Effect of cold spray deposition of a titanium coating on fatigue behavior of a titanium alloy

The deposition of titanium on a titanium alloy substrate is being examined for potential use as a surface treatment for medical prostheses. A Ti6Al4V alloy was coated with pure titanium by cold gas dynamic spraying. Coatings were deposited onto samples with two different surface preparation methods (as-received and grit-blasted). The fatigue life of the as-received and grit-blasted materials, both before and after coating, was measured with a rotating-bend fatigue rig. A 15% reduction in fatigue endurance limit was observed after application of the coating to the as-received substrate, but no significant reduction was observed on its application to the grit-blasted substrate. The reduction in fatigue endurance limit has been related to the substrate-coating interface properties, the elastic modulus, and the residual stress states. This article was originally published inBuilding on 100 Years of Success, Proceedings of the 2006 International Thermal Spray Conference, (Seattle, WA), May 15–18, 2006, B.R. Marple, M.M. Hyland, Y.-Ch. Lau, R.S. Lima, and J. Voyer, Ed., ASM International, Materials Park, 2006.     

冷喷涂技术的研究进展

冷喷涂是基于空气动力学原理的一种新型喷涂技术.它是利用低温(一般低于600℃)超音速气体射流加速喷涂粒子,使粒子不熔化,以固态形式与基体发生塑性碰撞而实现涂层沉积.相比于热喷涂技术,冷喷涂可以避免材料在喷涂过程中发生过热、氧化、晶粒长大等现象,适用于非晶、纳米晶涂层的制备.介绍了冷喷涂技术的原理、特点、沉积机制和工艺参数,总结了冷喷涂纳米涂层的研究进展.     

Influence of the preheated substrate temperature on the microstructure deposition behavior of the 304 stainless steel coatings deposited by cold gas dynamic spraying

The effects of the substrate temperature on the deposition and microstructure of the 304 stainless steel(SS)cold gas dynamic spraying(CGDS)coatings were investigated.It was found that the higher substrate temperature could increase the deposition rate of the 304 SS particles,even the oxide films existed at the interface.There was a critical oxide film with a thickness of 3-4 μm which could be destroyed by the impacted particles.The micro-hardness and microstructure of the 304 SS coatings under different substrate preheating temperatures were almost the sanle.     

冷喷涂工艺中粒子流轨迹的数值模拟

采用计算流体力学（CFD）技术模拟研究了冷气动力喷涂技术中粒子流的流场分布特性。通过计算,分析了不同粒子直径下粒子在气体流场中的轨迹,比较了平面基板和球形基体对粒子流轨迹的影响。模拟结果清楚给出了两种条件下粒子流的流动方向和速度大小,为冷喷涂系统粉末回收与除尘装置的设计提供了理论指导。     

碰撞速度对冷喷涂粒子沉积行为影响的数值模拟研究

采用有限元数值模拟方法研究了冷喷涂过程中304不锈钢粒子的碰撞速度对IF钢基板的碰撞和沉积变形行为的影响。结果表明,当粒子速度高于一个在产生绝热失稳变形并发生沉积的临界速度时,粒子的扁平率、有效接触界面积均显著增加。粒子沉积过程中的剪切失稳行为是由撞击过程中产生的压力与摩擦力共同作用的结果。这个临界速度可以由数值模拟计算得到,用于优化多种材料的冷喷涂工艺参数。     

喷嘴出口与基板间距离对冷喷涂超音速流场的影响

采用计算流体力学（CFD）模拟研究了冷气动力喷涂技术中喷嘴出口与基板距离（SoD）对超音速流场（包括气体流场和粒子流流场）的影响,通过计算流场的分布特性,分析了流场中速度、温度、压力和密度的变化规律。模拟结果发现,由于基体前激波的存在,极大影响了气体和粒子流流场。气流形成连续交替的膨胀波、压缩波波系,在马赫盘处气体速度达到超声速,越过马赫盘以后速度下降很大。SoD为40 mm时,1μm粒子流流场达到最优;SoD为50 mm时,5μm和22μm粒子流流场达到最优,此时粒子流对基体的轰击速度最大。     

Microstructure and micro-hardness of the Inconel 718 superalloy coating prepared by cold gas dynamic spraying

Inconel 718 superalloy coating was prepared on a martensitic steel substrate by cold gas dynamic spraying (CGDS).Microstructure and micro-hardness of the coating were characterized by means of scanning electronic microscope (SEM),energy dispersive spectrometer (EDS),and micro-hardness and nano-indentation tests.The results have indicated that the coating’s thickness can reach more than 300 μm,and there exists a good interfacial cohesion between the coating and the substrate.The quantity and size of the defects at the bottom,middle and top areas increase gradually.There is no significant change to the original microstructure of the Inconel 718 superalloy particle after the process of CGDS;and an obvious torsional deformation on the particle’s profile is produced while little deformation at the center part occurs.The micro-hardness of the coating at the bottom,middle and top areas decreases in turn.Compared with the bottom area,the micro-hardness of the middle and top areas decreases by about 10% and 21%,respectively.The nano-hardness of the coating is much lower than the original particle,which decreases by about 13.5% at the bottom area and 28% at the top area,respectively.The distribution of micro-defects is an important factor to the micro-hardness of the coating.     

Study on the 316L stainless steel coatings and their properties by cold gas dynamic spraying

316L stainless steel coatings were prepared by cold gas dynamic spraying ( CGDS) on a carbon steel. A new heater of sprayed powders was added to the traditional facility. The results show that the coating quality is obviously improved,due to better interface bonding and reduced porosity.     

冷喷涂Inconel 718高温合金涂层组织及微观硬度

采用冷喷涂技术在马氏体钢表面制备了Inconel 718高温合金涂层,利用SEM、显微硬度计和纳米压痕仪分析了涂层组织和微观硬度。结果表明,涂层厚度可达300μm以上,与基底界面结合良好,底部、中部和顶部涂层微观缺陷数量和尺寸依次增多;冷喷涂沉积过程不会对Inconel 718高温合金粒子的原始组织结构产生显著影响,沉积后粒子的外部轮廓发生了明显的扭曲变形,而心部变形较小;涂层底部、中部和顶部的显微硬度依次降低,与底部涂层相比,中部和顶部涂层显微硬度分别降低10%和21%;涂层平均纳米硬度较原始粒子显著降低,底部和顶部涂层分别降低13.5%和28%;涂层内部微观缺陷分布是影响涂层整体硬度的重要因素。     

Influence of the preheated substrate temperature on the microstructure deposition behavior of the 304 stainless steel coatings deposited by cold gas dynamic spraying

The effects of the substrate temperature on the deposition and microstructure of the 304 stainless steel (SS) cold gas dynamic spraying (CGDS) coatings were investigated. It was found that the higher substrate temperature could increase the deposition rate of the 304 SS particles,even the oxide films existed at the interface. There was a critical oxide film with a thickness of 3-4 μm which could be destroyed by the impacted particles. The micro-hardness and microstructure of the 304 SS coatings under different substrate preheating temperatures were almost the same.