化物的分解、合理的工艺参数（如高的速度）、合适的涂层厚度、选用高含量粘结物的碳化钨金属陶瓷粉末、合适的涂层后处理方法等措施。     

Alumina grit blasting parameters for surface preparation in the plasma spraying operation

This paper examines how the grit blasting process influences the surface roughness of different sub-strates, the grit residue, and the grit erosion. The influence of grit blasting conditions on induced sub-strate residual stresses is also discussed. Aluminum alloy, cast iron, and hard steel were blasted with white alumina grits of 0.5,1, and 1.4 mm mean diameters. Grit blasting was performed using either a suction-type or a pressure-type machine equipped with straight nozzles made of B4C. The influence of the follow-ing parameters was studied: grit blasting distance (56 to 200 mm), blasting time (3 to 30 s), angle between nozzle and blasted surface (30°, 60°, 90°), and blasting pressure (0.2 to 0.7 MPa). The roughness of the substrate was characterized either by using a perthometer or by image analysis. The grit residue remain-ing at the blasted surface was evaluated after cleaning by image analysis. The residual stresses induced by grit blasting were determined by using the incremental hole drilling method and by measuring the de-flection of grit-blasted beams. Grit size was determined to be the most important influence on roughness. The average values of R_a and Rt and the percentage of grit residue increased with grit size as well as the depth of the plastic zone under the substrate. An increase of the pressure slightly increased the values of Ä_a and Rt but also promoted grit breakdown and grit residue. A blasting time of 3 to 6 s was sufficient to obtain the highest roughness and limit the grit breakdown. The residual stresses generated under the blasted surface were compressive, and the depth of the affected zone depended on the grit diameter, the blasting pressure, and the Young’s modulus of the substrate. More-over, the maximum residual stress was reached at the limit of the plastic zone (i.e., several tenths of a mil-limeter below the substrate surface).     

钛合金表面激光熔覆技术的研究及展望

本文基于钛合金表面激光熔覆技术,综述了具有良好耐磨性、耐蚀性、抗高温氧化和生物活性等功能性涂层的研究进展,分析了熔覆层的选材规律与强化机理,以及激光熔覆仿生耦合单元与多功能涂层的优势与必要性。针对熔覆层裂纹和气孔等主要缺陷产生的原因,提出了预热基体、后处理、调整工艺参数和制备梯度涂层等改进措施,并对钛合金表面激光熔覆技术未来的应用和发展趋势进行了展望,旨在推进这一表面涂层技术的创新发展,为制备高质量、高效率、低成本的新型熔覆涂层的研究提供新思路。     

Pre-/During-/Post-Laser Processes to Enhance the Adhesion and Mechanical Properties of Thermal-Sprayed Coatings with a Reduced Environmental Impact

Lasers have been used to improve the ultimate performance of thermal spray coatings for specific applications, but the full potential of additional laser treatments must be further explored. Laser treatments (auxiliary processes) can be applied before, during or after thermal spraying (main process), leading to a wide range of coating improvements (microstructure, adhesion, etc.). The aim of this review is to introduce the most significant laser treatments for thermal spray applications. The potential improvements for thermal spray coatings are illustrated by a selection of representative research cases. Laser pretreatments (ablation and texturing) promote coating/substrate adhesion and are suitable to prepare the surface of sensitive substrates such as aluminum, titanium, or magnesium alloys. The use of these techniques, which leads to several benefits such as surfaces free of grit-particle inclusions, directly improves the quality of coatings. Laser treatments applied simultaneously during the spraying process deeply modify the coatings microstructure. These hybrid technologies allow in situ laser melting of coatings, resulting in improved mechanical properties and enhanced wear and corrosion behaviors. Finally, laser posttreatments can improve coatings density and adhesion, and also induce phase transformations and structure refinement. As a summary, laser treatments seem particularly promising for improving the thermal spray coating microstructure and the coating/substrate adhesion. In addition, they offer a more environmentally friendly alternative to the conventional surface preparation treatments.     

Formation and performance of an Fe-based amorphous-nanocrystalline composite coating by laser cladding and remelting

Abstract

A very important research topic in the area of the surface performance of engineering components, in particular their wear properties, recently has been the application of high quality surface layers on relatively cheap substrates. An Fe-based composite coating with both amorphous and nanocrystalline structures on a mild steel substrate offers a combination of high quality coating and low materials cost, at the same time extending the range of applications of traditional materials. The difficulties posed by preparation of Fe-based amorphous alloys have limited progress for many years. However, the recent development of high power lasers, and of laser material processing technology in general, has made the preparation of a Fe-based amorphous and nanocrystalline composite coatings over a large area a real possibility.